Block Foam Method of Accomplishing Ignition Mitigation in Aircraft Fuel Tanks

Abstract

A process method utilizing customized, specifically-shaped pieces of reticulated polyurethane foam (RPF) to fill an aircraft fuel tank or tank compartment to provide ignition mitigation and prevent explosion in the tank. The process involves inserting the shaped pieces of RPF through existing access ports into a fuel tank in order to fill the tank, excepting minimal planned void spaces. This process effects ignition mitigation by acting as an ignition blocker, mechanically interfering with the compression wave that precedes the flame front in an explosion, and changing the vaporous mixture above the fuel level (ullage) in the tank. The foam pieces are assembled and fitted together throughout the tank in a pattern that replicates the shape of the tank. After the foam insertion is complete, the fuel tank is filled with purging fluid, drained through a filter until no debris is found, and the new maximum fuel quantity is recalibrated.

Claims

1. A method for providing fuel ignition mitigation throughout the interior of at least one fuel tank of an aircraft, comprising the steps of: a) determining the internal dimensions, profile, connections, attachments, and integral components of the inner surfaces of the fuel tank at regular, measured linear increments along either the width or length dimension of the interior of the tank; b) rendering a to-scale engineering drawing of the cross-sectional profile of the fuel tank at each linear increment; c) numerically sequencing said drawings so as to correspond to each sequentially- measured increment within the tank: d) providing a plurality of planar sheets of reticulated polyurethane foam (RPF) material, said RPF comprising a thickness in the range of 1.0 inch to 2.0 inches; e) excising an aggregate of cutouts of RPF blocks from said planar sheets of RPF, each cutout conforming to each of said individual to-scale engineering drawings, and further, designating each cutout by a part number, an orientating UP arrow, and an orienting FORWARD arrow; f) arranging the aggregate of said RPF blocks in a progressive sequence corresponding to the installation sequence of each RPF block along the linear increments previously measured; g) sequentially packaging said aggregate of RPF blocks into groupings containing a specified number of RPF blocks per grouping; h) composing installation instructions to be used by technicians who shall perform the installation of said RPF blocks; i) parking the subject aircraft at the site of the installation, and emptying and purging the specific fuel tank into which the RPF blocks are to be installed: j)) removing a first fuel tank access panel or other external fuel tank cover which i) functions as a point of entry for maintenance personnel and/or technicians into the fuel tank, and ii) is proximate the starting point of the installation; k) inspecting the inside of the tank to ensure cleanliness and accessibility by the installers; l)) placing the first sequential RPF block at a specified location within the fuel tank as so designated in the installation instructions; m) placing each successively-ordered RPF block at its designated location within the fuel tank, as set forth in the installation instructions, until said fuel tank is filled with the required number of RPF blocks; n) performing an inspection of the installed RPF blocks, and afterwards, closing the fuel tank access panel; and p) re-fueling the fuel tank and verifying the fuel tank's maximum fuel quantity in accordance with FAA-certified fuel gauge calibrating procedures for the subject aircraft.

2. A method for providing fuel ignition mitigation throughout the individual interiors of multiple compartments of a fuel tank of an aircraft having such compartments. comprising the steps of a) determining the internal dimensions, profile, connections, attachments, and integral components of the inner surfaces of each compartment of the fuel tank at regular, measured linear increments along either the width or length dimension of the interior of each compartment; b) rendering a to-scale engineering drawing of the cross-sectional profile of each compartment at each linear increment; c) numerically sequencing said drawings corresponding to each sequentially-measured increment within each compartment; d) providing a plurality of planar sheets of reticulated polyurethane foam (RPF) material, said RPF material comprising a thickness in the range of 1.0 inch to 2.0 inches; e) excising an aggregate of cutouts of RPF blocks from said planar sheets of RPF, each cutout conforming to each of said individual to-scale engineering drawings for each particular compartment, and further, designating each RPF block by a part number, an orientating UP arrow, and an orienting FORWARD arrow; f) for each compartment, arranging the aggregate of said RPF blocks in a progressive sequence corresponding to the installation sequence of each RPF block along the linear increments previously measured for the compartment; g) for each compartment. sequentially packaging said aggregate of RPF blocks into groupings containing a specified number of RPF blocks per grouping; h) composing installation instructions for each compartment, said instructions to be used by technicians in the installation of said RPF blocks; i) parking the subject aircraft at a designated site of the installation of the RPF blocks, emptying and purging all compartments of the fuel tank; j) selecting a first compartment, then removing a first tank access panel or other external tank cover which i) functions as an opening for entry of maintenance personnel and/or technicians into the compartment, and ii) is proximate said first selected compartment; k) inspecting the inside of said first compartment to ensure cleanliness and accessibility by the installers; l) placing the first sequential RPF block at a specified location within the first compartment of the fuel tank as so designated in the installation instructions; m) placing each successively-ordered RPF block at its designated location within the first compartment as set forth in the installation instructions, until said first compartment is filled with the required number of RPF blocks; n) for each remaining compartment of the fuel tank, performing steps j) through m), above; o) performing an inspection of the installed RPF blocks, and afterwards, closing all open compartment or fuel tank access panels; p) re-fueling all compartments of the fuel tank and verifying the fuel tank's maximum fuel quantity in accordance with FAA-certified fuel gauge calibrating procedures for the subject aircraft.

