Interlocking Foam Insulation for Aircraft Frame Attachment
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Solution Overview
Problem
Existing methods for insulating structural frame members in transport vehicles, such as aircraft, require labor-intensive and costly fastener systems, leading to increased installation costs, weight, and potential acoustic leakage.
Innovation Solution
An insulation system using rigid foam insulation members with interlocking sidewalls that exert compression forces to secure themselves and the frame members without the need for fasteners, comprising multiple foam members with protective layers that cover and compress against the frame members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fastener devices are used to secure insulation blankets to frame members, then the insulation can be securely attached, but installation time and labor costs increase
Solution Approach 1:
The patent removes fastener devices entirely from the insulation system, extracting the attachment function from separate components and integrating it into the insulation blanket itself through self-adhering properties and interlocking seams, thereby eliminating installation time for fasteners while maintaining secure attachment
Solution Approach 2:
The insulation blanket is designed to be self-installing through self-adhering edges and self-interlocking seams that automatically secure the blanket to frame members and adjacent blankets without external fastening devices, making the system self-sufficient and eliminating labor-intensive fastener installation
2Reliability
If fastener devices are used to secure insulation blankets, then the insulation can be attached, but the overall weight of the transport vehicle increases
Solution Approach 1:
The patent extracts and removes all fastener devices from the system, eliminating their weight contribution to the vehicle while maintaining attachment security through the blanket's inherent self-adhering and interlocking properties
Solution Approach 2:
The patent replaces permanent metal fasteners with lightweight, consumable adhesive and seam structures that are integrated into the blanket material itself, significantly reducing the weight of attachment components while maintaining functional equivalence
3Reliability
If multiple fastener devices are used to secure insulation blankets, then the insulation can be attached, but the cost of installation and manufacturing increases
Solution Approach 1:
The patent removes fastener devices from the system, eliminating procurement, storage, inventory management, and installation costs associated with these components, thereby reducing overall manufacturing and installation costs while maintaining attachment security through integrated blanket design
Solution Approach 2:
The patent merges the attachment function into the insulation blanket itself by integrating self-adhering edges and interlocking seams directly into the blanket structure, consolidating multiple components (blanket and fasteners) into a single integrated unit that reduces overall system cost
4Reliability
If fastener devices are used to secure insulation blankets, then the insulation can be attached, but acoustic leakage may occur between blankets
Solution Approach 1:
The patent merges adjacent insulation blankets into a unified continuous barrier through self-interlocking seams that eliminate gaps and discontinuities, creating an unbroken acoustic barrier that prevents sound leakage while maintaining structural integrity
Solution Approach 2:
Instead of using fasteners to mechanically clamp blankets together (which can create gaps), the patent inverts the approach by having the blanket edges actively interlock and seal together through self-adhering properties, creating a tighter acoustic seal
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 solution reduces installation time and labor, eliminates the need for fasteners, decreases vehicle weight, and enhances acoustic and thermal insulation performance, while being cost-effective and durable.
Implementation Method 1
the second and third insulation members impart one or more compression forces on the first insulation member and on the first frame member in order to secure the first insulation member in place
Implementation Method 2
Such insulation can provide a thermal barrier to regulate temperature for the comfort of the vehicle occupants
Implementation Method 3
can provide an acoustic barrier to reduce engine noise and/or noise from outside air turbulence
Data Source
Figure 1
Figure 2~3
Figure 4A~4B
AI summary
There is provided an insulation system (100) and method for a trans¬ port vehicle (10). The system has first (106a) and second (106b) frame members; a first rigid foam insulation member (124a) extend¬ ing between the first (106a) and second (106b) frame members; a second rigid foam insulation member (124b), where a first sidewall (126) of the first insulation member (124a) integrates with a second sidewall (128) of the second insulation member (124b); and, a third rigid foam insulation member (124c) where the second sidewall of the first insulation member (128) integrates with a first sidewall (126) of the third insulation member (124c). Each of the insulation mem¬ bers (124) is surrounded by a protective layer (170). When the insu¬ lation members (124a, 124b, 124c) are integrated, the second (124b) and third (124c) insulation members impart one or more compression forces on the first insulation member (124a) and on the first frame (106a) member in order to secure the first insulation member (124a) in place without use of any fastener device.