Extruded Elastomeric Surface Layers for Thin Aircraft Components
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Solution Overview
Problem
Conventional elastomeric processes struggle to produce relatively thin sheets, limiting weight reduction and stacking of multiple sheets in aerospace components, which increases the likelihood of defects and reduces uniformity.
Innovation Solution
The use of extrusion to form thin elastomeric layers, allowing for multiple layers to be stacked and coupled with an adhesive, ensuring uniformity and reducing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional elastomeric processes (calendering) are used to form thin sheets, then manufacturing capability is maintained, but sheet thickness cannot be reduced below 50 thousandths of an inch (1.3 mm) and 0.00039 thousandths of an inch (10 nm)
Solution Approach 1:
The patent changes the manufacturing process parameters by transitioning from calendering to extrusion. Extrusion enables precise control of sheet thickness down to 0.00039 thousandths of an inch (10 nm) while maintaining manufacturing capability, resolving the contradiction between thickness precision and ease of manufacture.
Solution Approach 2:
The patent replaces the conventional calendering mechanical system with an extrusion system. This substitution enables the formation of uniformly thin elastomeric sheets that cannot be achieved through traditional calendering methods, achieving both thinness and manufacturability.
2Weight of moving object
If multiple elastomeric sheets are stacked together, then weight reduction is achieved, but defects (voids, thin or thick spots, bubbles) in one sheet affect the entire thickness
Solution Approach 1:
The patent segments the elastomeric structure into multiple thin layers formed by sequential extrusion. Each layer is formed independently with controlled thickness, preventing defect propagation across the entire thickness while enabling weight reduction through the use of multiple thin layers instead of one thick layer.
Solution Approach 2:
The patent transitions from forming a single thick elastomeric layer to forming multiple thin layers stacked in the thickness dimension. This dimensional approach allows weight reduction through multiple thin layers while isolating defects to individual layers, preventing them from affecting the entire structure.
3Ease of manufacture
If single thick elastomeric sheets are used, then manufacturing simplicity is maintained, but weight reduction possibilities are eliminated
Solution Approach 1:
The patent segments a single thick elastomeric sheet into multiple thin layers formed by sequential extrusion. This segmentation enables weight reduction while maintaining manufacturing simplicity through the use of extrusion, which can efficiently produce multiple uniform thin layers that are then bonded together.
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
Extrusion enables the formation of lightweight, defect-resistant elastomeric layers capable of withstanding a wide temperature range, enhancing the robustness and operating life of aircraft components.
Implementation Method 1
coupling the outer layer of the aircraft component to the inner portion of the aircraft component
Data Source
AI summary
A method for forming an aircraft component includes forming an inner portion of the aircraft component. The method further includes forming an outer layer of the aircraft component using extrusion of an elastomeric material. The method further includes coupling the outer layer of the aircraft component to the inner portion of the aircraft component.