Modular Flexible Duct Connectors for Static Discharge
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Solution Overview
Problem
Existing flexible ducts used in aircraft manufacturing for removing flammable and explosive vapors are difficult to handle in long lengths, leading to increased costs and operational delays, and pigtails used for connecting ducts are inconvenient and prone to failure.
Innovation Solution
A method and apparatus using a wire frame covered with material to form flexible ducts, equipped with mating connectors that allow for easy connection and electrical conductivity, enabling the formation of a desired length of airway by connecting multiple ducts, thereby reducing handling difficulties and maintaining static discharge conductance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If long lengths of flexible ducts are used, then the handling difficulty increases, but using multiple shorter ducts increases cost and interrupts operations
Solution Approach 1:
The flexible duct is divided into multiple sections with mating connectors that allow easy assembly and disassembly. Each section can be independently handled and stored, then quickly connected to form the required length, resolving the contradiction between handling ease and operational continuity.
Solution Approach 2:
The duct system transitions from a fixed long-length configuration to a dynamic modular assembly. The mating connectors enable the duct to be configured in different lengths and arrangements based on operational needs, improving both handling ease and flexibility.
2Reliability
If pigtails are used to connect flexible ducts, then connection is possible, but conductivity is inconsistent and prone to failure
Solution Approach 1:
The mechanical connection and electrical conductivity functions are merged into a single integrated mating connector design. The conductive material is built into the connector structure itself, eliminating the need for separate pigtails and ensuring consistent conductivity while simplifying the connection process.
Solution Approach 2:
The mating connectors are designed to automatically establish both mechanical and electrical connections upon engagement. The conductive material within the connector structure self-aligns and makes contact, eliminating the need for manual pigtail connection and ensuring reliable conductivity without additional complexity.
3Reliability
If flexible ducts are made conductive for static discharge, then safety is improved, but handling and assembly become more difficult
Solution Approach 1:
Conductive material is applied locally at the mating connectors and wire frame structures where electrical connectivity is needed, rather than requiring the entire duct to be conductive. This localized approach maintains safety functionality while preserving the flexible, easy-to-handle characteristics of the duct material.
Solution Approach 2:
The duct system uses composite construction with conductive wire frames and/or conductive coatings on flexible duct material. This combination provides the necessary electrical conductivity for static discharge while maintaining the flexibility and ease of handling of the flexible duct material.
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 simplifies the assembly of flexible ducts, reduces the time and complexity of forming a desired length, and effectively dissipates static electricity, enhancing safety by reducing the risk of ignition from flammable vapors and mists.
Implementation Method 1
The flexible ductwork may be required by National Fire Protection Association codes to maintain conductivity between sections and to a grounded ventilation/exhaust system for dissipating static electricity charges accumulating in the exhaust system.
Data Source
AI summary
An apparatus may comprise a wire frame, a material, and mating connectors. The wire frame is covered by the material to form a flexible duct having a first end and a second end. A first mating connector may be electrically connected to the wire frame and attached to the material at the first end. The first mating connector may be capable of being coupled to a first complementary mating connector to form a mechanical connection and an electrical connection. A second mating connector may be electrically connected to the wire frame and attached to the material at the second end. The second mating connector may be capable of being coupled to a second complementary mating connector to form the mechanical connection and the electrical connection.