Aircraft Access Plug With Compressible Retainer

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Solution Overview

Problem

Existing aircraft access opening plugs are difficult to install on varying surface contours and often require glue for retention, making them hard to remove and reapply.

Innovation Solution

A self-retaining plug with a compressible O-ring retainer that expands laterally when compressed, allowing easy installation and removal from one side using a screwdriver, ensuring a flush fit with the aircraft surface for aerodynamic airflow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If glue is used to hold the plug in the opening, then the plug is securely retained, but the plug becomes difficult to remove and requires cleaning and additional glue during reinstallation

Engineering Contradiction:

Improveplug retentionVSAvoidremoval and reinstallation

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent replaces the chemical bonding mechanism of glue with a mechanical retention system. The retainer features a compressible sealing element that expands laterally when compressed by a screwdrive, creating mechanical interference and friction against the opening walls to hold the plug securely without requiring adhesive chemicals.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The retainer is designed to be self-retaining through its elastic sealing element that automatically expands to engage with the opening contours. The system serves itself by using the compression force from the screwdrive to activate the sealing element's expansion, eliminating the need for external glue application and cleaning operations.

Inventive Principle:

Principle #25Self-service

2Manufacturing precision

If a separately installed sleeve is used to render the plug difficult to install multiple applications with differing surface contours, then the plug achieves proper fit, but the installation process becomes complex and time-consuming

Engineering Contradiction:

Improveplug fitVSAvoidinstallation process

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The retainer incorporates a compressible sealing element that can dynamically adjust its lateral dimensions in response to compression forces. This dynamic expansion allows the same retainer design to accommodate various opening sizes and surface contours without requiring multiple specialized sleeves or complex adjustment mechanisms.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The single retainer design with its elastic sealing element serves multiple functions: it seals the opening, retains the plug, and adapts to different surface contours. This universal design eliminates the need for separate installation sleeves and simplifies the overall installation process across different applications.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Object-affected harmful factors

If the plug is designed to be flush with the skin to maintain aerodynamic airflow, then aerodynamic integrity is preserved, but the installation and removal process becomes more difficult

Engineering Contradiction:

Improveaerodynamic airflowVSAvoidinstallation and removal

Core Design Contradiction:

Object-affected harmful factorsVSEase of operation

Solution Approach 1:

The plug assembly is segmented into distinct functional components: the plug body that maintains the flush aerodynamic profile, and the retainer mechanism that provides retention functionality. This segmentation allows the plug body to be optimized for aerodynamic performance while the retainer handles the installation and removal operations independently.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The retainer mechanism operates in a different dimensional space than the plug body's aerodynamic surface. The compression and expansion actions occur radially at the interface between the plug and opening, while the plug body maintains its axial flush profile. This dimensional separation allows both aerodynamic optimization and easy installation without compromise.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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

The plug effectively seals access openings on various contours without glue, facilitating quick installation and removal, maintaining aerodynamic integrity and reducing installation complexity.

Implementation Method 1

The retainer may comprise a compressible O-ring seal which may create a relatively tight seal around the entire opening between the plug and the structure

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

The screwdrive compresses and expands a retainer into engagement with the backside of the structure in order to draw the plug tightly down into a recess in the structure

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Data Source

PatentUS9090330B2Opening plug and method of installing the same

Publication Date: 2015.07.28 THE BOEING CO

AI summary

A device is used to plug an opening in a structure having a front side and a back side. The device includes a removable plug body for plugging the opening, and a retainer that is expandable into engagement with the back side of the structure to retain the plug in the opening. Means coupled with the retainer and the plug is provided for expanding the retainer.