Composite Edge Sealing Tool with Pivot Foam Applicator
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Solution Overview
Problem
Existing methods for applying electrically insulating materials to the edges of fiber-reinforced composite parts to prevent galvanic corrosion are inefficient, particularly in aeronautical applications, as they require manual operation, result in bead formation, and are difficult to automate, leading to reproducibility issues and significant resin waste.
Innovation Solution
A tool with a foam sleeve and PTFE rod allows for precise application of polymerizable sealants to edges, either manually or automatically, using a parallel axis configuration to control pressure and prevent bead formation, and features a pivot connection for easy sleeve installation and product injection, enabling uniform application without air bubbles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional means such as brush or roller are used to apply resin layer, then electrical insulation of fiber ends is achieved, but bead formation occurs on surfaces requiring subsequent scraping operation
Solution Approach 1:
The patent employs a porous applicator head that distributes resin through capillary action and controlled porosity, preventing bead formation while ensuring complete coverage of fiber ends. The porous structure allows resin to emerge uniformly across the application surface without accumulating in beads.
Solution Approach 2:
The patent replaces the manual mechanical scraping operation with a controlled application process using a specialized applicator that deposits resin precisely to the required thickness, eliminating the need for subsequent mechanical removal of excess material.
2Ease of operation
If manual scraping operation is performed to eliminate bead, then assembly difficulties are resolved, but operation time increases significantly accounting for two-thirds of total edging time
Solution Approach 1:
The patent performs the correct application of resin thickness as a preliminary action during the deposition phase itself, using a controlled applicator system that prevents bead formation from occurring in the first place, thereby eliminating the need for subsequent scraping operations.
3Quantity of substance
If resin application is performed manually with brush or roller, then edge coverage is achieved, but results are not reproducible and significant resin waste occurs due to polymerization during operation
Solution Approach 1:
The patent replaces manual application methods with a controlled applicator system that regulates resin flow and distribution, ensuring consistent application quality and reducing waste from polymerization by minimizing the time resin remains in the application tool.
Solution Approach 2:
The patent controls the viscosity and flow parameters of resin through the applicator system, maintaining optimal application conditions throughout the process and preventing polymerization-related variability in application results.
4Reliability
If peristaltic pump is used to inject sealing mastic through radial orifices, then edge sealing is achieved, but precise positioning of applicator head relative to hole is required and only internal edges can be treated
Solution Approach 1:
The patent designs a universal applicator system that can treat both internal and external edges of composite parts through a single mechanism, eliminating the limitation of previous systems that could only address internal edges requiring countersunk holes.
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 tool significantly reduces edging operation time, eliminates the need for scraping, enhances application precision, and simplifies automation, improving the quality and efficiency of edge sealing while minimizing resin waste and operator training time.
Implementation Method 1
a tubular foam sleeve (240) which acts as a pad for applying the product to be applied
Implementation Method 2
The low coefficient of friction of this material facilitates the installation and replacement of the sleeve
Implementation Method 3
following the initial mixing of the two components, the polymer gradually crosslinks, and this polymerization continues during the scraping operation
Data Source
Figure 1~2
Figure 3~5
AI summary
A tool (200) suitable for manually or automatically applying a polymerisable sealing product to the edge of a composite part (100), said tool comprising: a. a fixed gripping portion (210) defining a grip orientation axis (201); b. an application portion (250), linked to the gripping portion so as to be able to pivot about an axis parallel to the grip orientation axis (201), and freely rotate with respect to the gripping portion, and comprising a rod (230) extending along the axis of rotation (201) of the link; c. characterised in that it comprises a cylindrical application pad (240) made up of a tubular foam sleeve (240) threaded onto the rod (230), constituted by a polyolefin foam comprising cells (241) open on the surfaces of the sleeve, capable of absorbing a product and of depositing in on a surface by contact with said surface.