3. A method for providing fuel ignition mitigation for the interior of the center wing tank of a Boeing 737 aircraft of the type that is equipped with a center wing tank consisting of a forward, center, and aft compartment, said method comprising the steps of: a) determining the internal dimensions, profile, connections, attachments, and integral components of the inner surfaces of each of the forward, center, and aft compartments of the center wing tank at regular, measured linear increments along either the width or length dimension of the interior of each compartment; b) rendering a to-scale engineering drawing of the cross-sectional profile of each of the forward, center, and aft compartments at each linear increment; c) numerically sequencing said drawings corresponding to each sequentially-measured increment within each of the forward, center and aft compartments; d) providing a plurality of planar sheets of reticulated polyurethane foam (RPF) material, said sheets of RPF comprising a thickness in the range of 1.0 inch to 2.0 inches; e) excising an aggregate of cutouts of RPF blocks from said planar sheets of RPF, each block cutout conforming to said individual to-scale engineering drawing in each particular compartment. and further, designating each RPF block by a part number, an orientating UP arrow and an orienting FORWARD arrow; f) arranging the aggregate of said RPF blocks in a progressive sequence corresponding to the installation sequence of each RPF block along the linear increments previously measured for each of the forward, center, and aft compartments; g) for each compartment, sequentially packaging said aggregate of RPF blocks into groupings containing a specified number of RPF blocks per grouping; h) composing installation instructions for each compartment. said instructions to be used by technicians in the installation of said RPF blocks; i) parking the subject aircraft at a designated site of the installation of the RPF blocks, emptying and purging all compartments of the fuel tank; j) beginning with the aft compartment, removing a first tank access panel or other external tank cover which i) functions as an opening for entry of maintenance personnel and/or technicians into the compartment, and ii) is proximate said aft compartment; k) inspecting the inside of said aft compartment to ensure cleanliness and suitability; l) placing the first sequential RPF block at a specified location within the aft compartment, as so designated in the installation instructions; m) placing each successively-ordered RPF block at its designated location within the aft compartment as set forth in the installation instructions, until said aft compartment is filled with the required number of RPF blocks; n) performing an inspection of the installed RPF blocks in the compartment, then closing un-needed tank/compartment access panels, o) placing successively-ordered RPF blocks at their designated locations within the center compartment as set forth in steps j) through n), above until said center compartment is filled with the required number of RPF blocks; p) placing successively-ordered RPF block at their designated locations within the forward compartment as set forth in steps j) through n) above, until said forward compartment is filled with the required number of RPF blocks; and q) re-fueling all compartments of the fuel tank and verifying the fuel tank's maximum fuel quantity in accordance with FAA-certified fuel gauge calibrating procedures for the subject aircraft.

4. A method as in claim 1, wherein the reticulated polyurethane foam material comprises a purple color.

5. A method as in claim 2, wherein the reticulated polyurethane foam material comprises a purple color.

6. A method as in claim 3, wherein the reticulated polyurethane foam material comprises a purple color.

Description

BRIEF DESCRIPTION OF THE VIEWS OF THE DRAWINGS

[0032] FIG. 1 illustrates a general overall fuselage-cutaway view of a Boeing 737 jet aircraft, further showing the location of the center wing fuel tank.

