Contour-Matched Heating Tool for Uniform Adhesive Curing
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Solution Overview
Problem
The assembly of tiltrotor aircraft wings is complex and labor-intensive due to the need for precise alignment and fastening of composite materials, which requires extensive time and increases part count, leading to reduced fuel capacity and increased weight.
Innovation Solution
A heating tool with a manifold and diverging chamber provides uniform airflow for localized heating, allowing for efficient curing of temperature-sensitive adhesives and reducing assembly time by aligning the ventilation path with the wing's contour, thereby simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional assembly methods with multiple fixtures and fasteners are used, then structural strength is ensured, but assembly time increases and part count increases
Solution Approach 1:
The patent combines multiple fastening functions into a single integrated fixture system. The fixture incorporates both mechanical clamping elements and adhesive application mechanisms, allowing simultaneous fastening and bonding operations rather than sequential processes, thereby reducing assembly time while maintaining structural strength
Solution Approach 2:
The fixture is designed as a multi-functional device that can perform positioning, clamping, adhesive application, and curing support functions. This universal fixture replaces multiple specialized tools and fixtures, reducing part count and assembly complexity while ensuring proper structural alignment and strength
2Strength
If more internal supports and stringers are added to the wing structure, then structural strength is improved, but available space for fuel decreases
Solution Approach 1:
The patent employs thin-film composite materials and shell structures that provide high strength-to-weight ratios. The skin and internal supports are constructed using layered composite materials that maintain structural integrity while occupying minimal volume, thereby preserving fuel capacity
Solution Approach 2:
The wing structure utilizes composite materials with high specific strength (strength-to-weight ratio). These composite components provide the necessary structural strength with reduced material volume compared to traditional metals, increasing the space available for fuel storage
3Reliability
If reinforcement strips are pre-cut and stored in controlled atmosphere, then material quality is maintained, but identification and retrieval time increases
Solution Approach 1:
The reinforcement strips are pre-cut, pre-labeled with identification codes, and pre-positioned in the mold according to the assembly sequence. This preliminary preparation allows workers to quickly identify and retrieve the correct strips during assembly without time-consuming search or verification, while the controlled atmosphere storage maintains material quality
Solution Approach 2:
An identification and tracking system serves as an intermediary between the stored reinforcement strips and the assembly process. The labeling system with codes or barcodes allows rapid identification and retrieval of specific strips, bridging the gap between quality-controlled storage and efficient assembly operations
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 heating tool accelerates the curing process, reduces assembly time by up to 32%, and minimizes the need for complex fixtures, resulting in a lighter, more efficient wing structure with increased fuel capacity.
Implementation Method 1
a chamber coupled to the intake conduit having a ventilation path... provide uniform airflow through the ventilation path to provide heating to a surface
Data Source
AI summary
A method of curing an aircraft component including applying a temperature sensitive adhesive to a surface of a component, the surface having a contour; positioning a heating tool including a manifold with a ventilation path such that the ventilation path is adjacent to the surface by aligning the ventilation path to the contour of the component; and heating the surface of the component with uniform airflow from the ventilation path; wherein the manifold includes a chamber with a diverging portion configured to provide uniform airflow through the ventilation path to provide heating to the surface.