Film Material Applicator for Structural Members

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Solution Overview

Problem

The current process of preparing composite structural members for adhesive bonding is time-consuming and labor-intensive, involving manual application and trimming of film adhesive material, which can lead to damage and inefficiencies in material utilization.

Innovation Solution

A film material applicator apparatus and method that allows for the application, trimming, and compaction of film material in a single pass along the length of structural members using a carriage with rollers and a film cutter assembly, eliminating the need for manual labor and vacuum bag compaction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual trimming of film material is performed, then the film can be trimmed to match structural details, but the process is time-consuming and labor-intensive

Engineering Contradiction:

Improvefilm trimming precisionVSAvoidprocess speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces manual mechanical trimming with an automated water jet cutting system. The water jet cutter is guided along the structural member to automatically trim the film material to match the structural details, eliminating manual labor while maintaining precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The film material is applied with a release film that allows it to be self-adhering to the structural member. The material essentially trims itself by conforming to the structural details under its own weight and the application process, reducing the need for manual intervention.

Inventive Principle:

Principle #25Self-service

2Manufacturing precision

If hand trimming technique is used, then film material can be trimmed, but there is risk of damage to edges of base flange and production of foreign object debris

Engineering Contradiction:

Improvefilm trimming accuracyVSAvoidedge damage and foreign object debris

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent replaces manual blade trimming with a water jet cutting system. The water jet cuts the film material without physical contact between cutting tools and the base flange edges, eliminating the risk of edge damage and foreign object debris production.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The water jet acts as an intermediary cutting medium between the trimming operation and the film material. It transfers the cutting function without requiring direct mechanical contact that could damage the base flange or generate debris.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of operation

If film material is manually rolled out and flipped over, then the adhesive side can be applied to the base flange, but the process is labor-intensive and time-consuming

Engineering Contradiction:

Improvefilm application feasibilityVSAvoidprocess efficiency

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The patent inverts the traditional application method by applying the film material with the release film side down first, then flipping it over so the adhesive side contacts the base flange. This inversion eliminates the need for workers to manually handle and flip long film rolls, as the film is fed continuously from a roll during the flipping process.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The film material is prepared in advance with the release film already attached, and the entire length is positioned and flipped as a single unit before application. This preliminary preparation eliminates the need for repeated handling and positioning during the application process.

Inventive Principle:

Principle #10Preliminary action

4Manufacturing precision

If vacuum bag processing is used to compact film material, then the film can be compacted against the stringer base flange, but the process requires additional equipment and time

Engineering Contradiction:

Improvefilm compaction qualityVSAvoidequipment requirements

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent extracts the compaction function from the vacuum bag processing system and integrates it directly into the film application apparatus. A compaction roller is incorporated into the applicator, providing compaction at the moment of application without requiring separate vacuum bag equipment.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent combines multiple functions (application, flipping, trimming, and compaction) into a single integrated apparatus. The compaction roller is merged with the film application mechanism, eliminating the need for separate vacuum bag processing equipment and steps.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP2928667B1Method and apparatus for applying film material to elongate members

Publication Date: 2017.08.02 THE BOEING CO

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AI summary

Film material (32) is applied to a surface (60a) of an elongate structural member (34). A carriage (36) moved along the structural member (34) dispenses, compacts and cuts the film material (32) in a single pass along the structural member (34).