阅读说明：本技术 用于飞行器的水和废料的无衬里、可变形的复合罐结构 (Linerless, deformable composite tank structure for water and waste of aircraft ) 是由 E·萨尔赛普德斯 M·纳卡拉 D·斯佩恩 S·莫汉 M·拉尔 于 2020-03-27 设计创作，主要内容包括：一种用于航空航天器机载的废料或水系统的无衬里复合罐,包括整体式罐体,该整体式罐体具有与第二复合材料共固化的第一复合材料。第一复合材料包括第一树脂,第二复合材料包括与第一树脂不同的第二树脂。第一复合材料形成整体式罐体的最内表面,该最内表面限定整体式罐体的罐腔室。一种制造无衬里复合储罐的方法,包括提供具有整体式罐的期望内部形状的模具,将第一复合材料应用到模具,将第二复合材料应用到模具,以及将第一复合材料与第二复合材料共固化以形成整体式复合罐。(A linerless composite tank for a waste or water system onboard an aerospace vehicle includes a unitary tank body having a first composite material co-cured with a second composite material. The first composite material includes a first resin and the second composite material includes a second resin different from the first resin. The first composite material forms an innermost surface of the monolithic tank body that defines a tank cavity of the monolithic tank body. A method of manufacturing a linerless composite storage tank includes providing a mold having a desired interior shape of a monolithic tank, applying a first composite material to the mold, applying a second composite material to the mold, and co-curing the first composite material and the second composite material to form the monolithic composite tank.)

1. A method of manufacturing a unitary composite tank for a waste or water system onboard an aerospace vehicle, the method comprising:

providing a mold comprising a desired internal shape of the monolithic composite can body;

applying a first curable composite material to the mold, wherein the first curable composite material comprises a first resin;

applying a second curable composite material to the mold comprising the first curable composite material, wherein the second curable composite material comprises a second resin different from the first resin; and

co-curing the first curable composite material with the second curable composite material to form the monolithic composite tank body.

2. The method of claim 1, wherein the first resin comprises a thermoset material, and wherein applying the first curable composite material comprises: applying the thermoset material to the mold.

3. The method of claim 2, wherein the thermoset material comprises polyurethane, and wherein applying the thermoset material comprises: applying the polyurethane to the mold.

4. The method of claim 1, wherein the second resin comprises a thermoplastic material, and wherein applying the second curable composite material comprises: applying the thermoplastic material to the mold.

5. The method of claim 4, wherein the thermoplastic material comprises an epoxy, and wherein applying the thermoplastic material comprises: applying the epoxy to the mold.

6. The method of claim 1, wherein the second curable composite material further comprises at least one reinforcing fiber incorporated into the second resin, and wherein applying the second curable composite material comprises: applying the second resin comprising the at least one reinforcing fiber to the mold.

7. The method of claim 1, further comprising removing the mold after curing.

8. The method of claim 1, wherein applying the first curable composite material to the mold comprises: applying the first curable composite material such that the first curable composite material directly contacts a surface of the mold.

9. The method of claim 1, wherein the first resin comprises polyurethane and wherein the second resin comprises an epoxy.

10. A linerless composite tank for a waste or water system onboard an aerospace vehicle, the composite tank comprising a unitary tank body comprising a first curable composite material co-cured with a second curable composite material, wherein the first curable composite material comprises a first resin and the second curable composite material comprises a second resin different from the first resin, and wherein the first curable composite material forms an innermost surface of the unitary tank body, the innermost surface defining a tank cavity of the unitary tank body.

11. The linerless composite tank of claim 10, wherein the second curable composite material further comprises at least one reinforcing fiber incorporated into the second resin.

12. The linerless composite can of claim 11, wherein the at least one reinforcing fiber comprises at least one of carbon fiber, glass fiber, or aramid fiber.

13. The linerless composite tank of claim 11, wherein the at least one reinforcing fiber comprises a plurality of reinforcing fibers.

14. The linerless composite can of claim 10, wherein the first resin comprises a thermoset material.

15. The linerless composite tank of claim 14, wherein the thermoset material comprises polyurethane.

16. The linerless composite tank of claim 10, wherein the second resin comprises a thermoplastic material.

17. The linerless composite can of claim 16, wherein the thermoplastic material comprises an epoxy.

18. A linerless composite tank for a waste or water system onboard an aerospace vehicle, the composite tank comprising a unitary tank body including an inner surface and an outer surface, wherein the inner surface defines a tank cavity, wherein the unitary tank body comprises an epoxy-based curable composite material that is co-cured with a polyurethane-based curable composite material, and wherein the polyurethane-based curable composite material forms the inner surface of the tank body.

