Embedded Stranded Wire Composite Tube for Low-Resistance Fuel Gauging
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Solution Overview
Problem
Existing fuel gauging systems in aircraft face challenges in achieving a reliable and low-resistance electrical connection between carbon-fiber composite tubes and stranded wires, which affects the accuracy of fuel measurement and requires alternative connection methods.
Innovation Solution
A composite tube with an embedded stranded wire is formed by providing a core, applying layers of electrically conductive material, and embedding the stranded wire within these layers, resulting in a more reliable and efficient electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connection methods (rivets, screws, adhesives) are used to connect stranded wire to composite tube, then mechanical connection is achieved, but electrical connection reliability and low resistance are not sufficiently ensured
Solution Approach 1:
The patent merges the mechanical connection and electrical connection functions into a single integrated structure. The stranded wire is embedded within the composite tube during manufacturing, creating simultaneous mechanical anchoring and electrical contact without requiring separate connection components or steps.
Solution Approach 2:
The stranded wire is positioned and embedded within the composite tube layers during the tube manufacturing process, before the tube is completed. This preliminary placement ensures proper alignment and contact between the wire and conductive layers, guaranteeing reliable electrical connection from the outset.
2Manufacturing precision
If traditional external connection methods are used, then assembly is straightforward, but manufacturing precision and connection consistency are compromised
Solution Approach 1:
The stranded wire is positioned and embedded within the composite tube layers during the tube manufacturing process, before the tube is completed. This preliminary placement ensures proper alignment and contact between the wire and conductive layers, guaranteeing reliable electrical connection from the outset.
Solution Approach 2:
The patent merges the mechanical connection and electrical connection functions into a single integrated structure. The stranded wire is embedded within the composite tube during manufacturing, creating simultaneous mechanical anchoring and electrical contact without requiring separate connection components or steps.
3Reliability
If multiple connection components are used to ensure reliable electrical connection, then connection reliability improves, but device complexity and manufacturing steps increase
Solution Approach 1:
The patent merges the mechanical connection and electrical connection functions into a single integrated structure. The stranded wire is embedded within the composite tube during manufacturing, creating simultaneous mechanical anchoring and electrical contact without requiring separate connection components or steps.
Solution Approach 2:
The stranded wire is positioned and embedded within the composite tube layers during the tube manufacturing process, before the tube is completed. This preliminary placement ensures proper alignment and contact between the wire and conductive layers, guaranteeing reliable electrical connection from the outset.
Data Source
AI summary
The present disclosure includes a composite tube with a stranded wire and a method for making same. The method may include providing a core and providing at least one layer comprising electrically conductive material. The method may further include applying the at least one layer around at least a portion of the core. The method may further include providing the stranded wire comprising an embedded portion. The method may further include embedding the embedded portion of the stranded wire within the at least one layer of electrically conductive material.