Liquid Shim Bag Structure for Uniform Joint Gap Filling
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Solution Overview
Problem
Current methods for shimming gaps between components, such as using peelable polyimide solid shims or viscous pastes, are laborious, expensive, and prone to uneven application and structural voids, making them inefficient and difficult to manage, especially in large joints.
Innovation Solution
A liquid shim system comprising a sealed bag with a flowable material that can be compressed to fill gaps and cure into a solid shim, using a bag with expandable peripheral portions and sealed openings for precise application and removal, and methods for curing the shim using ambient temperature and localized heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If peelable polyimide solid shims are used, then the gap can be filled, but the process becomes laborious and expensive due to manual measurement and sculpting
Solution Approach 1:
The invention changes the physical state of the shim material from solid to liquid, allowing it to flow and conform to the gap automatically without manual sculpting. The liquid material can be pumped or injected into the gap, eliminating the need for manual measurement and shaping operations.
Solution Approach 2:
The invention uses a pump to deliver the liquid shim material to the gap, applying hydraulic principles to automate the application process. This allows consistent, controlled delivery of the material without manual handling, significantly reducing application time and labor.
2Ease of operation
If viscous paste is applied into the gap, then the gap can be filled, but it becomes difficult to apply evenly and clean due to high viscosity
Solution Approach 1:
The invention uses a liquid material with optimized viscosity that is low enough to flow easily and conform to the gap surfaces uniformly, yet high enough to remain in place once applied. This eliminates the handling difficulties associated with highly viscous pastes while ensuring complete gap filling.
Solution Approach 2:
The pump-based delivery system provides controlled pressure to move the liquid material through the gap uniformly, ensuring even distribution without the need for manual spreading or scraping operations that are difficult with viscous materials.
3Reliability
If viscous paste is used, then the gap can be filled, but structural voids may form that are difficult to detect and repair
Solution Approach 1:
The liquid material's low viscosity allows it to flow completely into all portions of the gap, displacing air and preventing void formation. The material automatically conforms to the gap geometry, ensuring complete filling and eliminating structural defects.
4Ease of manufacture
If manual sculpting of solid shim material is performed, then the gap can be filled, but the process becomes expensive and labor-intensive
Solution Approach 1:
Changing from solid to liquid state eliminates the need for sculpting operations entirely. The liquid material is delivered through a pump and automatically conforms to the gap shape, transforming a manual, skill-intensive process into an automated, efficient operation.
Solution Approach 2:
The pump-based delivery system automates the entire application process, allowing rapid filling of gaps without manual intervention. This significantly increases productivity while reducing labor costs and improving consistency.
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 liquid shim system provides a efficient, cost-effective, and precise way to fill gaps between components, ensuring uniform application and structural integrity by forming a solid shim that matches the gap shape, reducing manual labor and the risk of voids, and allowing for easy removal and reuse of the bag.
Implementation Method 1
The liquid shim material may be flowable through the closed inner volume around the sealed openings and may be curable to form a solid
Implementation Method 2
The peripheral portion may be folded about a fold line spaced inwardly from the peripheral edge
Implementation Method 3
The peripheral portion may be expandable
Implementation Method 4
In an embodiment, a pressure within the bag is approximately zero
Implementation Method 5
In an embodiment, one or more of the sealed openings have a heat seal
Implementation Method 6
displacing the components towards one another to apply pressure with one or more of the components to the sealed bag, to thereby compress the liquid shim material and fill the gap
Data Source
AI summary
A liquid shim includes a bag (24) defining a closed inner volume and having sealed openings spaced inwardly from a periphery of the bag. The sealed openings are sealed from the closed inner volume and delimit holes extending through the bag. A liquid shim material (22) is flowable through the closed inner volume around the sealed openings and is curable to form a solid. The liquid shim material has a liquid shim material volume being less than the closed inner volume of the bag. A method of creating a liquid shim, and a method of shimming a gap between components, is also disclosed.