Linerless Composite Tank Structure for Aircraft Using Co-Cured Resins
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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 compliance with flammability, smoke, toxicity, pressure, and chemical resistance requirements is achieved, but the tank weight increases substantially
Solution Approach 1:
The patent uses composite materials (fiberglass-reinforced plastic) to replace traditional metal tanks, achieving the required strength and regulatory compliance while significantly reducing weight. The composite structure provides the necessary mechanical properties without the substantial weight penalty of metal construction.
2Reliability
If composite tanks with liners are used to meet chemical and sealing requirements, then chemical resistance and sealing compliance are achieved, but production time increases to 20-30 hours due to pre-fabrication steps
Solution Approach 1:
The patent combines the liner and tank structure into a single integrated component. The gel coat layer serves both as the chemical-resistant liner and as part of the structural tank wall, eliminating the need for separate liner installation and reducing production time from 20-30 hours to a single curing cycle.
Solution Approach 2:
The gel coat liner is applied as the first layer during the initial molding process, establishing the chemical-resistant barrier before the structural layers are added. This preliminary formation of the liner eliminates subsequent liner installation steps and integrates the sealing function into the primary manufacturing process.
3Strength
If metal tanks are used to meet structural and impact requirements, then structural integrity is achieved, but the tank becomes heavy and difficult to form into complex geometries
Solution Approach 1:
The patent employs fiberglass-reinforced composite materials that can be easily molded into complex three-dimensional geometries while maintaining high structural strength and impact resistance. The composite structure with embedded fibers provides the necessary mechanical properties without the formability limitations of metal.
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 method reduces production time by 50% and weight, enhances flexibility, and allows for complex shapes, 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
Implementation Method 2
applying a first curable composite material to the mold, where the first curable composite material comprises a first resin. The method includes applying a second curable composite material to the mold having the first curable composite material
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.