Polyurea-Coated Foam Cushion for Aircraft Fuel Cell Protection
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Solution Overview
Problem
Current aircraft fuel system padding materials are heavy, difficult to produce, and require burdensome sealant application to prevent fuel absorption, failing to meet the nonabsorbent standards set by FAA regulations effectively.
Innovation Solution
A polyurea spray coating is applied to a shaped foam substrate to create a fuel cell cushion that is interposed between the fuel cell and the fuel cell receiving assembly, providing a lightweight, flexible, and nonabsorbent solution that adheres to the fuel cell, meeting the structural and safety requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current aircraft fuel system padding materials are used, then fuel absorption prevention is achieved through sealant application, but the system becomes heavy and complex
Solution Approach 1:
The patent changes the material parameter of the cushion from traditional absorbent foam to closed-cell foam, which inherently prevents fuel absorption without requiring additional sealants. This material parameter change eliminates the need for heavy sealant applications while maintaining fuel absorption prevention
Solution Approach 2:
The patent uses closed-cell foam as a composite material that combines cushioning properties with inherent fuel resistance. The closed-cell structure provides both mechanical protection and fuel absorption prevention in a single integrated component, reducing overall system weight
2Reliability
If traditional padding materials with sealants are used, then fuel absorption is prevented, but the manufacturing process becomes burdensome
Solution Approach 1:
The patent extracts the sealant application step from the manufacturing process by using closed-cell foam that inherently prevents fuel absorption. This eliminates the burdensome sealant application step while maintaining fuel absorption prevention, simplifying the manufacturing process
Solution Approach 2:
The closed-cell foam material provides self-service fuel absorption prevention through its inherent closed-cell structure, eliminating the need for additional sealants or complex manufacturing steps. The material protects itself and the fuel system without external assistance
3Weight of moving object
If foam substrate is used without coating, then weight is reduced, but fuel absorption occurs
Solution Approach 1:
The patent changes the cellular structure parameter of the foam from open-cell to closed-cell configuration. This structural parameter change provides inherent fuel absorption prevention while maintaining the lightweight foam substrate without requiring additional coatings or sealants
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 polyurea-coated foam cushions enhance the stiffness, puncture resistance, and flexibility of fuel cell components, reducing weight and eliminating the need for additional sealants, thus improving the overall safety and compliance with FAA regulations.
Implementation Method 1
The polyurea spray coating may be formed from a reaction between an isocyanate component and an amine component upon spraying the polyurea spray coating on the shaped foam substrate
Data Source
AI summary
An aircraft fuel system includes a fuel cell adapted to contain fuel. A fuel cell receiving assembly has an inner surface adapted to receive the fuel cell. A shaped foam substrate is machined from a foam substrate to fit between the inner surface of the fuel cell receiving assembly and the fuel cell. A polyurea spray coating substantially covers the shaped foam substrate to form a fuel cell cushion. The polyurea spray coating is sprayable onto the shaped foam substrate such that the fuel cell cushion is substantially nonabsorbent of fuel. The fuel cell cushion is interposable between the inner surface of the fuel cell receiving assembly and the fuel cell to cushion the fuel cell from damage.