Custom Pre-Cured Patch for Composite Scarf Rework
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for reworking inconsistencies in composite materials, such as those found in aircraft, often require inefficient and wasteful use of pre-sized patches, as these patches may be too large for the specific inconsistency, leading to material waste and inefficiency.
Innovation Solution
A method involving scanning the scarf area of the inconsistency to generate shape data, which is then used to create a custom pre-cured patch at a remote facility. This patch is pre-cured to match the specific dimensions of the scarf, reducing material waste and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pre-sized patches are used to rework inconsistencies in composite materials, then the rework process can be simplified, but material waste increases and manufacturing efficiency decreases
Solution Approach 1:
The patent applies local quality by creating patches with non-uniform thickness distributions that match the specific geometry of each inconsistency. Instead of using uniform pre-sized patches, the invention tailors the patch properties locally to the defect characteristics, ensuring material is applied only where needed and in the precise quantity required for repair.
Solution Approach 2:
The invention changes the parameters of the patch by varying thickness, material composition, and curing characteristics based on the scanned inconsistency data. This allows the patch to be optimized for each specific defect rather than using fixed-parameter pre-sized patches, reducing material waste while maintaining repair effectiveness.
2Productivity
If pre-sized patches are used for reworking inconsistencies, then the repair process becomes faster, but the precision of the repair decreases
Solution Approach 1:
The patent applies preliminary action by scanning the inconsistency and generating the custom patch design before the actual repair is performed. This advance preparation allows for precise digital modeling and simulation of the patch fit, ensuring manufacturing precision is achieved before physical application, thereby maintaining both speed and accuracy.
Solution Approach 2:
The invention uses digital copying of the inconsistency geometry through scanning and creates a virtual model to design the patch. This digital copy allows for precise planning and simulation of the repair process, ensuring the physical patch will fit precisely when applied, thereby maintaining high manufacturing precision without sacrificing repair speed.
3Loss of substance
If custom patches are generated for each inconsistency, then material waste is reduced, but the complexity of the rework process increases
Solution Approach 1:
The patent replaces manual measurement and physical trial-and-error methods with automated scanning and digital modeling systems. This substitution of mechanical processes with digital technologies reduces the perceived complexity by automating the custom patch generation process, making it more systematic and easier to manage despite the customization involved.
Solution Approach 2:
The invention creates a universal digital workflow platform that can handle various types of inconsistencies through the same scanning, modeling, and patch generation process. This multi-functional system reduces process complexity by providing a unified approach that works across different defect types, rather than requiring separate procedures for each inconsistency type.
4Ease of repair
If remote facilities generate custom patches, then on-site rework capabilities are improved, but logistics and coordination complexity increase
Solution Approach 1:
The patent uses digital data files as an intermediary between the remote scanning facility and the on-site repair location. The scanned inconsistency data is transmitted electronically to the remote patch generation facility, and the resulting custom patch specifications are communicated back to guide the on-site repair process. This digital intermediary simplifies logistics by replacing physical transportation of measurement tools and coordination of manual processes.
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 use of custom pre-cured patches ensures precise fitting and minimizes material waste, making the reworking process more efficient and cost-effective, while maintaining the structural integrity of the composite material.
Implementation Method 1
The method also includes pre-curing the patch
Data Source
AI summary
A method for curing a patch. The method includes generating the patch according to a negative of a scan of a scarf in a composite material. The method also includes pre-curing the patch.