Additively Manufactured Curved Canister for Aircraft Nitrogen Generation
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Solution Overview
Problem
Conventional nitrogen generation systems for aircraft face limitations in air separation module design due to restricted installation volumes, which restrict the size and capacity of air separating membranes, thereby reducing the system's effectiveness in fuel tank inerting.
Innovation Solution
The use of additively manufactured, shaped canisters with complex geometries such as S-shapes, banana shapes, and helix shapes, formed through selective laser sintering with thermoplastics, allows for increased internal surface area and membrane capacity within constrained installation envelopes, enabling larger air separating membrane installations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional straight canisters are used in air separation modules, then the system structure is simple and easy to manufacture, but the installation volume is restricted and membrane capacity is limited
Solution Approach 1:
The patent applies curved and complex geometries to the canister structure, transitioning from conventional straight cylindrical canisters to curved, S-shaped, banana-shaped, and helical configurations. This curvature principle allows the canister to utilize restricted installation volumes more effectively while increasing the internal surface area available for membrane installation, thereby resolving the contradiction between membrane capacity and device complexity.
Solution Approach 2:
The patent employs additively manufactured canisters with complex three-dimensional geometries that utilize spatial volume more efficiently. By transitioning from simple one-dimensional straight cylinders to multi-dimensional curved and helical structures, the design maximizes the use of available installation envelope space, increasing membrane capacity without proportionally increasing overall device complexity.
2Area of stationary object
If additively manufactured shaped canisters are used, then the internal surface area and membrane capacity increase, but the manufacturing process becomes more complex
Solution Approach 1:
The patent replaces conventional mechanical manufacturing methods (such as sheet metal forming or extrusion) with additive manufacturing technology. This substitution enables the production of complex curved and helical canister geometries that would be difficult or impossible to manufacture using traditional mechanical processes, thereby achieving increased internal surface area while managing manufacturing complexity through advanced fabrication techniques.
Solution Approach 2:
The patent utilizes additive manufacturing to achieve precise control over canister geometric parameters, including curvature radius, helical pitch, and wall thickness distribution. By changing manufacturing parameters in the additive process, the design optimizes the balance between internal surface area and manufacturing feasibility, allowing complex shapes to be produced with controlled complexity.
3Reliability
If larger air separating membranes are installed to improve inerting effectiveness, then the system performance improves, but the installation volume requirements increase
Solution Approach 1:
The curved and helical canister geometries allow the membrane to be arranged in three-dimensional space more efficiently, increasing the effective membrane surface area within a compact volume. This curvature principle enables larger membrane capacity (improving inerting effectiveness) without requiring proportionally larger installation volume, as the membrane utilizes the internal volume of curved paths rather than requiring extended linear space.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the nitrogen generation system's capability by increasing the amount of air separating membrane that can be installed, improving the system's efficiency in displacing flammable gases and reducing fuel tank flammability, while also offering a lightweight and high-strength solution suitable for both new and retrofitted aircraft systems.
Implementation Method 1
formed through selective laser sintering with thermoplastics
Implementation Method 2
selective laser sintering process to form the shaped canister
Data Source
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AI summary
Disclosed is a method of manufacturing an air separation module (ASM) (140) of a nitrogen generation system (NGS) (130), the method providing: determining an at least partially nonlinear shape between opposing ends of a canister (160), the canister (160) being configured to fit within an installation envelope for the ASM (140) in the NGS (130) and configured to have installed therein an air separating membrane; and additively manufacturing the canister (160).