Integral Bonding Attachment for Aircraft Grounding
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Solution Overview
Problem
Traditional methods for connecting conductive wires to support structures in aircraft, such as lugs, face issues like weakness at the conductor-lug interface, potential for corrosion, and inefficiencies in providing a robust ground reference, especially with composite wing structures.
Innovation Solution
An integral bonding attachment is used, where a conductive sleeve covers both insulated and uninsulated sections of the wire, forming a flattened section with tubular ends and an inner seal to create a unitary grounding structure, allowing for secure attachment without cutting the wire and providing a low-impedance path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional lugs are used to connect conductive wires to support structures, then the connection can be established, but the weakness exists between the conductor cable and the lug sleeve, and the stress on the conductor at the crimp might cause the conductor to break
Solution Approach 1:
The patent combines the conductor and the bonding attachment into a single integral structure, eliminating the separate lug component. The bonding attachment is formed directly from the conductor material itself, creating a unified structure that eliminates the weak interface between conductor and lug while distributing stress throughout the entire bonding attachment rather than concentrating it at a crimp point.
Solution Approach 2:
The bonding attachment is divided into distinct functional zones: a tubular section for receiving the conductor, a flattened section for attachment to the support structure, and a transition section connecting them. This segmentation allows each zone to be optimized for its specific function while maintaining structural integrity throughout the entire assembly.
2Ease of manufacture
If traditional lugs are used with dissimilar metals, then the connection can be made, but corrosion may occur between the dissimilar metals and at the lug-to-cable interface
Solution Approach 1:
The bonding attachment is formed from the same material as the conductor, creating a homogeneous structure throughout. This eliminates galvanic corrosion between dissimilar metals and prevents moisture accumulation at interfaces between different materials, as there are no interfaces between dissimilar materials in the bonding attachment itself.
Solution Approach 2:
The tubular section of the bonding attachment encloses the conductor end, creating a protected environment that shields the conductor-bonding attachment interface from moisture and corrosive atmospheric elements, effectively creating a corrosion-resistant zone.
3Reliability
If traditional lugs are used, then the connection can be established, but the crimped lug may not provide a good low resistance or low impedance path through the end of the conductor
Solution Approach 1:
The bonding attachment is formed as an integral extension of the conductor itself, creating a continuous metallic path from the conductor through the bonding attachment to the support structure. This eliminates any potential resistance at interfaces between separate components, ensuring a low-impedance electrical path throughout the entire connection.
4Productivity
If traditional lugs are used for attachment along a long length of cable, then the connection can be made, but it is necessary to cut the cable, attach two lugs to the cut end, and then bolt the two lugs to the frame, which is time consuming and costly
Solution Approach 1:
The bonding attachment is formed as a single integral piece from the conductor itself, eliminating the need for separate lugs and their associated attachment hardware. This simplifies the attachment process to a single operation rather than requiring multiple steps of cutting, attaching separate lugs, and bolting.
Solution Approach 2:
The bonding attachment serves multiple functions simultaneously: it provides mechanical strength for attachment to the support structure, maintains electrical continuity as a low-impedance path, and protects the conductor end from corrosion. This multi-functionality in a single component reduces the overall complexity of the attachment system.
Data Source
Figure 1
Figure 2~6
Figure 7~11
AI summary
An integral bonding attachment (34) includes an insulated section (65) of a conductive wire (43) with an exposed, uninsulated section (66). A sleeve (44) covers the insulated and uninsulated sections of the conductive wire, and the sleeve (44) includes a flattened section (50) encasing at least a portion of the uninsulated wire section to form a generally integral structure with the core (63) of the conductive wire. At least one generally tubular section (46), (48) is positioned at an end of the flattened section (50) to engage the insulated section (65) of the conductive wire (43). An aperture (54) may pass simultaneously through the inner core (63) and flattened sleeve section (50) for attaching the integral bonding attachment to a structure.