[0033] FIG. 2 shows the location of the center wing tank of the Boeing 737 aircraft, as would be seen looking through the bottom of the fuselage, and further, a tank access panel utilized by maintenance personnel for ground servicing.

[0034] FIG. 3 depicts a close-up view of the access panel to the center wing tank shown in FIG. 2.

[0035] FIG. 3(A) is an illustration of the manner in which the access panel is removed from the exterior of the center wing tank

[0036] FIG. 4 shows a cutaway view of the structural members of the center wing tank, in accordance with section line 4-4 of FIG 1.

[0037] FIG. 5 illustrates the profile of a single, specifically-shaped RPF block which has been precisely cut to fit, in a vertical orientation, the exact contour of one section of the center wing tank.

[0038] FIG. 5(A) presents a side view of the RPF block of FIG. 5.

[0039] FIG. 6 presents a diagram of the aggregate of a plurality of sequentially-arranged, pre-cut RPF blocks to be installed adjacent to one another, thereby conforming to the contour of the forward compartment of the center wing tank.

[0040] FIG. 7 is a stylized rendering of the center wing tank, further showing the packing arrangement of a plurality of RPF blocks properly installed in the forward compartment of the center wing tank.

[0041] FIG. 8 depicts the initiation of installation of RPF blocks on the right side of the aft compartment.

[0042] FIG. 8A shows the initiation of installation of RPF blocks on the left side of the aft compartment, the right side of the compartment having been completed

[0043] FIG. 8B presents depicts the beginning of installation of RPF blocks in the middle section of the aft compartment.

[0044] FIG. 8C depicts the completion of installation of RPF blocks in the aft compartment.

[0045] FIG. 9 illustrates a diagram of the resultant installation of all RPF blocks in the forward, center, and aft compartments of the center wing tank of a typical Boeing 737 aircraft.

DETAILED DESCRIPTION OF THE INVENTION

[0046] The present inventive concept includes the use of shaped, interrelated, sequential blocks of reticulated polyurethane foam (RPF) blocks to fill specific fuel tank(s) of a transport category aircraft. The objects, features, and advantages of the concept presented in this application are more readily understood when referring to the accompanying drawings. The drawings, totaling nine figures, show the basic components and functions of embodiments and/or the proper method steps. In the several figures, like reference numbers are used in each figure to correspond to the same component as may be depicted in other figures.

[0047] For illustrative purposes only, and not by way of limitation, the methods and systems described in this disclosure apply primarily to Boeing 737 series aircraft. This detailed description section is merely exemplary in nature and is not intended to limit the methods and uses shown in this inventive concept. There is no intention for the applicant to be bound or constrained by any expressed or implied theory(ies) set forth in the relevant technical fields, background, brief summary, or the present detailed description of the inventive concept as it relates to Boeing 737 aircraft. Further, there is no intent to confine the inventive method disclosed to one particular make, model, or series of aircraft, or particular configurations of aircraft fuel tanks.

[0048] By utilizing the disclosed method of installing RPF blocks 50 to fill one or more fuel tanks of an aircraft, the aircraft operator prevents or minimizes the potentially damaging or catastrophic effects of fuel ignition, fire, and/or explosion. For ease of explanation and for illustrative purposes, the disclosed method is described with regard to installation of the RPF blocks into the center wing tank 112 of a Boeing 737 aircraft 110.

[0049] The discussion of the present inventive concept will be initiated with FIG. 1, which illustrates an overall view of a Boeing 737 jet aircraft 110. FIG 1 also depicts the fuselage 111, and the center wing tank 112. which is encircled. As in most similar jet aircraft, the predominance of the fuel load is generally carried in fuel tanks constructed within the left wing 104 and right wing 105, with equal quantities in each wing 104, 105. The wing-loaded fuel serves to add a counter-balancing weight to offset the upward wing structural bend due to the aerodynamic lift force generated by the wings 104, 105 when in flight. However, for substantially increased range, the aircraft 110 may be loaded with additional fuel in the center wing tank 112 and other internal tanks, if available.

