Fuel cells for aircraft having extensible fitting regions

1 . A fuel cell for an aircraft, the fuel cell comprising:

a textile support substrate having one or more textile extensible fitting regions and an outer surface; and

a shell layer conforming to the outer surface of the textile support substrate to form the fuel cell, the shell layer having one or more shell extensible fitting regions adjacent to the one or more textile extensible fitting regions;

wherein, the one or more textile extensible fitting regions and the one or more shell extensible fitting regions form one or more fuel cell extensible fitting regions each configured for extensible motion.

2 . The fuel cell as recited in claim 1 wherein, the textile support substrate has a first thickness at the one or more textile extensible fitting regions and a second thickness at nonextensible regions of the textile support substrate, the second thickness greater than the first thickness.

3 . The fuel cell as recited in claim 2 wherein, the first thickness is between 25 percent and 33 percent thinner than the second thickness.

4 . The fuel cell as recited in claim 1 wherein, the textile support substrate has a first fabric density at the one or more textile extensible fitting regions and a second fabric density at nonextensible regions of the textile support substrate, the second fabric density greater than the first fabric density.

5 . The fuel cell as recited in claim 1 wherein, the textile support substrate has a first material composition at the one or more textile extensible fitting regions and a second material composition at nonextensible regions of the textile support substrate, the second material composition different from the first material composition.

6 . The fuel cell as recited in claim 1 wherein, the textile support substrate is formed from a plurality of material plies joined together with a resin.

7 . The fuel cell as recited in claim 1 wherein, the shell layer has a first thickness at the one or more shell extensible fitting regions and a second thickness at nonextensible regions of the shell layer, the second thickness greater than the first thickness.

8 . The fuel cell as recited in claim 1 wherein, the shell layer comprises a first chemical composition at the one or more shell extensible fitting regions and a second chemical composition at nonextensible regions of the shell layer, the first chemical composition different from the second chemical composition.

9 . The fuel cell as recited in claim 1 wherein, the shell layer has a first material composition at the one or more shell extensible fitting regions and a second material composition at nonextensible regions of the shell layer, the second material composition different from the first material composition.

10 . The fuel cell as recited in claim 1 wherein, the shell layer is formed from an elastomeric material.

11 . The fuel cell as recited in claim 1 wherein, the shell layer is sprayed on the outer surface of the textile support substrate.

12 . The fuel cell as recited in claim 1 wherein, the extensible motion of each of the fuel cell extensible fitting regions is configured for at least one of linear motion, angular motion and rotary motion.

13 . The fuel cell as recited in claim 1 wherein, each of the fuel cell extensible fitting regions has a tiered profile.

14 . The fuel cell as recited in claim 1 wherein, each of the fuel cell extensible fitting regions has an accordion profile.

15 . The fuel cell as recited in claim 1 wherein, each of the fuel cell extensible fitting regions has a stepped profile.

16 . An aircraft comprising:

an airframe forming a fuel cell compartment; and

a fuel cell disposed inside the fuel cell compartment, the fuel cell comprising:

a textile support substrate having one or more textile extensible fitting regions and an outer surface; and

a shell layer conforming to the outer surface of the textile support substrate to form the fuel cell, the shell layer having one or more shell extensible fitting regions adjacent to the one or more textile extensible fitting regions;

wherein, the one or more textile extensible fitting regions and the one or more shell extensible fitting regions form one or more fuel cell extensible fitting regions each configured for extensible motion.

17 . A method of manufacturing a fuel cell for an aircraft, the method comprising:

providing a fuel cell mold having one or more extensible fitting protrusions;

applying a textile support substrate on the fuel cell mold and forming one or more textile extensible fitting regions on the one or more extensible fitting protrusions;

applying a shell layer on the textile support substrate and forming one or more shell extensible fitting regions on the one or more textile extensible fitting regions; and

removing the fuel cell mold to form the fuel cell, the one or more textile extensible fitting regions and the one or more shell extensible fitting regions forming one or more fuel cell extensible fitting regions each configured for extensible motion.

18 . The method as recited in claim 17 further comprising applying one or more elastomeric layers on the fuel cell mold prior to applying the textile support substrate on the fuel cell mold such that the one or more elastomeric layers are interposed between the fuel cell mold and the textile support substrate.

19 . The method as recited in claim 17 wherein, applying the shell layer on the textile support substrate, further comprises spray coating the shell layer on the textile support substrate.

20 . The fuel cell produced by the method recited in claim 17 .