A quick-sealing and repair device for aircraft cockpit canopy punctures and its usage method

Abstract

This invention relates to the field of emergency repair technology for aircraft cockpit canopies, specifically a rapid sealing and repair device and method for repairing punctures and damage to aircraft cockpit canopies. The repair device includes a double-sided adhesive rubber pad that adheres to the inner and outer surfaces of the acrylic canopy; an acrylic patch connected to the double-sided adhesive rubber pad via an adhesive; transparent tape positioned at the edges of the acrylic patch and the double-sided adhesive rubber pad; a bolt passing through a hole in the acrylic canopy and connected to the acrylic patch and the double-sided adhesive rubber pad; and a nut mating with the bolt. The bolt is coated with sealant. This invention can further shorten the repair time for external structures, simplify the operation process, and improve support capabilities. Compared with conventional mechanical connection repair of damaged airframe structures, a semi-circular groove is provided at the connection interface, and the interference fit between the rubber pad, patch, and bolt enhances the sealing performance of the sealing structure.

Description

Technical Field

[0001] This invention relates to the field of emergency repair technology for the external structure of aircraft cockpit canopies, specifically to a rapid sealing and repair device and method for repairing punctures and damage to aircraft cockpit canopies. Background Technology

[0002] The aircraft canopy is mainly composed of a canopy frame and a transparent acrylic glass component. In wartime, it is highly vulnerable to external attacks, resulting in various types of damage such as holes and scratches, potentially leading to cockpit declassification and jeopardizing flight safety and mission support. To effectively ensure the continuous generation of combat power, temporary, rapid field repairs are necessary to address canopy damage, enabling the aircraft to relocate or continue operations.

[0003] A search revealed that Chinese patent application CN202210312805.4 and publication CN114851603A disclose a method for repairing broken acrylic glass canopies of aircraft in field applications. The method involves repairing canopy damage by adding acrylic glass patches and reinforcing patches. The patches are bonded to the original canopy with adhesive and then cured in situ by heating. However, this method requires several hours to repair.

[0004] In the 2014 "Proceedings of the Academic Symposium on Aviation Safety and Equipment Maintenance Technology" (pages 809-813), Wang Dingjiang et al. disclosed a rapid repair process for damage to transparent parts of aircraft cockpit canopies. The process involved removing the damage and manufacturing patches using specialized tooling, and then using a self-developed adhesive to plug and bond the patches. However, this method is only suitable for repairing holes with a diameter of Φ30mm or less, and the damage repair takes 50 minutes.

[0005] Both of the above methods involve using adhesives to cure the damaged surface, which takes a long time and requires heating, and may cause local deformation of the structure. In order to further shorten the repair time of the field structure, simplify the operation process, and improve the protection capability, it is necessary to develop new mechanical connection treatment methods. Summary of the Invention

[0006] To address the aforementioned technical problems, this invention proposes a rapid sealing and repair device and method for repairing damage to aircraft cockpit canopies with holes.

[0007] The technical problem to be solved by this invention is achieved by the following technical solution:

[0008] A rapid sealing and repair device for punctures in an aircraft cockpit canopy includes a double-sided adhesive rubber pad that adheres to the inner and outer surfaces of the plexiglass canopy; a plexiglass patch connected to the double-sided adhesive rubber pad via an adhesive; transparent tape positioned at the edges of the plexiglass patch and the double-sided adhesive rubber pad; a bolt passing through a hole in the plexiglass canopy and connected to the plexiglass patch and the double-sided adhesive rubber pad; and a nut mating with the bolt, wherein the bolt is coated with sealant.

[0009] Preferably, a high-elasticity shock-absorbing rubber ring that mates with the bolt is nested inside the hole in the plexiglass cover, and grooves are cut into the plexiglass patch and the plexiglass cover to increase the sealing performance.

[0010] A method for using a rapid sealing and repair device for punctures in an aircraft cockpit canopy, comprising the following steps:

[0011] Step (1) Make a dust leak-proof bag around the inner hole of the plexiglass hatch cover using sealant and vacuum bag film;

[0012] Step (2) Remove burrs from the edges of the holes, use plaster or high-strength vacuum putty to trace the shape of the damaged area, and make a patch molding mold;

[0013] Step (3) Grind the hole to make it neat. If there are cracks on the edge of the hole, drill a 1mm diameter anti-crack hole 2mm from the tip of the crack.

[0014] Step (4) Using a ball end mill on the outside of the plexiglass cover, mill a semi-circular groove 2mm wide and 1mm deep, 5mm away from the edge of the ground hole.

