Linerless Composite Aircraft Tank Co-Curing for Complex Shapes
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Solution Overview
Problem
Metal tanks used in aerospace liquid systems are heavy and difficult to form into complex geometries, while composite tanks with liners require time-consuming pre-fabrication steps and are costly due to the need for a separate liner.
Innovation Solution
A method of manufacturing a monolithic composite tank by co-curing a first curable composite material with a second curable composite material, eliminating the need for a separate liner, using thermoset and thermoplastic resins like polyurethane and epoxy, and incorporating reinforcing fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal tanks are used to meet aerospace regulatory requirements, then reliability and compliance are improved, but weight increases substantially
Solution Approach 1:
The patent applies composite materials (fiber-reinforced plastics such as carbon fiber, glass fiber, or aramid fiber combined with thermosetting resins like epoxy or polyester) to manufacture tank structures that meet aerospace regulatory requirements for flammability, smoke toxicity, and structural integrity while significantly reducing weight compared to traditional metal tanks. The composite structure achieves the required strength-to-weight ratio and compliance without using metal materials.
2Reliability
If composite tanks with liners are used to meet chemical resistance requirements, then reliability is improved, but production time increases to 20-30 hours
Solution Approach 1:
The patent merges the liner layer and the structural composite layers into a single integrated manufacturing process. Instead of separately fabricating a liner and then assembling it to the tank structure, the invention co-cures the liner material with the structural composite materials in one continuous autoclave cycle, reducing production time from 20-30 hours to a single curing cycle while maintaining chemical resistance and structural integrity.
Solution Approach 2:
The patent applies the liner material to the mold surface before applying the structural composite layers, preparing the chemical-resistant barrier in advance during the same manufacturing setup. This preliminary placement of the liner material eliminates subsequent assembly steps and reduces overall production time while ensuring proper adhesion and chemical resistance from the start.
3Strength
If metal tanks are used to meet structural requirements, then strength is improved, but ease of manufacture decreases due to difficulty in forming complex geometries
Solution Approach 1:
The patent uses composite materials with fiber reinforcement (carbon fiber, glass fiber, or aramid fiber) that can be easily molded into complex three-dimensional geometries while maintaining high structural strength. The composite structure allows for integrated tailoring of strength properties in different directions and can conform to complex aircraft fuselage shapes that would be difficult or impossible to achieve with metal tanks.
4Weight of moving object
If composite tanks with pre-fabricated liners are used to reduce weight, then weight is reduced, but device complexity increases due to separate liner fabrication and assembly steps
Solution Approach 1:
The patent combines the liner fabrication and tank structure fabrication into a single integrated process. The liner material is applied to the mold and co-cured with the structural composite layers in one continuous manufacturing operation, eliminating the need for separate liner fabrication, handling, and assembly steps. This reduces both weight and process complexity simultaneously.
Solution Approach 2:
The patent segments the manufacturing process into a single integrated curing cycle rather than multiple separate steps. By organizing the process to co-cure all layers (liner and structural) together, the invention eliminates the need for separate fabrication and assembly operations, reducing overall process complexity while maintaining the lightweight benefit of composite materials.
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
Reduces production time by 50% and weight, enhances flexibility, and allows for complex shapes, while meeting aerospace standards without a separate liner.
Implementation Method 1
co-curing the first curable composite material with the second curable composite material to form the monolithic composite tank body
Data Source
AI summary
A linerless composite tank for a waste or water system on board an aerospace vehicle includes a monolithic tank body having a first composite material co-cured with a second composite material. The first composite material includes a first resin and the second composite material includes a second resin that is different from the first resin. The first composite material forms an innermost surface of the monolithic tank body defining a tank chamber of the monolithic tank body. A method of manufacturing the linerless composite tank includes providing a mold having a desired interior shape of the monolithic tank, applying the first composite material to the mold, applying the second composite material to the mold, and co-curing the first composite material with the second composite material to form the monolithic composite tank.