Composite Tank Wall Connector Electrical Insulation
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Solution Overview
Problem
The use of composite materials in aircraft fuel tanks poses compatibility issues with traditional metallic tank wall connectors, leading to corrosion and potential electric potential differentials that can cause spark ignition.
Innovation Solution
A tank wall connector system featuring a metallic connector body with a composite interface made of polyetheretherketone and fibreglass, providing electrical insulation and preventing physical contact between the connector and the tank wall, thereby addressing corrosion and ignition risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic tank wall connectors are used with composite tank walls, then structural connectivity is achieved, but corrosion and electric potential differential issues arise
Solution Approach 1:
The connector system is divided into two distinct components: a metallic connector body for structural connectivity and a composite interface for electrical insulation. This segmentation allows each component to fulfill its specific function without compromising the other, resolving the contradiction between structural strength and corrosion/ignition safety.
Solution Approach 2:
The composite interface acts as an intermediary element between the metallic connector body and the composite tank wall. It provides electrical insulation while allowing mechanical connection, thereby preventing both corrosion and electric potential differential issues while maintaining structural connectivity.
2Weight of moving object
If composite materials are used for tank walls, then weight reduction is achieved, but compatibility issues with traditional metallic connectors arise
Solution Approach 1:
The interface is made from composite material (specifically PEEK and fibreglass) that is compatible with composite tank walls. This allows the connector system to work effectively with composite materials, maintaining weight reduction benefits while ensuring proper compatibility and electrical insulation.
3Object-affected harmful factors
If electrical insulation is provided between connector and tank wall, then spark ignition risk is reduced, but physical contact and secure connection may be compromised
Solution Approach 1:
The connector system is segmented into a metallic body for mechanical strength and a composite interface for electrical insulation. The interface includes features like a radial wall and anti-rotation feature that provide secure mechanical connection while maintaining electrical insulation to prevent spark ignition.
Solution Approach 2:
Different parts of the connector system have different properties: the metallic body provides structural strength and connectivity, while the composite interface provides electrical insulation and mechanical engagement features. This local differentiation of properties allows simultaneous achievement of connection security and spark ignition prevention.
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 system effectively prevents corrosion and spark ignition by ensuring electrical insulation and secure, anti-rotation connectivity, ensuring safe and reliable operation of composite aircraft fuel tanks.
Implementation Method 1
the interface having a second electrical conductivity property, different from the first electrical conductivity property
Data Source
AI summary
A tank wall connector system for use with a composite tank, the connector comprises a connector having a body extending from an interior of the tank to an exterior of the tank when installed through a hole in the composite tank. The connector has a first electrical conductivity property. An interface is positioned between the connector and a wall of the composite tank when installed to the tank thereby preventing physical contact between the connector and the tank wall in the interior of the tank, the interface having a second electrical conductivity property, different from the first electrical conductivity property.