Composite Repair Components with Customizable Shims for Rapid Repairs
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Solution Overview
Problem
Repairing damaged composite structures, such as those made from carbon fiber-reinforced plastics (CFRPs), is time-consuming and expensive due to the need for custom-fabricated parts that match complex geometries, and there is a lack of prefabricated repair components suitable for various structures.
Innovation Solution
A system of prefabricated repair components, including shims, that fit over damaged sections of composite members, with adjustable lengths and bolt holes for secure attachment, and optional shims to fill gaps, allowing for quick and efficient repairs across multiple composite structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom repair parts are fabricated for each damaged component, then the repair fits the specific geometry requirements, but the repair process becomes time-consuming and expensive
Solution Approach 1:
The patent applies universality by designing a standardized repair component with a universal interface that can be used across multiple damaged components. The repair component includes a body portion with a first interface for engagement with a damaged component and a second interface for engagement with a substrate, allowing the same component to serve multiple repair applications without requiring custom fabrication for each specific damage location.
Solution Approach 2:
The patent segments the repair system into distinct modular components: a standardized repair component body, adjustable shims with customizable thickness, and fastening mechanisms. This segmentation allows each component to be independently manufactured and adjusted, enabling precise fitting without requiring custom fabrication of the entire repair assembly for each specific application.
2Manufacturing precision
If custom repair parts are fabricated for each damaged component, then the repair matches the specific geometry, but the cost increases due to fabrication and inventory management
Solution Approach 1:
The patent implements universality through a standardized repair component design that can be used across multiple damaged components. The universal interface design eliminates the need for custom fabrication for each specific damage location, reducing manufacturing complexity and cost while maintaining geometric precision through standardized engagement features.
Solution Approach 2:
The patent applies parameter changes by using adjustable shims with customizable thickness to accommodate varying gap dimensions. Instead of fabricating different repair components for each gap size, the system uses a standardized component with adjustable thickness parameters achieved through shim selection, reducing fabrication complexity while maintaining precise geometric matching.
3Productivity
If prefabricated repair components are used, then the repair process becomes faster and more cost-effective, but the components must be designed to fit various composite structures
Solution Approach 1:
The patent segments the repair system into standardized components with simplified interfaces. The repair component body includes a first interface for engagement with the damaged composite structure and a second interface for engagement with a substrate, allowing for rapid assembly without complex custom interfaces. This segmentation enables prefabricated components to be quickly deployed across various composite structures.
Solution Approach 2:
The patent introduces an intermediary substrate interface that simplifies the connection between the standardized repair component and the diverse composite structures. The substrate serves as an intermediary element that provides a consistent reference surface, allowing the standardized repair component to interface with various composite geometries through a uniform connection mechanism, thereby reducing interface complexity.
4Manufacturing precision
If shims are added to fill air gaps, then the repair component fits tightly against the composite member, but the assembly complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-configuring shims with specific thickness values before assembly. The shims are manufactured in advance with predetermined thicknesses that correspond to expected gap dimensions, allowing for quick selection and installation during repair. This preliminary preparation eliminates the need for complex on-site adjustments while maintaining precise gap filling.
Solution Approach 2:
The patent implements local quality by using shims with customized thickness values tailored to specific gap dimensions at different locations. Instead of requiring a complex adjustable mechanism throughout the entire assembly, the system uses locally optimized shim thicknesses that precisely fill gaps at specific positions, maintaining high precision while minimizing overall assembly complexity.
Data Source
AI summary
The present disclosure provides repair systems, repair components, and methods for repairing composite structure systems using a set number of prefabricated repair components including a repair component and various shims which are fabricated to repair multiple composite members in a composite structure system.