Multilayer Thermoplastic Fuel Pipe for Aircraft
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Solution Overview
Problem
Current composite fuel pipes for aircraft, designed to manage electrical conductivity and reduce mass, are heavier and more expensive due to the use of glass fibers in insulating layers, and existing solutions do not effectively balance conductivity control with weight reduction and manufacturing cost.
Innovation Solution
A multilayer pipe design featuring internal and external layers made of composite thermoplastic materials with conductive reinforcement, separated by an intermediate layer that provides stiffness and electrical insulation, allowing for efficient electrostatic charge evacuation and lightning diversion while minimizing mass and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass fibers are used in the insulating intermediate layer of composite pipes, then electrical insulation and structural strength are improved, but the mass of the pipe increases significantly
Solution Approach 1:
The patent changes the material parameters of the intermediate layer from glass fiber-reinforced thermosetting composite to unreinforced thermoplastic material. This parameter change maintains electrical insulation properties while significantly reducing the mass of the pipe, as thermoplastic materials without heavy glass fibers provide sufficient insulation for fuel pipes.
Solution Approach 2:
The patent extracts the glass fibers from the intermediate layer composition, removing the source of excessive mass. By taking out the reinforcing fibers that cause weight increase, the design achieves electrical insulation through the thermoplastic matrix alone, resolving the contradiction between insulation reliability and weight reduction.
2Reliability
If three-layer thermosetting composite structure is used, then electrical conductivity control is improved, but manufacturing cost and process complexity increase
Solution Approach 1:
The patent changes the manufacturing parameters from thermosetting composite processing to thermoplastic processing. Thermoplastic materials allow for simpler, more cost-effective manufacturing processes such as extrusion and molding, eliminating the need for complex layer-by-layer deposition and consolidation operations required for thermosetting composites.
Solution Approach 2:
The patent extracts the complex three-layer thermosetting composite structure and replaces it with a simplified design using thermoplastic materials. This extraction of complexity from the manufacturing process reduces both cost and operational difficulty while maintaining the essential functionality of electrical conductivity control through the multilayer structure.
3Strength
If successive deposition and consolidation operations are used for thermosetting layers, then structural integrity is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent changes the material state parameters from thermosetting to thermoplastic, which fundamentally alters the manufacturing process. Thermoplastic materials can be processed using continuous extrusion and molding operations that are inherently more efficient than the batch-wise deposition and consolidation required for thermosetting composites, thereby improving productivity while maintaining structural integrity.
Solution Approach 2:
The patent substitutes the mechanical deposition and consolidation system used for thermosetting layers with a more efficient thermoplastic processing system. This substitution replaces complex multi-step mechanical operations with simpler, more automated thermoplastic forming processes, enhancing manufacturing efficiency without compromising the structural strength of the pipe.
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 solution achieves effective electrical conductivity control with reduced mass and lower manufacturing costs compared to traditional thermosetting structures, enabling a lightweight and cost-effective fuel pipe solution.
Implementation Method 1
The conductivity of the internal and external layers which is conferred by the electrically conductive carbon fibers is provided to allow the evacuation by the internal layer of the electrostatic charges
Implementation Method 2
The conductivity of the internal and external layers which is conferred by the electrically conductive carbon fibers is provided to allow the evacuation by the internal layer of the electrostatic charges and the diversion by the external layer of the lightning vis-à-vis the interior of the pipe
Implementation Method 3
it is essentially intended to electrically insulate the outer layer from the inner layer by the glass fibers that it incorporates
Data Source
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Figure 5~6
AI summary
The tubing has a multilayer pipe (1) including a radial internal layer (2) and a radial external layer (3) that are made of composite plastic material. Each of the internal and external layers has a closed coil winding of continuous element i.e. band, made of composite thermoplastic material, incorporating electrically conducting reinforcement fibers e.g. long carbon fibers, such that the pipe evacuates electrostatic charges by the internal layer and diverts electrical discharges by the external layer while producing a high inertia and reduced mass module. The pipe has connecting mouthpieces made of thermoplastic composite material or metallic material. The continuous element is made of graphite or mixture of carbon fibers and glass or aramid fibers. Independent claims are also included for the following: (1) an airplane wing comprising a fuel line (2) a method for fabricating a multilayer pipe for a tubing.