Modular Composite Cable Trunking for Aircraft Electrical Continuity
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Solution Overview
Problem
Aircraft made of composite materials face challenges in maintaining electrical conductivity and protection against short-circuits, as traditional metal structures are no longer effective, and existing trunking elements do not allow for easy expansion to accommodate increasing electrical cable volumes without increasing weight or compromising protection.
Innovation Solution
A device comprising a basic trunking element with attachment means for a lateral extension trunking element, ensuring mechanical attachment and electrical continuity with low resistance, allowing for simple and quick expansion of cable capacity while maintaining protection against short-circuits and electromagnetic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional metal structures are used for aircraft, then electrical conductivity and electromagnetic protection are achieved, but weight increases and composite material advantages are lost
Solution Approach 1:
The trunking element is divided into a basic trunking element and detachable extension elements. The basic element provides essential electromagnetic protection and electrical continuity, while extensions can be added only when needed to accommodate increasing cable volumes, avoiding unnecessary weight from a fully oversized single piece.
Solution Approach 2:
The trunking element uses a composite structure combining metal components (for electrical conductivity and electromagnetic protection) with non-metallic materials (for insulation and structural support). This allows the system to maintain the essential electrical functions while reducing overall weight compared to traditional all-metal structures.
2Adaptability or versatility
If trunking element volume is increased to accommodate more cables, then cable capacity increases, but electromagnetic protection effectiveness decreases when filled beyond 80%
Solution Approach 1:
Instead of using one large trunking element that would exceed the 80% fill limit, the system segments the cable routing capacity into multiple smaller elements (basic element + extensions). Each element maintains optimal fill ratios while collectively accommodating the total required cable volume, thus preserving electromagnetic protection effectiveness.
Solution Approach 2:
The trunking element system is designed to be dynamically expandable. Extensions can be detached or attached based on the actual cable installation needs, allowing the system to adapt its capacity while maintaining optimal electromagnetic protection characteristics in each segment.
3Adaptability or versatility
If a second trunking element is installed to the side for lateral extension, then cable capacity increases, but weight is virtually doubled and attachment complexity increases
Solution Approach 1:
The trunking element is designed as a modular system where extensions are separate detachable components rather than integrated permanent structures. This allows the basic element to remain lightweight while extensions are only added when needed, avoiding the weight penalty of having a pre-configured large-capacity single piece.
Solution Approach 2:
The attachment means are pre-configured on the basic trunking element during manufacturing, but the actual extension elements are only installed later when cable capacity requirements demand it. This preliminary preparation without immediate installation avoids unnecessary weight while maintaining expansion capability.
4Reliability
If trunking elements are used to protect carbon structures from cable contact, then protection against short-circuits is achieved, but the system becomes rigid and cannot adapt to evolving cable requirements
Solution Approach 1:
The protective trunking system is segmented into modular components that can be independently added or removed. This maintains the essential protection function in the basic element while allowing flexible adaptation through extensions when cable requirements evolve, without compromising the short-circuit protection capability.
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 enables flexible and cost-effective expansion of cable capacity without significant weight or cost penalties, ensuring electrical continuity and protection against short-circuits and electromagnetic interference, addressing the limitations of existing trunking systems.
Implementation Method 1
provide an electrical continuity over the whole of its length
Implementation Method 2
protection, by a Faraday cage effect, against the direct and indirect effects of lightning
Data Source
AI summary
Device for holding the cables of an aircraft onto the structure of the said aircraft, the said device having substantially the shape of a first trunking element, forming a basic trunking element, comprising means for coupling to the aircraft structure that are positioned on the side of its bottom and arranged to receive at least one cable running along the structure of the said aircraft and to provide an electrical continuity over the whole of its length, characterized in that the said basic trunking element comprises first attachment means capable of interacting with corresponding attachment means of a second trunking element, forming a lateral extension trunking element.