Adhesive Injection Apparatus for Void-Free Composite Patch Repair
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Solution Overview
Problem
Existing patch repair techniques for composite and metal structures are labor-intensive, time-consuming, and often result in undesirable bondlines with residual voids, reducing the effectiveness of the repair.
Innovation Solution
The method involves using an adhesive injection apparatus with a vacuum bag and seal ring to evacuate the repair area and inject adhesive, ensuring a void-free bondline by removing air before adhesive injection, and utilizing a three-way valve for efficient evacuation and injection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive is placed in the void between the patch and the structure surface, then the bondline is formed, but air becomes trapped creating residual voids that reduce repair strength
Solution Approach 1:
The patent applies preliminary action by evacuating air from the bondline voids before adhesive injection. The vacuum bag seal is applied to the repair area prior to adhesive placement, and air is evacuated through ports to create negative pressure. This preliminary vacuum treatment prevents air from interfering with the subsequent adhesive filling process, ensuring complete void elimination and high-quality bondlines without residual air pockets.
Solution Approach 2:
The patent utilizes pneumatic principles by employing vacuum pressure to evacuate air from the bondline area and pressure differential to force adhesive into the voids. The system uses vacuum ports connected to a vacuum source to create negative pressure, and adhesive injection ports to introduce adhesive under pressure. This pneumatic approach ensures complete filling of the bondline space while eliminating air entrapment, directly addressing the void-free bondline requirement.
2Ease of manufacture
If traditional patch repair techniques are used, then the repair process can be completed, but it is labor intensive and time consuming
Solution Approach 1:
The patent applies segmentation by dividing the adhesive application process into distinct functional components: vacuum bag sealing, port placement, air evacuation, and adhesive injection. This segmented approach allows each step to be optimized independently and performed in a systematic sequence, reducing overall process complexity and time. The segmentation of functions enables streamlined operations compared to traditional manual methods.
Solution Approach 2:
The patent replaces manual mechanical adhesive application with a controlled injection system. Instead of labor-intensive manual adhesive placement and void filling, the system uses automated adhesive injection through ports combined with vacuum assistance. This substitution of mechanical manual operations with a controlled injection-evacuation system significantly reduces labor intensity and process time while improving consistency and reliability.
3Strength
If residual voids are present in the bondline, then the repair strength is reduced, but performing supplemental repair increases time and labor requirements
Solution Approach 1:
The patent applies preliminary action by evacuating air from the bondline voids before adhesive injection. The vacuum bag seal is applied to the repair area prior to adhesive placement, and air is evacuated through ports to create negative pressure. This preliminary vacuum treatment prevents air from interfering with the subsequent adhesive filling process, ensuring complete void elimination and high-quality bondlines without residual air pockets.
Solution Approach 2:
The patent utilizes pneumatic principles by employing vacuum pressure to evacuate air from the bondline area and pressure differential to force adhesive into the voids. The system uses vacuum ports connected to a vacuum source to create negative pressure, and adhesive injection ports to introduce adhesive under pressure. This pneumatic approach ensures complete filling of the bondline space while eliminating air entrapment, directly addressing the void-free bondline requirement.
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
This approach reduces the frequency of residual voids, decreases the need for additional repairs, and creates a bondline with desirable structural capacity, making the process more efficient and reliable.
Implementation Method 1
evacuating, via an adhesive injection apparatus attached to the repair-patch hole and the seal ring of the vacuum bag, the repair area and an injection channel of the adhesive injection apparatus
Data Source
Figure 1A~1B
Figure 2
Figure 3A~3C
AI summary
In an example, a method is described. The method comprises placing a repair patch (122) over a repair area (124) of a structure (120), the repair patch (122) comprising a repair-patch hole (126). The method also comprises sealing the repair patch (122) and repair area (124) with a vacuum bag (130) having a seal ring (132) around a periphery of the vacuum bag (130). The method also comprises evacuating, via an adhesive injection apparatus (200) attached to the repair-patch hole (126) and the seal ring (132) of the vacuum bag (130), the repair area (124) and an injection channel (206) of the adhesive injection apparatus (200). The method also comprises forcing adhesive (205) through the evacuated injection channel (206) and into the evacuated repair area (124).