Non-Conductive Clamp for Aircraft Fuel Systems
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Solution Overview
Problem
Conventional clamps used in aircraft fuel tanks are conductive and do not accommodate the structural flexibility of composite wing materials, leading to increased axial movement of hydraulic tubes and potential electrical arcing due to lack of grounding and electromagnetic shielding.
Innovation Solution
A non-conductive clamp with a strap and base design, incorporating a cushion for axial movement and multiple layers of insulation to prevent electrical arcing, allowing for one-handed installation and retention within the clamp body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional conductive clamps are used to secure tubing in aircraft fuel tanks, then grounding paths can dissipate lightning currents, but the clamps cannot accommodate the structural flexibility of composite wing materials and may cause electrical arcing
Solution Approach 1:
The patent introduces non-conductive clamp bodies and cushion members as intermediary elements between the tubing and the composite wing structure. These intermediaries provide mechanical coupling while preventing electrical conduction, thereby accommodating composite structure flexibility without causing electrical arcing or requiring grounding paths.
Solution Approach 2:
The patent changes the electrical conductivity parameter of the clamp body from conductive (metal) to non-conductive (composite or polymer materials). This parameter change allows the clamp to adapt to composite wing flexibility while eliminating the risk of electrical arcing in fuel tank environments.
2Object-affected harmful factors
If non-conductive clamp materials are used to prevent electrical arcing, then grounding paths are eliminated, but the clamps must accommodate increased axial movement of tubes
Solution Approach 1:
The patent employs cushion members made from flexible non-conductive materials that can deform axially to accommodate tube movement. These flexible cushions maintain electrical isolation while providing the necessary mechanical compliance to handle increased axial movement in composite wing structures.
Solution Approach 2:
The clamp assembly uses composite construction combining non-conductive clamp bodies with flexible non-conductive cushion members. This composite approach provides both electrical isolation properties and mechanical flexibility to accommodate tube movement without compromising safety.
3Adaptability or versatility
If rubber cushions are used to accommodate tube movement, then axial movement is allowed, but the cushions may become debris in the fuel tank if worn through
Solution Approach 1:
The patent extracts the cushion member from the traditional rubber material and replaces it with non-conductive materials that have superior wear resistance and fuel compatibility. This extraction eliminates the risk of conductive debris while maintaining the axial movement accommodation function.
Solution Approach 2:
The patent designs the cushion member as a replaceable component with extended service life due to the use of durable non-conductive materials. While still subject to wear, the non-conductive cushions can degrade without creating hazardous conductive debris, and can be replaced as consumable parts.
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 non-conductive clamp provides electrical isolation and accommodates axial movement of tubes, reducing the risk of electrical arcing and ensuring safe operation in composite aircraft structures by eliminating the need for grounding paths and accommodating structural flexibility.
Implementation Method 1
The clamp body is made from a non-conductive material... providing electrical isolation between the tube and any metallic structure or fasteners
Implementation Method 2
The cushion is made from a different insulating material than that of the clamp body... allowing the tube to move axially within the cushion
Implementation Method 3
The structural features of the clamp body and corresponding cushion allow for increased axial movement of the object being secured
Data Source
AI summary
Apparatus and methods provide an electrically isolating clamp that is suitable for use, among other locations, within a composite wing structure and other fuel environments. According to embodiments described herein, the clamp includes a clamp body and cushion. The clamp body is manufactured from a non-conductive material and includes a strap and a base. The cushion may be manufactured from a different non-conductive material to provide at least two layers of electrical isolation between the tube or other object being secured and a structure. The cushion material allows for axial movement of the tube through the cushion. The cushion is disposed between the strap and the base. Shoulder flanges prevent axial movement of the cushion with respect to the clamp body. The clamp may have a cushion retention mechanism to secure the cushion within the strap prior to installation around the tube.