Nested Metallic Conduit System for Vehicle Resource Transfer
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Solution Overview
Problem
The conventional manufacturing and installation of conduits in vehicles, such as aircraft, are time-consuming and expensive due to the numerous manufacturing and installation steps involved, with each conduit being fabricated and installed independently, occupying significant space and requiring extensive access for installation, replacement, or repair.
Innovation Solution
A method and apparatus for producing a conduit system using Additive Manufacturing (AM) that involves creating a digital model of conduits to be nested together, sharing common walls, and manufactured as a single metallic object, optimizing heat transfer and minimizing space, with the ability to include valves or structures like flow separators, to reduce the number of parts and installation complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional independent conduit fabrication and installation methods are used, then each conduit can be manufactured and installed separately, but the manufacturing time and installation time increase significantly
Solution Approach 1:
Multiple separate conduits are merged into a single integrated conduit system manufactured as one piece using additive manufacturing. This combines what were previously multiple independent manufacturing processes into one, reducing total manufacturing time while maintaining the functional independence of each conduit pathway.
Solution Approach 2:
The integrated conduit system is designed with internal segmentation that allows individual conduit pathways to be accessed and serviced independently through the external surface, maintaining ease of maintenance while achieving manufacturing consolidation.
2Strength
If conventional independent conduit installation with multiple attachment points is used, then each conduit can be securely attached, but the volumetric space occupied increases significantly
Solution Approach 1:
Multiple separate conduits are merged into a single integrated structure that occupies significantly less volumetric space than multiple separate conduits with their individual attachment points, fasteners, and clearance zones.
Solution Approach 2:
Multiple conduit pathways are nested within a single integrated conduit body, with internal partitions creating separate flow paths. This nesting approach minimizes the external volume required while maintaining internal functional separation.
3Ease of operation
If conventional conduit installation with access space provision is used, then installation and maintenance can be facilitated, but the space required for access increases
Solution Approach 1:
The integrated conduit system incorporates external segmentation features such as removable panels or access ports that allow individual conduit pathways to be accessed independently. This segmentation enables maintenance workers to access specific conduits without needing to access the entire conduit system, reducing the total access space required.
4Adaptability or versatility
If multiple separate conduits are used, then individual conduit functions can be maintained, but the number of manufacturing and installation steps increases
Solution Approach 1:
Multiple separate conduits are merged into a single integrated conduit system manufactured in one additive manufacturing process. The digital model contains all conduit pathways, and they are all manufactured simultaneously as one piece, eliminating the need for multiple separate manufacturing, assembly, and installation steps.
5Ease of manufacture
If conventional conduit manufacturing processes are used, then traditional manufacturing methods can be employed, but the manufacturing cost increases
Solution Approach 1:
The patent applies additive manufacturing technology, which fundamentally changes the manufacturing parameter from traditional subtractive or formative methods to a layer-by-layer additive process. This enables complex integrated geometries to be manufactured directly from digital models without requiring molds, dies, or assembly operations, significantly reducing manufacturing time despite being a newer technology.
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
This approach reduces manufacturing time and cost by creating a complex conduit system as a single object, minimizing space requirements, and simplifying installation, while enhancing thermal and electrical isolation and structural integrity, thus reducing the risk of defects and installation time.
Implementation Method 1
using a powerful heat source such as a laser beam, electron beam or an electric, or plasma welding arc, melting an amount of that material and depositing the melted material
Implementation Method 2
using a powerful heat source such as a laser beam, electron beam or an electric, or plasma welding arc, melting an amount of that material and depositing the melted material
Implementation Method 3
using a powerful heat source such as a laser beam, electron beam or an electric, or plasma welding arc, melting an amount of that material and depositing the melted material
Implementation Method 4
arranging the conduits in a nested configuration such that at least part of each conduit shares a common conduit wall with at least part of at least one other conduit of the conduit system, and such that, in use, heat transfer between the first conduit and second conduit is maximised
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Disclosed are a method and apparatus for producing a conduit system (10) for use on-board a vehicle (3). The method comprises: identifying a plurality of source apparatuses (4) located on-board the vehicle (3) and from which a resource is to be transferred via the conduit system (10); for each identified source apparatus (4), identifying one or more sink apparatuses (6)located on- board the vehicle (3) and to which that source apparatus (4) is to transfer, via the conduit system (10), a resource; using relative locations of the identified source and sink apparatuses, producing a digital model (62) for the conduit system (10) including specifying conduits (12-24) for coupling the source apparatuses (4) to the sink apparatuses (6) and arranging the conduits (12-24) such that each conduit (12-24) shares a common conduit wall with at one other conduit (12-24); and, using the digital model (62), producing the conduit system (10).