Fuel Cell Cushion with Sprayable Coating for Aircraft Fuel Systems
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Solution Overview
Problem
Current aircraft fuel system padding is heavy, cumbersome to produce, and requires burdensome sealant application to meet nonabsorbent standards, failing to provide a lightweight, easy-to-produce solution for fuel cell protection from damage and fuel absorption risks.
Innovation Solution
A fuel cell cushion system comprising a shaped foam substrate machined to fit between the fuel cell receiving assembly and fuel cells, coated with a sprayable polyurethane-based cushion coating to provide structural support and prevent fuel absorption, with varying densities and compression strengths for floor and wall cushions to address specific protection needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current aircraft fuel system padding materials are used, then fuel cell protection and nonabsorbent standards are met, but the system becomes heavy and requires burdensome sealant application
Solution Approach 1:
The patent changes the physical and chemical parameters of the cushion material by using cross-linked polyethylene foam with specific density (15-45 kg/m³) and compression strength (5-20% at 0.5 inches deflection). The foam is further treated with fuel-resistant coatings and can be cross-linked through radiation or chemical methods to enhance fuel resistance while maintaining lightweight properties and eliminating the need for heavy sealants.
Solution Approach 2:
The patent creates a composite structure by combining foam substrate with fuel-resistant coatings (such as polyurethane, epoxy, or fluoropolymer coatings applied at 0.002-0.010 inches thickness). This composite approach provides both cushioning protection and fuel resistance in a lightweight package, replacing the need for heavy traditional padding materials and sealants.
2Reliability
If current aircraft fuel system padding materials are used, then fuel cell protection is provided, but the application process becomes cumbersome requiring sealant or wrapping
Solution Approach 1:
The foam cushion is designed to be self-adhering through direct contact bonding to the fuel cell and receptacle surfaces. The foam's inherent properties allow it to conform and bond without requiring external sealants or wrapping materials, simplifying the application process while maintaining protective functionality.
Solution Approach 2:
The patent modifies the foam's surface properties and chemical composition through coating applications and cross-linking treatments, enabling the foam to achieve fuel resistance and adhesive properties inherently. This eliminates the need for separate sealant application steps while maintaining protective and nonabsorbent requirements.
3Reliability
If traditional padding materials are used, then nonabsorbent standards are met through sealant application, but production complexity increases
Solution Approach 1:
The patent achieves nonabsorbent properties by controlling the foam's cellular structure (closed-cell or cross-linked morphology) and applying fuel-resistant coatings that create a barrier to fuel absorption. The foam's intrinsic properties and coating treatments provide fuel resistance without requiring complex multi-layer constructions or heavy sealant applications.
Solution Approach 2:
The patent creates a simplified composite system where the foam substrate combined with thin fuel-resistant coatings (0.002-0.010 inches) provides both structural cushioning and fuel resistance in a single integrated component, reducing construction complexity compared to traditional multi-material assemblies.
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
The solution offers lightweight, easy-to-produce fuel cell cushions with enhanced energy absorption capabilities, preventing fuel cell damage and absorption, while meeting FAA nonabsorbent standards, thus improving safety and reducing weight in aircraft fuel systems.
Implementation Method 1
The cushion coating is sprayable onto the shaped foam substrate such that the fuel cell cushion is substantially nonabsorbent of fuel
Data Source
AI summary
An aircraft fuel system includes one or more fuel cells adapted to contain fuel, a fuel cell receiving assembly having an inner surface adapted to receive the one or more fuel cells and a fuel cell cushion disposed between the inner surface of the fuel cell receiving assembly and the one or more fuel cells. The fuel cell cushion is machined from a foam substrate to form a shaped foam substrate that is substantially covered with a cushion coating. The cushion coating is sprayable onto the shaped foam substrate such that the fuel cell cushion is substantially nonabsorbent of fuel. The fuel cell cushion is interposable between the inner surface of the fuel cell receiving assembly and the one or more fuel cells to cushion the one or more fuel cells from damage.