Deformable Corrugated Ring Repair for Multilayer Structures

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Solution Overview

Problem

Current repair techniques for damaged intermediate layers in multilayer structures are inadequate, as they either cause punctures or fail to withstand heavy loads and high stresses, especially when using composite materials or oversized fasteners.

Innovation Solution

A repair device and method utilizing deformable corrugated rings and a tool to gradually deform the rings, matching the diameter of a damaged cavity to a smaller coaxial cavity, eliminating the need for puncture-prone inserts and allowing the use of strong metal materials to maintain structural integrity under heavy loads.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If rigid metal parts are introduced into the reamed zone to fill the damaged area, then the structural strength is improved, but punctures or pinched areas are caused in the reamed zone creating new defects

Engineering Contradiction:

Improvestructural strengthVSAvoidpunctures or pinched areas

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The insert changes its physical state from a contracted condition (at low temperature or with internal pressure applied) to an expanded condition (at room temperature or after internal pressure is released), allowing it to fill the reamed zone without causing punctures during insertion, while maintaining structural strength after expansion

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If composite materials based on organic resin are used for the insert, then the ease of manufacture is improved, but the mechanical strength is reduced making them unsuitable for heavy loads and high stresses

Engineering Contradiction:

Improveease of manufactureVSAvoidmechanical strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The insert utilizes temperature or pressure parameter changes to transition from a manageable insertion state to a high-strength operational state, enabling the use of materials that can achieve both ease of manufacture and high mechanical strength under different conditions

Inventive Principle:

Principle #35Parameter changes

3Strength

If mineral-based composite materials are used for the insert, then the mechanical strength is improved, but the manufacturing difficulty and cost increase, and they are poorly suited to the zones to be filled

Engineering Contradiction:

Improvemechanical strengthVSAvoidmanufacturing difficulty

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The insert employs parameter changes (temperature or pressure) to achieve the desired form and fit during installation, then maintains structural integrity under load, providing a balance between manufacturability and mechanical strength that overcomes the limitations of mineral-based composites

Inventive Principle:

Principle #35Parameter changes

4Strength

If an oversized fastener is used to secure the repair, then the structural strength is improved, but the complexity of the repair process increases

Engineering Contradiction:

Improvestructural strengthVSAvoidcomplexity of the repair process

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The insert's ability to change parameters (temperature or pressure) allows it to be installed in a contracted state through a smaller opening, then expanded to provide full structural support, eliminating the need for oversized fasteners and simplifying the repair process

Inventive Principle:

Principle #35Parameter changes

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 solution effectively fills damaged zones without inducing punctures and enables the structure to withstand heavy loads and stresses, ensuring reliable repair of multilayer structures like aircraft, boats, and petrochemical installations.

Implementation Method 1

at least one ring that has a deformable corrugated shape (that is to say has at least two inversions of curvature that are modifiable by deformation), and is intended to be positioned in the first cavity

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

a deformable corrugated shape (that is to say has at least two inversions of curvature that are modifiable by deformation)

Methodology Applied

Scientific EffectCorrugation deformation: Corrugation

Data Source

PatentUS9517536B2Device and method for repairing a damaged zone of an intermediate layer of a multilayer structure by way of deformable corrugated rings

Publication Date: 2016.12.13 AIRBUS OPERATIONS (SAS)

AI summary

A device for repairing a damaged zone in a first cavity, with a first diameter, of an intermediate layer interposed between two layers that have a second cavity with a second diameter smaller than the first diameter. The device includes a stop that forms an abutment at the interface between the first cavity and one of the second cavities, a ring having a deformable corrugated shape, an initial inside diameter, an initial outside diameter smaller than the second diameter, and being positioned in the first cavity, a deformation element having an elastically variable outside diameter initially smaller than the initial inside diameter of the ring, and a tool being able to increase the outside diameter of the deformation element so that it deforms the ring in the first cavity in order to reduce the difference between the first and second diameters.