Cellular Deformable Shim for Aircraft Assembly Gap Compensation
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Solution Overview
Problem
Current shimming methods for aircraft components are inefficient in addressing manufacturing-related geometrical variations and assembly gaps, particularly in complex structures, as they require separate steps and may not effectively maintain a predefined distance between components.
Innovation Solution
A deformable shim with a cellular structure that undergoes plastic deformation to create a predefined distance between aircraft components, utilizing a compressible cellular solid material that maintains its deformed shape without further compression, and can be combined with a filler material and interface layer for enhanced stiffness and bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional shimming methods are used to correct manufacturing variations, then assembly gaps can be compensated, but the process requires multiple separate steps and reduces productivity
Solution Approach 1:
The patent combines the shimming function with the mounting bracket itself by integrating a compressible cellular material into the bracket structure. This merging eliminates the need for separate shimming operations, as the bracket directly provides the necessary gap compensation through its compressible特性, thereby improving productivity while maintaining assembly precision
Solution Approach 2:
The cellular material is pre-configured with specific compression characteristics during manufacturing. The bracket is designed with predetermined compression zones that will automatically compensate for assembly gaps when mounted, eliminating the need for post-assembly adjustments and streamlining the assembly process
2Manufacturing precision
If rigid shims are used to maintain predefined distances, then dimensional stability is achieved, but adaptability to manufacturing variations is reduced
Solution Approach 1:
The patent employs a cellular material that changes its physical parameters (volume, density, stiffness) through controlled compression. The material can be compressed to different degrees to accommodate various gap sizes while maintaining the predefined distance after compression, thus adapting to different manufacturing variations while preserving dimensional stability
Solution Approach 2:
The mounting bracket combines a rigid structural framework with a compressible cellular material. This composite structure provides both the adaptability needed to accommodate manufacturing variations (through cellular compression) and the dimensional stability required to maintain predefined distances (through the rigid framework that retains the compressed shape)
3Adaptability or versatility
If cellular solid material is compressed to compensate for gaps, then adaptability to variations is improved, but the structural stiffness decreases
Solution Approach 1:
The cellular material is strategically placed only in specific zones of the mounting bracket where gap compensation is needed, while other critical structural areas maintain full rigidity. This localized application allows the bracket to adapt to variations in gap-sized without compromising the overall structural stiffness required for load-bearing functions
Solution Approach 2:
The combination of rigid structural elements with localized cellular material creates a composite structure that exhibits both adaptability (through cellular compression) and structural integrity (through the rigid framework). The rigid portions maintain structural stiffness while the cellular portions provide gap compensation, resolving the contradiction between adaptability and strength
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 deformable shim effectively compensates for manufacturing defects and variations, providing a consistent and adjustable gap between components, improving assembly quality and reducing the need for multiple assembly steps, while allowing for post-compression filler infiltration and interface layer bonding for enhanced stability.
Implementation Method 1
The deformable shim comprises a main structure of an at least partly cellular region. The main structure is compressible by plastic deformation from an initial volume to a deformed volume, wherein the deformed volume is smaller than the initial volume. In a deformed state, the main structure maintains the deformed volume without a further or continuing compression force
Data Source
AI summary
A method of providing a deformable shim that comprises a main structure of an at least partly cellular region. The main structure is compressible by plastic deformation from an initial volume to a deformed volume, wherein the deformed volume is smaller than the initial volume. In a deformed state, the main structure maintains the deformed volume without further or continuing compression force. Further, the main structure is arrangeable between a first aircraft component and a second aircraft component to create a predefined distance between the first and the second aircraft component.