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

VSEngineering 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

Engineering Contradiction:
Improvemembrane capacityVSAvoidcanister geometry
Core Design Contradiction:
Quantity of substanceVSDevice complexity

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.

Inventive Principle:
Principle #14Spheroidality (Curvature)

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.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

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

Engineering Contradiction:
Improveinternal surface areaVSAvoidmanufacturing process
Core Design Contradiction:
Area of stationary objectVSEase of manufacture

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.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

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.

Inventive Principle:
Principle #35Parameter changes

3Reliability

If larger air separating membranes are installed to improve inerting effectiveness, then the system performance improves, but the installation volume requirements increase

Engineering Contradiction:
Improveinerting effectivenessVSAvoidinstallation volume
Core Design Contradiction:
ReliabilityVSVolume of stationary object

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.

Inventive Principle:
Principle #14Spheroidality (Curvature)

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

Methodology Applied
Scientific EffectSelective laser sintering: Selective Laser Sintering

Implementation Method 2

selective laser sintering process to form the shaped canister

Methodology Applied
Scientific EffectLaser heating: Laser

Data Source

PatentEP3741450B1Additively manufactured canister for a nitrogen generation system
Publication Date: 2024.07.17 HAMILTON SUNDSTRAND CORP
  • EP3741450B1 patent drawingFigure 1~2
  • EP3741450B1 patent drawingFigure 3
  • EP3741450B1 patent drawingFigure 4

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).