19. The linerless composite can of claim 18, wherein the epoxy-based curable composite material further comprises at least one reinforcing fiber incorporated into the epoxy-based curable composite material.

20. The linerless composite can of claim 19, wherein the at least one reinforcing fiber comprises at least one of carbon fiber, glass fiber, or aramid fiber.

Technical Field

The present application relates to composite tank structures for aerospace water and waste applications.

Background

Waste and water systems (or other liquid delivery systems) for aircraft typically include one or more tanks for holding a volume of liquid (e.g., water and/or waste). In some cases, such cans can be formed using various metals, such as titanium, corrosion resistant steel, other metals, as such metals comply with aerospace regulatory requirements, such as flammability, smoke and toxicity compliance, drinkability and/or FDA compliance, pressure requirements, temperature requirements, chemical resistance requirements, structural and/or impact requirements, and/or other requirements. While metal cans meet these aerospace requirements, they are typically heavy thus adding considerable weight to the aircraft, and it is difficult to form the metal into the complex geometries that may be required on the aircraft.

An alternative to metal cans are cans formed from composite materials, such as thermoplastic or thermoset materials. Traditionally, such composite tanks require a liner to be provided on the interior surface of the tank to enable the composite tank to meet various chemical and sealing requirements. Traditionally such liners are seam welded metal liners or preformed thermoplastic liners. The process of forming composite tanks with these liners requires a pre-fabrication step of the liner, which includes placing the liner by hand in a pre-cut pattern, winding using a winder, or gluing. Although composite tanks with liners are lightweight compared to metal tanks, the formation process of such tanks can be time consuming and therefore costly due to the need for pre-fabrication steps. For example, it is not uncommon for the composite tank production process to require 20-30 hours of production time.

Disclosure of Invention

The terms "invention," "said invention," "this invention," and "the invention" as used in this patent are intended to refer broadly to all subject matter of this patent and the patent claims that follow. Statements including these terms should be understood as not limiting the subject matter described herein or as not limiting the meaning or scope of the following patent claims. Embodiments of the invention covered by this patent are defined by the following claims, rather than by this summary. This summary is a high-level overview of various aspects of the invention and introduces a few concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used alone to determine the scope of the claimed subject matter. The subject matter should be understood by reference to the entire specification of this patent, any or all of the drawings, and appropriate portions of each claim.

According to certain embodiments of the present disclosure, a method of producing a unitary composite tank for a waste or water system onboard an aerospace vehicle comprises: providing a mold having a desired internal shape of the unitary composite tank body, and applying a first curable composite material to the mold, wherein the first curable composite material comprises a first resin. The method includes applying a second curable composite material to the mold with the first curable composite material, wherein the second curable composite material includes a second resin different from the first resin. The method also includes co-curing the first curable composite material with the second curable composite material to form a monolithic composite tank body.

In some embodiments, the first resin comprises a thermoset material, and applying the first curable composite material comprises applying the thermoset material to a mold. The thermoset material may comprise polyurethane, and applying the thermoset material may comprise applying the polyurethane to a mold. In various examples, the second resin comprises a thermoplastic material, and applying the second curable composite material comprises applying the thermoplastic material to a mold. In some cases, the thermoplastic material includes an epoxy, and applying the thermoplastic material includes applying the epoxy to the mold.

In various embodiments, the second curable composite material further comprises at least one reinforcing fiber incorporated in a second resin, and applying the second curable composite material comprises applying the second resin comprising the at least one reinforcing fiber to the mold. In certain aspects, the method includes removing the mold after curing. In some cases, applying the first curable composite material to the mold includes applying the first curable composite material such that the first curable composite material directly contacts a surface of the mold. In some embodiments, the first resin comprises polyurethane and the second resin comprises epoxy.

According to certain embodiments of the present disclosure, a linerless composite tank for a waste or water system onboard an aerospace vehicle includes a unitary tank body including a first curable composite material co-cured with a second curable composite material. The first curable composite material includes a first resin and the second curable composite material includes a second resin different from the first resin, the first curable composite material forming an innermost surface of the unitary tank body, the innermost surface defining a tank cavity of the unitary tank body.

