Conformal Repair Manifold for Crack Injection on Nonplanar Surfaces
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Solution Overview
Problem
Existing methods for repairing cracks in structures, such as drill-and-fill and vacuum-assisted techniques, are inadequate for irregular shapes and surfaces, often weakening the structure and failing to establish proper vacuum integrity, especially in composite and bonded metal structures with nonplanar surfaces.
Innovation Solution
A method and apparatus involving a flexible manifold with a base portion and cover portion, equipped with an injection port and vent port, that conforms to the nonplanar surface contour of the structure, allowing for the precise delivery and curing of bonding material into cracks while accommodating structural irregularities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If drill-and-fill repair methods are used, then cracks can be repaired, but the structure is weakened due to extensive drilling of holes
Solution Approach 1:
The invention extracts the harmful drilling operation from the repair process. Instead of drilling holes to inject bonding material, the system uses a flexible manifold that conforms to the surface and delivers material through a channel system that does not require penetrating holes, thereby repairing cracks while preserving structural strength.
Solution Approach 2:
The flexible manifold acts as an intermediary device between the bonding material and the crack. It delivers the material through its internal channel system without requiring direct drilling into the structure, thus mediating the repair process in a way that avoids structural weakening.
2Reliability
If vacuum-assisted repair methods are used, then bonding material can be drawn into cracks, but vacuum integrity cannot be established on nonplanar surfaces with honeycomb cores or permanent hardware
Solution Approach 1:
The invention employs a flexible manifold made of compliant material that can conform to nonplanar surfaces, including those with honeycomb cores and permanent hardware. This flexibility allows the manifold to adapt to various surface geometries while maintaining sealing integrity, enabling bonding material delivery without requiring vacuum assistance.
Solution Approach 2:
The invention changes the operating parameter from vacuum-based negative pressure to pressure-based positive delivery. By pressurizing the bonding material and using the flexible manifold's compliance to maintain sealing, the system achieves reliable material infiltration without needing vacuum integrity, thus adapting to complex surfaces.
3Ease of manufacture
If injection style repairs are used, then bonding material can be delivered into cracks, but accurate determination of crack location, depth, and propagation is required which is difficult to achieve
Solution Approach 1:
The flexible manifold is designed to over-cover the crack area, extending beyond the visible or known crack boundaries. This excessive coverage ensures that the entire crack, including any unknown propagation, is enclosed and treated. The manifold's flexibility allows it to adapt to the actual crack extent without requiring precise pre-characterization.
Solution Approach 2:
The system allows the bonding material to self-distribute within the crack space through the flexible manifold's compliance and pressure delivery. The material naturally flows to where it is needed based on pressure gradients and crack geometry, eliminating the need for precise pre-determination of crack location, depth, and propagation.
4Strength
If a rigid manifold is used for crack repair, then structural support is provided, but the manifold cannot conform to nonplanar surface contours
Solution Approach 1:
The manifold is constructed from flexible yet structurally sound material that can conform to nonplanar surfaces while maintaining integrity. The flexibility allows surface conformity, while the material properties and internal channel design provide sufficient structural support to withstand pressurization and maintain sealing during the repair process.
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 effective in situ crack repair by ensuring proper bonding material distribution and curing within complex structural geometries, maintaining structural integrity without the need for extensive drilling or vacuum assistance.
Implementation Method 1
pressurizing the bonding material in the channel to a first pressure while the crack is open
Implementation Method 2
holding the bonding material in the channel at the second pressure while the bonding material cures
Implementation Method 3
applying an infrared light through the cover portion and around the base portion onto the structure
Data Source
AI summary
A method for repairing a crack in a structure includes mounting a manifold to the structure around the crack. The structure has a nonplanar surface contour that surrounds the crack. The manifold has a base portion, a cover portion, and a plug. The base portion has a grip surface configured to conform to the nonplanar surface contour of the structure. The cover portion is connected to the base portion, and has an injection port and a vent port in fluid communication with a channel aligned to the crack. The injection port transfers a bonding material into and out of the channel. The plug closes and opens the vent port. The method includes filling the channel with the bonding material to direct the bonding material into the crack, and draining the bonding material from the manifold.