[0050] FIG. 2 is a stylized rendering looking upward at the undersurface of the Boeing 737 fuselage 111, further revealing the location of the center wing tank 112. Also shown in FIG. 2 is a center wing tank access panel 20 utilized by maintenance personnel during ground servicing of this particular model and series of the Boeing 737.

[0051] FIG. 3 depicts an expanded view of the access panel 20 shown in FIG. 2. FIG. 3(A) is an illustration of the manner in which the access panel 20 is removed from the exterior of the center wing tank 112, further showing a clamp ring 21. one of a plurality of washers 22, and one of a plurality of bolts 23. the washers 22 and bolts 23 utilized for insertion through apertures 24 for fastening the clamp ring 21 onto a lower center wing panel 26.

[0052] FIG. 4 illustrates a stand-alone sectional view of the center wing tank 112, in accordance with section line 4-4 of FIG. 1. The structural integrity of the center wing tank 112, as positioned within the fuselage 111, substantially determines the internal contour of the center wing tank 112. The aircraft 110 structural members shown in FIG. 4 include the front spar 120, the rear spar 121, the floor beams 122, and the tank ceiling 127 abutting the aircraft floor beams 122. As shown in FIG. 4, the center wing tank 112 comprises a forward compartment 131, a center compartment 132, and an aft compartment 133. The three compartments 131, 132, 133 are separated by spanwise beam #2 124 and spanwise beam 41 125. In each of the three compartments 131, 132, 133, the fuel tank floor 128 comprises lower stiffeners 128 and the fuel tank ceiling 127 comprises upper stiffeners 129, which give additional rigidity to the tank compartments 131, 132, 133.

[0053] Before continuing with the immediate discussion of installation of the RPF aggregate blocks 50, explanation will be given of the methodology and process of measuring, sizing, and cutting the RPF blocks 50. Shown in FIG. 5 there is illustrated, by way of example, a forward compartment RPF block 51.

[0054] FIG. 5 shows a profile view of a forward compartment RPF block 51. This forward compartment RPF block 51 is designated as such due to the fact that the contour of its outer perimeter corresponds to the location of a specific, vertically-oriented cross-section of the forward compartment 131 of the center wing tank 112. In examining FIG. 5, the topmost section shows four upper cutouts 52 which provide clearance for the upper stiffeners 129 of the forward compartment 131 as shown in FIG. 4. The left edge 55 of RPF block 51 is fabricated so as to correspond to the forward tank wall 123, and further shows an arcuate cutout 53 which provides clearance for a tank fuel pump, or other tank component. The bottommost section of the forward compartment RPF block 51 illustrates three cutouts 54 which allow clearance for the three lower stiffeners 130 of the forward compartment 131, as shown in FIG. 4.

[0055] The right edge 56 of the forward compartment RPF block 51 corresponds to spanwise beam #2 124, as is depicted in FIG. 4. FIG. 5(A) is a view looking directly at the right edge 56 of the forward compartment RPF block 51, and further showing the nominal width 57 of the forward compartment RPF block 51. The width of the aggregate RPF blocks 50 are fabricated in the range of 2.0 inches to 4.0 inches, depending on the size and contour of the fuel tank in which RPF blocks 50 are to be installed. A directional UP arrow and a FORWARD arrow are printed on the surface of the RPF block 51 to further ensure the installer places the block 51 in the correct orientation.

[0056] The illustrated forward compartment RPF block 51 of FIG. 5 is further given a part number (P/N) to indicate its exact location in the forward compartment 131 of the center wing tank 112. The part number also defines the order of its loading in the installation sequence of all RPF blocks 50. The general manner of construction of the contour of the previously-described forward compartment RPF block 51 is typical of the parameters to be met for each of the aggregate RPF blocks 50 to be inserted in the forward compartment 131 of the center wing tank 112 of a Boeing 737 series 400 aircraft as well as those RPF blocks to be installed in the mid compartment and aft compartment of the center wing tank 112. Similarly, the general manner of construction of the contour of any other RPF block described above is typical of the parameters to be met for any RPF block to be installed in any of a variety of aircraft fuel tanks.