In various embodiments, the second curable composite material further comprises at least one reinforcing fiber incorporated into the second resin. The at least one reinforcing fiber may include at least one of carbon fiber, glass fiber, or aramid fiber. In some cases, the at least one reinforcing fiber comprises a plurality of reinforcing fibers.

In some embodiments, the first resin comprises a thermoset material, and in various examples, the thermoset material comprises polyurethane. In certain embodiments, the second resin comprises a thermoplastic material, and in some examples, the thermoplastic material comprises an epoxy resin.

According to certain embodiments of the present disclosure, a linerless composite tank for a waste or water system onboard an aerospace vehicle includes a unitary tank body including an inner surface and an outer surface, wherein the inner surface defines a tank cavity. The unitary can body includes an epoxy-based curable composite material co-cured with a polyurethane-based curable composite material, and the polyurethane-based curable composite material forms an interior surface of the can body.

In some embodiments, the epoxy-based curable composite material further comprises at least one reinforcing fiber incorporated into the epoxy-based curable composite material. The at least one reinforcing fiber may include at least one of carbon fiber, glass fiber, or aramid fiber.

The various embodiments described herein may include additional systems, methods, features and advantages that are not necessarily expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features and advantages be included within this disclosure and be protected by the following claims.

Drawings

Fig. 1 illustrates an example of a composite tank structure according to an embodiment of the present disclosure.

Fig. 2 illustrates a forming process of forming a composite tank structure according to an embodiment of the disclosure.

Detailed Description

The subject matter of embodiments of the present invention is described with specificity herein to meet statutory requirements, but such description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other present or future technologies. The description should not be construed as implying any particular order or arrangement between various steps or elements unless an order of individual steps or arrangement of elements is explicitly described.

A composite tank structure for an airborne spacecraft such as, but not limited to, an on-board water and/or waste system of an aircraft is described herein. The composite tank structure includes a first curable composite material that is co-cured with a second curable composite material to form a unitary tank body of the composite tank structure. The first curable composite material includes a first resin and the second curable composite material includes a second resin different from the first resin. In some non-limiting examples, the first resin comprises a thermoset material and the second resin comprises a thermoplastic material, and in one non-limiting example, the first resin comprises polyurethane and the second resin comprises an epoxy resin. Optionally, one or more reinforcing fibers may be combined with a second resin to form a second composite. In various aspects, after the first curable composite material is co-cured with the second curable composite material, the first curable composite material may form an innermost surface of the tank body, the innermost surface defining a tank cavity of the tank body.

In certain aspects, the first curable composite material allows the resulting composite tank body to meet various chemical, sealing, and/or other aircraft requirements or standards for scrap or water applications without the need for a separate liner as the innermost surface. In some non-limiting examples, a tank having a first curable composite co-cured with a second curable composite, may comply with emission standards for aircraft flammability, smoke, and toxicity, may be chemically resistant (e.g., may withstand scrap in aircraft water and scrap applications, cleaning and disinfection solutions), may comply with FDA/potable standards, may comply with aircraft pressure standards (e.g., withstand positive and negative pressure cycles), and the like.

The omission of a separate liner reduces the production time (and associated costs) required to form the composite tank because the liner pre-fabrication step is no longer required compared to existing composite tanks. In some cases, the production time may be reduced by about 50% compared to the production time required for existing tanks with liners. Omitting a separate liner may also reduce the overall weight of the composite tank compared to existing tanks having liners. Composite tank structures without liners may also be more flexible and may better withstand forces that may occur during use than composite tanks with liners. Composite tanks can also be formed into a variety of shapes that are not available with existing lined composite tanks.

Fig. 1 shows an example of a composite tank structure (100) for waste and/or water applications onboard an aerospace vehicle, such as an aircraft, according to an embodiment. A composite tank structure (100) includes a unitary or monolithic tank body (102) having an outer surface (104) and an inner surface (106). The inner surface (106) may define one or more tank chambers (108) that may store a quantity of liquid, and/or waste, and/or other solutions for water applications. One or more openings (110) may provide access to the tank chamber(s) (108), and a fitting (112) (or other suitable coupler or other component) may be connected to the opening (110) such that the composite tank structure (100) is in fluid communication with waste and/or other components of a water application (e.g., pipes, conduits, sinks, toilets, faucets, etc.). The particular shape of canister (102) shown in fig. 1 should not be considered limiting of the present disclosure, as canister (102) may have various other suitable shapes as desired. For example, FIG. 2 shows a non-limiting example of a can (202A-C) having a different shape than can (102). Optionally, the composite tank structure (100) may include various water and/or waste sensors.

