Aircraft Tail Lighting Thermal Insulator Mounting Flange
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Solution Overview
Problem
Aircraft exterior lights, particularly those on the tail cone, face issues with electrostatic discharge and excessive heat buildup due to harsh operating conditions, which can be exacerbated by aerodynamic forces, vibrations, and exposure to hazardous gases like exhaust fumes, and existing solutions do not adequately address thermal management and EMI suppression.
Innovation Solution
The aircraft tail cone assembly incorporates a lighting unit with a thermal insulator that has significantly lower thermal conductivity than the mounting flange, covering at least 50% to 75% of the proximal end surface, and is designed to reduce heat transfer from the tail cone to the lighting unit, including a printed circuit board, while also providing EMI suppression through a gasket and mounting flange configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the lighting unit is mounted directly on the tail cone, then the mounting structure is simple, but excessive heat from the tail cone transfers to the lighting unit causing reliability issues
Solution Approach 1:
A thermal insulator is introduced as an intermediary component between the tail cone and the lighting unit mounting flange. This thermal insulator has low thermal conductivity and prevents heat transfer from the hot tail cone to the lighting unit, thereby improving reliability without significantly complicating the mounting structure.
Solution Approach 2:
The mounting structure uses composite materials with different thermal properties. The mounting flange is made of a material with appropriate thermal conductivity, while the thermal insulator uses a material with low thermal conductivity (such as ceramic or polymer). This composite approach allows thermal management while maintaining structural integrity.
2Strength
If the lighting unit is mounted close to the exhaust outlet, then the aerodynamic forces and vibrations are reduced, but the exposure to hazardous gases and heat increases
Solution Approach 1:
The thermal insulator serves as a protective intermediary that also provides chemical resistance. It forms a barrier between the lighting unit and the hazardous exhaust gases, protecting the electronic components while allowing the mounting location to be optimized for aerodynamic performance.
Solution Approach 2:
A gasket is used to create a sealed interface between the lighting unit and the tail cone. This flexible sealing element protects the interior of the lighting unit from hazardous gases while maintaining the mounting structure's integrity under aerodynamic loads.
3Temperature
If a thermal insulator with low thermal conductivity is used, then heat transfer to the lighting unit is reduced, but the mounting flange and support structure become more complex
Solution Approach 1:
The thermal insulator is segmented into multiple sections that fit between the support structures. This segmentation allows the insulator to be installed in the existing mounting flange geometry without requiring complete redesign of the support structure, thereby reducing thermal conductivity while limiting complexity increases.
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 configuration effectively reduces heat transfer and electrostatic discharge risks, enhancing the reliability and performance of aircraft tail lights by maintaining the lighting unit at a lower temperature and minimizing the impact of hazardous conditions.
Implementation Method 1
a thermal insulator that has significantly lower thermal conductivity than the mounting flange, covering at least 50% to 75% of the proximal end surface, and is designed to reduce heat transfer from the tail cone to the lighting unit
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
The disclosure addresses an external lighting unit for an aircraft. This external lighting unit includes a lighting unit housing (310) have a mounting flange that is configured to provide a reduced contact with a supporting structure (e.g., a tail cone (60, 130) of an aircraft), which in turn reduces conductive heat transfer between the supporting structure and the lighting unit housing (310) (more specifically reduces conductive heat transfer between the supporting structure and a printed circuit board that is disposed within the lighting unit housing (310) and that may be seated on a portion of the lighting unit housing (310)). Open spaces on the surface of the mounting flange that face toward the supporting structure may be occupied by a thermal insulator (340).