[0057] The contours of the aggregate of all RPF blocks 50 are a culmination of determinations made of the internal dimensions, profile, connections, attachments, and integral components of the inner surface of the fuel tank at the specific measured increment along one length of the forward, center, and aft compartments 131, 132, 133 of the center wing tank 112. This methodology is applicable to the determination of the size and contour of any RPF block that may be fabricated for insertion into any of an unlimited variety of aircraft fuel tanks.

[0058] In preparing for installation of RPF blocks in the center wing tank 112, a plurality of planar sheets of reticulated polyurethane foam (RPF) material is manufactured. Each of said sheets, in the preferred embodiment, generally comprises a thickness 57 of 2.0 inches. However, in general applicability, the thickness is dependent upon the size and type of aircraft fuel tank in which the RPF blocks are to be inserted. During the manufacturing process, the planar sheets of reticulated polyurethane foam may be dyed a purple color. The purple color facilitates the trouble-shooting of fuel contamination or irregularities associated with the engine fuel feed or tank.

[0059] By way of example only, in the case of the center wing tank 112 of a -300 series Boeing 737 aircraft, engineering drawings are executed in a sequential series of scaled renderings of the profile of the forward compartment 131 of the center wing tank 112. The profile of the compartment is measured and scaled at regularly-spaced increments (2.0 inches in the preferred embodiment) along an essentially horizontal line extending from the right side to the left side of the interior of the forward compartment 131. In the same manner, engineering drawings are rendered for the incremental profile of the center compartment 132 and aft compartment 133 of the center wing tank 112.

[0060] A plurality of cutouts of RPF blocks 50 is made from the manufactured sheets of RPF, each block cutout excised according to the previously-described scaled renderings and further, each RPF block cutout is progressively identified with a part number and an orientating UP arrow and FORWARD arrow is printed thereon. Cutting and shaping of the individual RPF block cutouts from the RPF sheets is accomplished by use of several optional means: a mechanical blade type cutting, specially designated/manufactured smooth blade type cutting tools, an extremely fine-toothed band saw-type blade, or a hot-wire type cutting tool per SAE AIR4170A.

[0061] Once the entirety of the aggregate RPF blocks 50 required for the center wing tank 112 have been excised, each cutout is painted with a part number (P/N) and numerical sequencing corresponding to the sequential placement of each RPF block cutout along the line of measured increments within each of the forward, center, or aft compartments 131, 132, 133. The RPF blocks 50 are individually packaged and arranged in a stack or stacks which correspond to the orderly, sequential installation of each RPF block 50 along the horizontal line of increments previously measured. Further, detailed written instructions regarding the installation are drafted and organized in a manual for the guidance of technicians who will install said RPF blocks 50.

[0062] To install the shaped block reticulated polyurethane foam in the center wing tank 112, the aircraft 110 must be positioned on a level surface and at a convenient height for access to the center wing tank 112. The access opening cover is then removed and the RPF blocks 50 are inserted through the access openings with the exercise of care to avoid tearing or abrading the RPF blocks on the lip of the opening. FIG. 2, FIG. 3 and FIG. 3(A) illustrate the relative position of the access panel 20 of the center wing tank 112.

[0063] As stated previously, a very specific order of insertion of the RPF blocks 50 must be followed so that all spaces that are intended to be filled in the center wing tank 112 are indeed filled. Empty spaces in the tank can only be those left by design, which is referred to as planned voiding. The center wing tank 112 under discussion here should be filled with the RPF blocks 50 fitted according to the patterns specified in the specific engineering drawings and installation instructions of each designed block contour.

[0064] By way of further illustration, FIG. 6 depicts a diagram of a plurality of sequentially-arranged, pre-cut RPF blocks to be installed adjacent to one another, thereby conforming to the interior contour of the forward compartment 131 of the center wing tank 112 of a Boeing 737 aircraft. Each of the RPF blocks 50 has a shape and an order of installation which ultimately conforms to a specific contour of the forward compartment 131 at a precise point in the forward compartment 131. FIG. 7 is a stylized rendering of the center wing tank 112, further showing the packing arrangement of a plurality of RPF blocks 50 in the process of being installed in the forward compartment 131 of the center wing tank 112.