The monolithic can body (102) includes a first curable composite material that is co-cured with a second curable composite material to form the monolithic can body (102). In various aspects, the first curable composite material at least partially forms an inner surface (106) of the monolithic can body (102).

In various embodiments, the first curable composite material comprises a first resin and the second curable composite material comprises a second resin different from the first resin. In some embodiments, the first resin may comprise a thermoset material. In one embodiment, the first resin comprises polyurethane. Optionally, additives may be added as part of the first curable composite material to improve the performance of the composite tank and/or meet various aircraft requirements and/or standards. As one example, additives may be included to improve the compliance of the composite tank with flammability, smoke, and toxic emissions standards.

In some embodiments, the second curable composite material may comprise a thermoplastic material or a thermoset material. Such thermoplastic materials suitable as the second curable composite material may include, but are not limited to, polyethyleneimine, polyphenylene sulfide, polyphenylsulfone, polyetheretherketone, polyetherketoneketone, polyvinylidene fluoride, or any other suitable thermoplastic material or combination of materials, and such thermosetting materials suitable as the second curable composite material may include, but are not limited to, epoxy, vinyl ester, or any other suitable thermosetting material or combination of materials. The second curable composite material may optionally include reinforcing fibers, such as carbon fibers, glass fibers, aramid fibers (e.g., carbon fibers, glass fibers, aramid fibers, etc.)Etc.), any other suitable reinforcing fibers, or combinations thereof. The fibers may be continuous or short fibers and may also be unidirectional, multidirectional, woven, braided, or a combination of these. Depending on the process chosen, the fibers may be dried by introducing resin (thermoplastic or thermoset) at the time of part lay-up, or pre-impregnated fiber(s) may be used.

Fig. 2 illustrates an example of a manufacturing process for manufacturing a can body according to an embodiment of the present disclosure. Fig. 2 illustrates a process for forming different cans (202A-C), but it should be understood that any of the cans discussed herein can be formed by the process illustrated in fig. 2.

In block (201), the process includes providing a mandrel or die that defines a desired internal shape of the monolithic composite can body. In the example of FIG. 2, three exemplary molds (214A-C) are shown, each having a mold surface (215A-C) that defines a different interior shape of the can body. The mold may be formed from a variety of suitable materials, such as metal, plastic, or silicone. In some cases, the mold(s) may be inflatable and deflatable, although in other examples they are not required.

In block (203), the process includes applying a first curable composite material (216) to a mold (214A-C). In block (205), the process includes applying a second curable composite material (218) to the mold (214A-C) already having the first curable composite material (216). In various aspects, the second curable composite material (218) and the first curable composite material (216) are applied to the mold (214A-C) such that the first curable composite material contacts the mold surface (215A-C) and/or an inner surface that will form the can body (202A-C). In block (207), the process includes co-curing the first curable composite material (216) with the second curable composite material (218) in an oven or other suitable apparatus to form the can body (202A-C). In various examples, the molds (214A-C) may be removed from the formed cans (202A-C), respectively, after the co-curing stage. Depending on the type of mold, the mold may be removed by various suitable processes, such as pulling the can (202A-C) in the mold (214A-C), deflating the mold (214A-C), dissolving the mold (214A-C), deforming the mold (214A-C), and so forth. In some alternative cases, a second curing process is performed on the can (202A-C) after the mold (214A-C) is removed.

Other processes for manufacturing composite materials may include Resin Transfer Molding (RTM) and/or Vacuum Assisted Resin Transfer Molding (VARTM). These are variants of wetting the reinforcing fibers with a resin (thermoplastic or thermosetting).

The following provides a collection of exemplary embodiments, including at least some exemplary embodiments explicitly enumerated as "examples," which provide additional description of various embodiment types in accordance with the concepts described herein. These examples are not meant to be mutually exclusive, exhaustive, or limiting; and the invention is not limited to these exemplary embodiments but includes all possible modifications and variations within the scope of the issued claims and their equivalents.

Example 1: a method of manufacturing a unitary composite tank for an airborne waste or water system of an aerospace vehicle, the method comprising: providing a mold comprising a desired internal shape of a monolithic composite can body; applying a first curable composite material to a mold, wherein the first curable composite material comprises a first resin; applying a second curable composite material to a mold comprising the first curable composite material, wherein the second curable composite material comprises a second resin different from the first resin; and co-curing the first curable composite material with the second curable composite material to form the unitary composite tank body.

