Electrical Isolator Reinforcing Composite for Hydraulic Systems
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Solution Overview
Problem
Existing electrical isolators for hydraulic fluid lines in aircraft fail to effectively balance electrical isolation with high-pressure resistance and weight optimization, often requiring excessive fibers and complex manufacturing processes.
Innovation Solution
A reinforcing composite using interwoven fibers in a resin matrix, which provides a conductive path while minimizing fiber usage, allowing for optimized shape and reduced weight, and is manufactured using triaxial braiding or biaxial weaving techniques, eliminating the need for filament winding and resulting in a smooth surface finish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional filament winding technique is used to create reinforcing composite, then high-pressure resistance is achieved, but device complexity increases and manufacturing cost increases
Solution Approach 1:
The patent replaces the complex filament winding mechanical system with a simpler braiding or weaving system. The reinforcing composite is formed by interlacing fibers in a braided or woven pattern around the fluid-carrying members, eliminating the need for complex winding equipment and processes while maintaining structural integrity and pressure resistance.
Solution Approach 2:
The patent uses composite materials consisting of reinforcing fibers (such as aramid, glass, or carbon fibers) embedded in a polymer matrix. This composite structure provides the necessary mechanical strength and pressure resistance while allowing for simpler manufacturing methods compared to traditional filament winding of homogeneous materials.
2Strength
If excessive fibers are used to ensure high-pressure resistance, then strength is improved, but weight increases and manufacturing cost increases
Solution Approach 1:
The patent applies local quality by concentrating fiber reinforcement only where structurally necessary - specifically in the regions surrounding the fluid-carrying members and at stress concentration points. The fiber density and orientation are optimized locally rather than uniformly throughout the entire isolator, reducing overall weight while maintaining required strength.
Solution Approach 2:
The patent uses partial action by applying fiber reinforcement only to the extent necessary for withstanding operating pressures. Rather than over-reinforcing the entire structure, the fiber content and distribution are precisely controlled to provide adequate strength with minimal weight penalty.
3Strength
If filament winding technique is used, then high-pressure resistance is achieved, but manufacturing time increases and productivity decreases
Solution Approach 1:
The patent substitutes the time-consuming filament winding process with faster braiding or weaving techniques. These alternative methods can be performed more quickly and with simpler equipment, significantly improving manufacturing throughput while still producing structurally adequate reinforcing composites.
Solution Approach 2:
The patent employs preliminary action by pre-forming the fiber bundles into braided or woven configurations before applying them to the isolator structure. This pre-preparation allows for faster assembly and reduces on-site manufacturing time, thereby increasing overall productivity.
4Strength
If complex fiber arrangement is used to optimize strength, then high-pressure resistance is improved, but ease of manufacture decreases
Solution Approach 1:
The patent replaces complex fiber arrangement requirements with standard braiding or weaving patterns that are well-established in the textile and composite industries. These conventional patterns are easier to manufacture using off-the-shelf equipment and skilled labor, while still providing adequate structural performance.
5Strength
If rough surface finish is produced by filament winding, then high-pressure resistance is achieved, but detection of impact damage becomes difficult
Solution Approach 1:
The patent applies a smooth outer surface finish to the isolator, which may include a uniform coating or gel layer. This smooth surface reflects light uniformly, making it easier to spot anomalies, discolorations, or deformations that indicate impact damage. The smooth finish acts as a visual indicator surface that enhances detectability of structural issues.
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 effectively dissipates electrostatic charges, withstands high pressures, and reduces manufacturing costs and weight, while enabling easy detection of impact damage, making it suitable for hydraulic systems operating at pressures up to 55.2 MPa (8000 psi).
Implementation Method 1
The resin mixture comprises a conductive additive, for example carbon black, graphene and/or carbon nanotubes... the reinforcing composite acts to hold the components of the electrical isolator together to provide strength and resistance when high pressure fluids are passed through the electrical isolator
Implementation Method 2
a reinforcing composite material comprising interwoven fibres and a resin mixture... the first fibres and the second fibres may form a triaxial braid... providing good performance against both axial and radial loads
Data Source
Figure 1
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AI summary
An isolator (10) is provided, the isolator (10) comprising: a first fluid-carrying member (12) and a second fluid-carrying member (14) spaced apart from the first fluid-carrying member (12); and a resistive, semi-conductive or non-conductive component (16) located between the first and the second fluid-carrying member (12, 14). The resistive, semi-conductive or non-conductive component (16) is adapted to convey fluid flowing from the first fluid-carrying member (12) to the second fluid-carrying member (14). The isolator (10) further comprises a reinforcing composite (30) encircling the first fluid-carrying member (12), the second fluid-carrying member (14) and the resistive, semi-conductive or non-conductive component (16). The reinforcing composite (30) comprises: first fibres extending at an angle of between -30 degrees and +30 degrees to a longitudinal axis (A-A) of the resistive, semi-conductive or non-conductive component (16); second fibres interwoven with the first fibres and extending around the first fluid-carrying member (12), the second fluid-carrying member (14) and the resistive, semi-conductive or non-conductive component (16) at an angle of between +60 degrees and +90 degrees and/or between -60 degrees and -90 degrees to the longitudinal axis (A-A); and a resin.