Conformable Composite Tank with Sandwich Walls for Aircraft

The patent applies composite materials by constructing the tank wall as a sandwich structure with a core and facing layers. The core provides structural rigidity and strength to withstand pressure and flight loads, while the composite construction significantly reduces weight compared to solid metal tanks. This resolves the contradiction by achieving both structural integrity and weight reduction through the synergistic combination of materials with different properties.

The patent employs thin composite wall structures instead of thick metal walls. The sandwich structure with core and facing layers creates a lightweight shell that maintains structural integrity through its geometric configuration and material properties rather than relying on thick metal sections. This enables weight reduction while preserving the tank's ability to withstand pressure and mechanical loads.

The sandwich structure with core and facing layers provides both lightweight properties and high pressure resistance. The core resists compressive loads and maintains structural rigidity, while the facing layers handle tensile stresses from internal pressure. This composite configuration achieves pressure resistance comparable to metal tanks at a fraction of the weight.

The patent incorporates curved surfaces in the tank design where applicable, as curved geometries naturally distribute stress more evenly under pressure loads. This geometric feature enhances the pressure resistance of the lightweight composite structure by reducing stress concentration points, allowing the thin-walled construction to withstand higher pressures without failing.

The patent applies different wall configurations to different locations based on stress requirements. Flat walls with internal bracing are used in areas where manufacturing simplicity is prioritized and stress levels are manageable, while curved surfaces are implemented in regions subjected to higher pressure and bending stresses. This localized approach optimizes both manufacturability and structural performance.

The patent introduces curved surfaces and rounded transitions in the tank design to eliminate sharp corners that create stress concentration points. The curved geometries distribute bending stresses more uniformly across the wall structure, reducing peak stresses under pressure loads while maintaining reasonable manufacturability through formable composite construction.