[0015] Step (5) Use acrylic glass of the same material as the acrylic glass canopy, heat it to soften it, and use a vacuum bag to press and shape it into an acrylic glass patch. The size of the acrylic glass patch needs to be 20-40mm larger than the diameter of the hole after grinding and regularizing in step (3). It is required to cover the crack prevention hole and bevel the edges. The mating surface of the acrylic glass patch is provided with a semi-circular groove of the same specifications as in step (4).

[0016] Step (6) Cut the double-sided adhesive rubber pad. The diameter of the double-sided adhesive rubber pad should be about 3-6mm larger than the diameter of the acrylic patch. The double-sided adhesive rubber pad has semi-circular grooves on both sides that match the position and specifications of the semi-circular grooves on the acrylic cover and the acrylic patch.

[0017] Step (7) Drill holes in the acrylic patch and the double-sided adhesive rubber pad according to the marked positions. The diameter of the hole in the double-sided adhesive rubber pad is 0.5mm-1mm smaller than the diameter of the hole in the acrylic patch. Apply pressure-sensitive adhesive tape to the surface of the acrylic patch when drilling holes.

[0018] Step (8) First, install the double-sided adhesive rubber pad onto the acrylic patch to form a composite patch. Then, press the composite patch onto the inner and outer surfaces of the acrylic hatch cover. Apply sealant to the bolts. Then, pass the bolts through the holes and the composite patches on the inner and outer surfaces of the acrylic hatch cover, and fix them with nuts. If the hole size is too large, nest a high-elasticity shock-absorbing rubber ring inside the hole. The bolts pass through the high-elasticity shock-absorbing rubber ring and the composite patches on the inner and outer surfaces of the acrylic hatch cover, and then fix them with nuts.

[0019] Step (ix) Seal the edges of the composite patch further using transparent tape;

[0020] Step (10) After installing the composite patch, use sealing strips, vacuum bag film, breathable felt, and vacuum gauge to form a vacuum bag on the inside and outside of the plexiglass cover, and evacuate the air to further compact the composite patch and check the sealing condition of the composite patch.

[0021] Preferably, in step (iii), the holes are polished into a circular or elliptical shape.

[0022] Preferably, a transparent double-sided adhesive rubber pad is used in step (vi).

[0023] Preferably, in step (viii), after the double-sided adhesive rubber pad is installed on the plexiglass patch, it is rolled on one side with a scraper. If necessary, a hot air blower is used to soften the double-sided adhesive rubber pad, and the temperature shall not exceed 50°C.

[0024] Preferably, the sealant applied to the bolts in step (viii) is required to be surface dry in about 20 minutes at room temperature and cured within 1 hour.

[0025] Preferably, in step (viii), if the diameter of the hole is greater than 10 mm, the hole is considered too large.

[0026] Preferably, after evacuating for 5 minutes in step (x), the vacuum level remains unchanged and is maintained at -0.87 atmospheres.

[0027] Preferably, if the sealing performance of the composite patch is found to be insufficient in step (x), it can be improved by increasing the tightening force of the bolts. If it still does not meet the requirements, the operation process needs to be checked and the patch resealed.

[0028] The beneficial effects of this invention are:

[0029] This invention provides a rapid sealing and repair device and method for aircraft cockpit canopy puncture damage, which can further shorten the repair time of field structures, simplify the operation process, and improve the protection capability. Compared with conventional mechanical connection repair of bolts for airframe structural damage, a semi-circular groove is set at the connection interface, and the sealing structure is enhanced by the interference fit between the rubber gasket, patch, and bolt. The use of double-sided adhesive rubber gasket and transparent tape enhances the ease of operation and sealing performance. A rubber ring is nested at the bolt shank to prevent the patch from being damaged by pressure. A simple vacuum bag pressurization method is used to improve the structural sealing and inspection tightness. Attached Figure Description

[0030] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0031] Figure 1 This is a schematic diagram of the structure of the rapid sealing and repair device of the present invention.

[0032] In the picture: 1. Bolt; 2. Acrylic glass patch; 3. Double-sided adhesive rubber pad; 4. Transparent tape; 5. Acrylic glass cover; 6. Nut; 7. High-elasticity shock-absorbing rubber ring. Detailed Implementation

[0033] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0034] like Figure 1 As shown, a rapid sealing and repair device for puncture damage in an aircraft cockpit canopy includes a bolt 1, an acrylic patch 2, a double-sided adhesive rubber pad 3, transparent tape 4, a nut 6, and a high-elasticity shock-absorbing rubber ring 7.