Example 2: the method of any preceding or subsequent example or example combination, wherein the first resin comprises a thermoset material, and wherein applying the first curable composite material comprises applying the thermoset material to the mold.

Example 3: the method of any preceding or subsequent example or example combination, wherein the thermoset material comprises polyurethane, and wherein applying the thermoset material comprises applying the polyurethane to the mold.

Example 4: the method of any preceding or subsequent example or example combination, wherein the second resin comprises a thermoplastic material, and wherein applying the second curable composite material comprises applying the thermoplastic material to the mold.

Example 5: the method of any preceding or subsequent example or example combination, wherein the thermoplastic material comprises an epoxy, and wherein applying the thermoplastic material comprises applying the epoxy to the mold.

Example 6: the method of any preceding or subsequent example or example combination, wherein the second curable composite material further includes at least one reinforcing fiber incorporated into a second resin, and wherein applying the second curable composite material includes applying the second resin including the at least one reinforcing fiber to the mold.

Example 7: the method of any preceding or subsequent example or example combination, further comprising removing the mold after curing.

Example 8: the method of any preceding or subsequent example or example combination, wherein applying the first curable composite material to the mold includes applying the first curable composite material such that the first curable composite material directly contacts a surface of the mold.

Example 9: the method of any preceding or subsequent example or example combination, wherein the first resin comprises polyurethane and wherein the second resin comprises an epoxy resin.

Example 10: a linerless composite tank for an aerospace vehicle-borne waste or water system, the composite tank comprising a unitary tank body comprising a first curable composite material co-cured with a second curable composite material, wherein the first curable composite material comprises a first resin and the second curable composite material comprises a second resin different from the first resin, and wherein the first curable composite material forms an innermost surface of the unitary tank body, the innermost surface defining a tank cavity of the unitary tank body.

Example 11: the linerless composite tank of any preceding or subsequent example or example combination, wherein the second curable composite material further includes at least one reinforcing fiber incorporated into the second resin.

Example 12: the linerless composite tank of any preceding or subsequent example or example combination, wherein the at least one reinforcing fiber comprises at least one of carbon fiber, glass fiber, or aramid fiber.

Example 13: the linerless composite tank of any preceding or subsequent example or example combination, wherein the at least one reinforcing fiber comprises a plurality of reinforcing fibers.

Example 14: the linerless composite tank of any preceding or subsequent example or example combination, wherein the first resin comprises a thermoset material.

Example 15: the linerless composite can of any preceding or subsequent example or example combination, wherein the thermoset material comprises polyurethane.

Example 16: the linerless composite tank of any preceding or subsequent example or example combination, wherein the second resin comprises a thermoplastic material.

Example 17: the linerless composite can of any preceding or subsequent example or example combination, wherein the thermoplastic material comprises an epoxy.

Example 18: a linerless composite tank for an aerospace vehicle-borne waste or water system, the composite tank comprising a unitary tank body including an inner surface and an outer surface, wherein the inner surface defines a tank cavity, wherein the unitary tank body comprises a curable epoxy-based composite co-cured with a curable polyurethane-based composite, wherein the curable polyurethane-based composite forms the inner surface of the tank body.

Example 19: the linerless composite tank of any preceding or subsequent example or example combination, wherein the epoxy-based curable composite material further includes at least one reinforcing fiber incorporated into the epoxy-based curable composite material.

Example 20: the linerless composite tank of any preceding or subsequent example or example combination, wherein the at least one reinforcing fiber comprises at least one of carbon fiber, glass fiber, or aramid fiber.

Example 21: an aerospace vehicle-mounted water system comprising a linerless composite tank of any preceding or subsequent example or combination of examples.

Example 22: the water system of any preceding or subsequent example, or combinations of examples, wherein the aerospace vehicle comprises an aircraft.

Example 23: a waste system on board an aerospace vehicle comprising a linerless composite tank of any preceding or subsequent example or combination of examples.

Example 24: the scrap system of any preceding or subsequent example or combination of examples, wherein the aerospace vehicle comprises an aircraft.

Different arrangements of the components depicted in the drawings or described above, as well as components and steps not shown or described, are possible. Similarly, some features and subcombinations are of utility and may be employed without reference to other features and subcombinations. Embodiments of the present invention have been described for illustrative, but not restrictive, purposes, and alternative embodiments will become apparent to the reader of this patent. Accordingly, the present invention is not limited to the embodiments described above or depicted in the drawings, and various embodiments and modifications may be made without departing from the scope of the appended claims.