[0065] Generally, the installation of the RPF blocks 50 is accomplished by technicians entering through existing fuel tank access bays and openings, along with the uploading of the RPF blocks 50 into the tank 112. In the preferred embodiment, as disclosed in this inventive concept, and for illustrative purposes only, the center wing tank 112 of a typical Boeing 737 aircraft is depicted as undergoing installation of the RPF blocks. On aircraft other than the Boeing 737, existing fuel tank access openings that may be used for insertion and installation include, but are not limited to, maintenance access holes, wet and dry access bays found on non-cylindrical auxiliary fuel tanks, inspection holes in belly tanks, and the like. A very specific order of insertion of the RPF blocks 50 must be followed so that all spaces that are intended to be filled in the tank are indeed filled.

[0066] The shaped blocks 50 of reticulated polyurethane foam (RPF) are inserted through one or more of the access bays, ports, etc., and fitted together in accordance with the present invention. Care is necessarily exercised to avoid tearing or abrading the foam on the lip of the access bays. Shaped block foam pieces are inserted and positioned in a manner to ensure that the required internal tank void is filled and maximum ignition source prevention is achieved. The foam material used is considered to be a memory foam type, the kind that returns to its original shape after compression down to 40% of its original volume. These memory foam RPF blocks 50 may be compressed for passage through the access ports. A key feature of the present inventive concept is that the design of the shaped block foam pieces to allow them to fit through the existing access bays or ports of various aircraft fuel tanks. Previously, installation of similar material had to be accomplished by removing some portions of the aircraft wing skin in some areas.

[0067] The majority of Boeing 737 series 300 and series 400 aircraft are characterized by a first internal access port 18 between the aft compartment 133 and the center compartment 132 of the aircraft and a second internal access port 19 between the center compartment 132 and the forward compartment 131. These access ports are depicted in FIGS. 8, 8A, 8B, and 8C. In the installation of RPF blocks 50 in the center wing tank 112 of a Boeing 737 aircraft, the procedure begins with the right side of the aft compartment 133 of the center wing tank 112. The installer(s) must gain access to the aft compartment 133 first, through the lower access panel 20 located on the underside of the fuselage 111 of the aircraft. as shown in FIG. 2 and FIG. 3. Access is sequentially accomplished through the second internal access port 19. and the first internal access port 18.

[0068] FIG. 8 depicts a quantity of RPF blocks 50 having been installed on the right side of the aft compartment 133. Next, the installer(s) work the left side of the aft compartment 133. FIG. 8A showing the completion of installation of RPF blocks on the left side of the aft compartment 133, the right side of the compartment 133 having been completed. As the installer(s) begins exiting the aft compartment 133 through the first access port 18, he/she installs RPF blocks 50 in the middle section of the aft compartment 133, as shown in FIG. 8B, FIG. 8C depicts the completion of installation of RPF blocks 50 in the aft compartment 133.

[0069] FIG. 9 illustrates a diagram of the resultant installation of all RPF blocks in the forward, mid, and aft compartments of the center wing tank 112 of a typical Boeing 737 aircraft. The diagram depicts the aft compartment 133, the mid

[0070] The fitted size, shape and installation of the aggregate of RPF blocks 50 should be such that no internal tank voids longer than 2.5 feet exist (with the internal tank fuel probes installed). The RPF blocks 50 must be kept clear of the tank components such as the fuel ports, fuel probes, float switches. and tank vents. The planned voiding areas around these structures should not exceed a volume of 10% of the total fuel tank volume and there should be no connecting voids between any of the planned void spaces. The minimum space of foam filled area required between the planned void areas is three (3.0) inches if maximum void size is used.

[0071] While the present invention has been described above in terms of specific embodiments, it is understood that the invention is not limited to these disclosed embodiments. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications, variations, and other embodiments of the invention will come to mind of those skilled in the art to which this invention pertains, and which are intended to be and are covered by both this disclosure and hereafter submitted claims. It is indeed intended that the scope of the invention should be determined by proper interpretation and construction of the hereafter submitted claims and their legal equivalents, as understood by those of skill in the art relying upon the disclosure in this specification and the attached drawings. It is intended that the scope of the invention is not limited to any particular aircraft.