[0035] The double-sided adhesive rubber pad 3 is bonded to the inner and outer surfaces of the acrylic glass cover 5. The acrylic glass patch 2 is connected to the double-sided adhesive rubber pad 3 via an adhesive. The transparent tape 4 is placed at the edges of the acrylic glass patch 2 and the double-sided adhesive rubber pad 3. The bolt 1 is coated with sealant and passes through a hole in the acrylic glass cover 5, connecting to the acrylic glass patch 2 and the double-sided adhesive rubber pad 3. The nut 6 engages with the bolt 1 to secure it to the acrylic glass cover 5. For large holes, the high-elasticity shock-absorbing rubber ring 7 is nested within the hole and engages with the bolt 1. Grooves are cut into the acrylic glass patch 2 and the acrylic glass cover 5 to increase sealing.

[0036] A method for using a rapid sealing and repair device for punctures in an aircraft cockpit canopy, comprising the following steps:

[0037] Step (1) Use sealant and vacuum film to make a dust leak-proof bag around the inner hole of the plexiglass cabin cover 5 to prevent debris from entering the cabin.

[0038] Step (2) Remove burrs from the edges of the holes, use plaster or high-strength vacuum putty to trace the shape of the damaged area, and make a patch molding mold.

[0039] Step (3) Grind the hole to make it regular, preferably into a round or oval shape. If there are cracks on the edge of the hole, a 1mm diameter anti-crack hole must be drilled 2mm from the tip of the crack.

[0040] Step (4) Using a ball end mill on the outside of the plexiglass cover 5, mill a semi-circular groove with a width of 2mm and a depth of 1mm at a distance of 5mm from the edge of the ground hole.

[0041] Step (5) Using acrylic glass of the same material as the acrylic glass cover 5, heat it to soften it, and then use a vacuum bag to press and shape it into acrylic glass patch 2. The size of acrylic glass patch 2 needs to be 20-40mm larger than the diameter of the hole after grinding and straightening in step (3). It is required to cover the crack prevention hole and have chamfered edges. Therefore, if the crack length is too long, it cannot be repaired by mechanical connection of the patch. A semi-circular groove of the same specification as in step (4) is set on the bonding surface of acrylic glass patch 2.

[0042] Step (6) Cut the double-sided adhesive rubber pad 3. When using a transparent patch for repair, it is preferable to use a transparent double-sided adhesive rubber pad 3. The diameter of the double-sided adhesive rubber pad 3 should be about 3-6mm larger than the diameter of the acrylic patch 2. The double-sided adhesive rubber pad 3 has semi-circular protrusions on both sides that match the position and specifications of the semi-circular groove on the acrylic cover 5 and the semi-circular groove on the acrylic patch 2.

[0043] Step (7) Drill holes in the acrylic patch 2 and the double-sided adhesive rubber pad 3 according to the marked positions. To ensure the sealing of the bolt connection, the hole diameter of the double-sided adhesive rubber pad 3 is 0.5mm-1mm smaller than the hole diameter of the acrylic patch 2. When drilling the acrylic patch 2, apply pressure-sensitive tape to the surface to prevent stress concentration and silver streaks caused by drilling.

[0044] Step (8) To reduce air bubbles on the bonding surface, first install the double-sided adhesive rubber pad 3 onto the acrylic patch 2, and roll it out on one side with a scraper. If necessary, use a hot air blower to soften the rubber pad, but the temperature should not exceed 50℃, forming a composite patch. Then press the composite patch onto the inner and outer surfaces of the acrylic cover 5. Apply sealant to the bolt 1. The sealant should be surface dry in about 20 minutes at room temperature and cured within 1 hour. The purpose of applying sealant is to fill the tiny gaps between the rubber pad, bolt, and patch, improving the sealing performance.

[0045] Then, bolt 1 passes through the hole and the composite patch on the inner and outer surfaces of the plexiglass cover 5, and is secured by nut 6. For large holes with a diameter of 100mm or more, to prevent the patch from cracking or deforming under external high pressure, a high-elasticity shock-absorbing rubber washer is nested at the bolt shaft, with the washer diameter larger than the bolt head diameter. The preload of the bolt compacts the rubber gasket, and the gasket deformation can be observed at the edge of the patch. If the hole is large and more than one bolt is required, a torque-limiting wrench must be used to ensure that the tightening torque of each bolt is consistent.

[0046] Step (ix) Use transparent tape 4 to further seal the edges of the composite patch to prevent warping of the double-sided adhesive rubber pad 3 and the plexiglass patch 2 at the edges.

[0047] Step (10): After installing the composite patch, use sealing strips, vacuum bag film, breathable felt, and a vacuum gauge to form a vacuum bag on the inner and outer sides of the plexiglass cover 5, and then evacuate the air to further compact the composite patch and check its sealing condition. The required vacuum level is that after evacuating for 5 minutes, the vacuum level remains unchanged and maintains at -0.87 atmospheres. If the patch sealing is found to be insufficient, it can be improved by increasing the tightening force of the bolts. If the requirement is still not met, the operation process needs to be checked and resealed.

