Aircraft Protective Liner Molding for Quasi-Continuous Production
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Solution Overview
Problem
Existing methods for manufacturing protective liners for aircraft structural profile parts are inefficient and lack a cost-effective, automated process for producing high-quality protective liners.
Innovation Solution
A method and apparatus involving the use of base molds with molding features, a sealant application mechanism, and a curing apparatus to create a continuous molding feature, applying and curing uncured sealant to form a protective liner, which is then attached to the structural profile part, allowing for a quasi-continuous, automated process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manual methods are used to manufacture protective liners, then flexibility and adaptability are maintained, but productivity is low and manufacturing cost is high
Solution Approach 1:
The manufacturing process is segmented into distinct modular steps: preparing base molds with molding features, arranging them in sequences, applying uncured sealant, curing the sealant, and releasing the protective liner. Each step can be independently optimized and automated, enabling high-volume production while maintaining process clarity and control.
Solution Approach 2:
The process enables continuous production by arranging base molds in sequences where uncured sealant is applied continuously along the continuous molding feature, followed by continuous curing. This eliminates idle time between production cycles and maximizes productivity while the modular nature keeps device complexity manageable.
2Productivity
If automated processes are introduced to increase productivity, then production volume increases, but manufacturing cost increases
Solution Approach 1:
The base molds serve multiple functions: they provide the molding feature for the protective liner, form part of the continuous molding feature when arranged in sequences, and can be reused repeatedly after release. This multi-functionality reduces the need for specialized equipment for each production step, lowering overall manufacturing cost while maintaining high productivity.
Solution Approach 2:
The uncured sealant is applied and then cured in-place within the base mold arrangement, eliminating the need for separate transfer operations or additional handling equipment. The process uses the materials' own properties (flow and curing characteristics) to achieve the manufacturing objective, reducing equipment requirements and cost.
3Manufacturing precision
If conventional sealant application methods are used, then process simplicity is maintained, but manufacturing precision and quality are insufficient
Solution Approach 1:
Multiple base molds are arranged in sequences such that their molding features are at the same level and form a continuous molding feature. This equipotential arrangement ensures uniform sealant application and consistent curing conditions along the entire length, improving manufacturing precision while the modular base mold design keeps individual components simple.
4Productivity
If protective liners are manufactured for each component individually, then adaptability is maintained, but productivity is low
Solution Approach 1:
The production system is segmented into modular base molds that can be arranged in different sequences and configurations. Each base mold can be designed with specific molding features for different component types, allowing customization while maintaining high productivity through continuous production of standardized units.
Solution Approach 2:
The base mold system is designed to be universal, where the same type of base mold can be used for different protective liner configurations by changing the arrangement sequence or molding feature configuration. This enables production of multiple product variants from the same equipment, maintaining adaptability while achieving high-volume production.
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
Enables high-volume, cost-effective production of protective liners with improved quality by utilizing self-curing sealants in a partially automated process, enhancing the protection of aircraft structural components.
Implementation Method 1
applying an uncured wet sealant to the continuous molding feature; curing the wet sealant into a cured sealant member within the base mold
Data Source
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AI summary
In order to improve the manufacture of protected structural profile parts (50), particularly for mass-fabrication for a fuselage (52) of an aircraft, a quasicontinuous process is proposed. A plurality of base molds (10) are prepared by forming molding features (12) that matche a portion to be protected of the structural profile part (14). The base molds (10) are arranged such that their molding features (12) cooperatively form a continuous molding feature (16). A sealant applicator (26) is used to apply an uncured wet sealant (28) to the groove, wherein the sealant applicator (26) also acts as a complementary mold member (30) in order to give the uncured wet sealant (28) the desired shape. The wet sealant is cured and forms a cured sealant member (38), which is released from the base mold (10) and fixed to the structural profile part (14) as a protective liner (48), thereby generating the desired protected structural profile part (50).