Induction-Softened Thermoplastic Shims for Rapid Void Filling
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Solution Overview
Problem
Dimensional mismatch between components in large structures often results in voids at interfaces, which are difficult to fill quickly with existing shims, especially when bag-side surfaces are involved, as liquid shims take a day or more to set.
Innovation Solution
An induction-softened thermoplastic shim assembly where a wire embedded within the shim material is heated above a predetermined temperature using an induced electrical current, allowing the shim to become moldable and conform to the components, thereby filling voids efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If liquid shim is used to fill voids between components, then the voids can be filled, but the setting time takes a day or more
Solution Approach 1:
The patent changes the physical state of the shim material from liquid to thermoplastic solid, and uses temperature as a control parameter to transition the material from solid to moldable state and back, enabling rapid setting while maintaining void filling precision
Solution Approach 2:
The patent utilizes phase transition of thermoplastic material between solid and moldable states through temperature control. The material transitions to a moldable state during assembly to fill voids, then returns to solid state for rapid setting, eliminating the long curing time of liquid shims
2Adaptability or versatility
If thermoplastic shim is heated to become moldable, then the shim can conform to components, but the temperature must not exceed component curing temperature
Solution Approach 1:
The patent applies localized heating through induction coils positioned near the shim material, creating a localized high-temperature zone only where the shim needs to become moldable, while the rest of the assembly remains at safe temperatures that do not damage components or exceed curing temperatures
Solution Approach 2:
The patent replaces conventional contact heating methods with induction heating technology, using electromagnetic fields to generate heat directly in the shim material through embedded or proximate induction coils, providing precise temperature control without thermal damage to surrounding components
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
Enables rapid filling of voids between components, allowing for quicker assembly and ensuring precise fit without damaging the components, as the shim material sets within a controlled temperature range that does not exceed the curing temperature of the components.
Implementation Method 1
A wire is in contact with the shim material. The wire is configured to heat the shim material to above a predetermined temperature
Implementation Method 2
An electrical current is then induced in the wire. The electrical current causes the wire to heat the shim material
Implementation Method 3
the shim material becomes moldable above the predetermined temperature such that the shim material is able to conform to the first component and the second component
Data Source
AI summary
A shim assembly includes a shim material configured to be positioned between a first component and a second component. A wire is in contact with the shim material. The wire is configured to heat the shim material to above a predetermined temperature, and the shim material becomes moldable above the predetermined temperature such that the shim material is able to conform to the first component and the second component.