[0048] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely prisms of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A method for rapid sealing and repair of damage to an aircraft cockpit canopy with holes, characterized in that: Includes the following steps: Step (1) Make a dust leak-proof bag around the inner hole of the plexiglass hatch cover (5) using sealant and vacuum bag film; Step (2) Remove burrs from the edges of the holes, use plaster or high-strength vacuum putty to trace the shape of the damaged area, and make a patch molding mold; Step (3) Grind the hole to make it neat. If there are cracks on the edge of the hole, drill a 1mm diameter anti-crack hole 2mm from the tip of the crack. Step (4) Using a ball end mill on the outside of the plexiglass cover (5), mill out a semi-circular groove with a width of 2mm and a depth of 1mm at a distance of 5mm from the edge of the ground hole. Step (5) Use plexiglass of the same material as the plexiglass cover (5), heat it to soften it, and use a vacuum bag to press and shape it into a plexiglass patch (2). The size of the plexiglass patch (2) needs to be 20-40mm larger than the diameter of the hole after grinding and regularization in step (3). It is required to cover the crack-stopping hole and bevel the edges. The mating surface of the plexiglass patch (2) is provided with a semi-circular groove of the same specifications as in step (4). Step (6) Cut the double-sided adhesive rubber pad (3). The diameter of the double-sided adhesive rubber pad (3) should be 3-6 mm larger than the diameter of the acrylic patch (2). The double-sided adhesive rubber pad (3) has semi-circular grooves on both sides that match the position and specifications of the semi-circular grooves on the acrylic cover (5) and the acrylic patch (2). Step (7) Drill holes in the acrylic patch (2) and the double-sided adhesive rubber pad (3) according to the marked positions. The hole diameter of the double-sided adhesive rubber pad (3) is 0.5mm-1mm smaller than the hole diameter of the acrylic patch (2). Apply pressure-sensitive adhesive tape to the surface of the acrylic patch (2) when drilling. Step (8) First, install the double-sided adhesive rubber pad (3) on the acrylic patch (2) to form a composite patch. Then press the composite patch onto the inner and outer surfaces of the acrylic hatch cover (5). The double-sided adhesive rubber pad (3) is attached to the inner and outer surfaces of the acrylic hatch cover (5). Apply sealant to the bolt (1). Then, the bolt (1) passes through the hole and the composite patch on the inner and outer surfaces of the acrylic hatch cover (5) and is fixed by the nut (6). If the diameter of the hole is greater than 10mm, the hole is too large. If the hole is too large, a high-elasticity shock-absorbing rubber ring (7) is nested in the hole. The bolt (1) passes through the high-elasticity shock-absorbing rubber ring (7) and the composite patch on the inner and outer surfaces of the acrylic hatch cover (5) and is fixed by the nut (6). Step (ix) Use transparent tape (4) to further seal the edges of the composite patch; Step (10) After installing the composite patch, use sealing strips, vacuum bag film, breathable felt and vacuum gauge to form a vacuum bag on the inside and outside of the plexiglass cover (5), and evacuate the air to further compact the composite patch and check the sealing of the composite patch.

2. The method for rapid sealing and repair of aircraft cockpit canopy puncture damage according to claim 1, characterized in that: In step (3), the holes are polished into a round or oval shape.

3. The method for rapid sealing and repair of damage to an aircraft cockpit canopy with holes according to claim 1, characterized in that: In step (six), a transparent double-sided adhesive rubber pad (3) is used.

4. The method for rapid sealing and repair of aircraft cockpit canopy puncture damage according to claim 1, characterized in that: In step (8), after the double-sided adhesive rubber pad (3) is installed on the plexiglass patch (2), it is rolled on one side with a scraper and softened with a hot air blower. The temperature should not exceed 50°C.

5. A method for rapid sealing and repair of damage to an aircraft cockpit canopy with holes, as described in claim 1, characterized in that: In step (eight), the sealant applied to the bolt (1) is required to be surface dry in about 20 minutes at room temperature and cured within 1 hour.

6. A method for rapid sealing and repair of damage to an aircraft cockpit canopy with holes, as described in claim 1, characterized in that: After evacuating for 5 minutes in step (10), the vacuum level remains unchanged and is maintained at -0.87 atmospheres.

7. A method for rapid sealing and repair of damage to an aircraft cockpit canopy with holes, as described in claim 1, characterized in that: If the sealing performance of the composite patch is found to be insufficient in step (10), it can be improved by increasing the tightening force of the bolt (1). If it still does not meet the requirements, the operation process needs to be checked and resealed.

Images