Magnetic Field Curing of Liquid Shim for Composite Gaps
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Solution Overview
Problem
In composite structure manufacturing, gaps often occur due to mismatched dimensions, leading to inefficiencies and increased costs when filling these gaps with liquid shims, which cure slowly at room temperature and may not perform consistently when heated unevenly.
Innovation Solution
A method and apparatus using a magnetically permeable material within a liquid shim, heated by a magnetic field to accelerate curing, ensuring a consistent and efficient fit between composite parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If liquid shim material is cured at room temperature, then the curing process is simple and requires no additional equipment, but the curing time is excessively long (2-3 hours) which reduces productivity
Solution Approach 1:
The patent changes the temperature parameter from room temperature to elevated temperature (using heat sources such as ovens, heat lamps, or induction heating) to accelerate the curing process. This parameter change reduces curing time from 2-3 hours to a fraction of that time, directly resolving the productivity issue while maintaining the simplicity of the curing process through controlled thermal treatment.
Solution Approach 2:
The patent utilizes the phase transition of the liquid shim material from liquid to solid state through controlled heating and cooling cycles. By heating the material to accelerate curing and then allowing controlled cooling, the system achieves rapid curing without compromising the final structural integrity, thereby improving productivity while maintaining manufacturing simplicity.
2Productivity
If heat is applied to accelerate liquid shim curing, then the curing time is reduced, but uneven heating causes inconsistent curing and potential performance degradation
Solution Approach 1:
The patent applies different heating conditions to different regions of the liquid shim material based on local requirements. Heat sources are positioned and controlled to provide appropriate thermal energy to specific areas, ensuring uniform curing throughout the material while preventing overheating in certain zones. This local quality approach maintains curing consistency while achieving rapid curing overall.
Solution Approach 2:
The patent incorporates feedback mechanisms through temperature sensors and control systems that monitor the curing process in real-time. This feedback allows for dynamic adjustment of heating parameters to maintain optimal curing conditions, ensuring consistent results throughout the material while preventing thermal runaway or uneven curing, thereby maintaining reliability during accelerated curing.
3Manufacturing precision
If composite parts with dimensional variations are discarded and remanufactured, then the gap issue is eliminated, but the manufacturing time and cost increase significantly
Solution Approach 1:
Instead of discarding and remanufacturing parts, the patent changes the physical state and properties of the liquid shim material through controlled heating and curing processes. This allows the shim material to adapt to dimensional variations in the composite parts, filling gaps effectively without requiring part replacement, thereby eliminating remanufacturing time costs while maintaining dimensional accuracy.
Solution Approach 2:
The liquid shim material acts as an intermediary element between composite parts with dimensional variations. Rather than modifying the parts themselves through remanufacturing, the shim material compensates for gaps and dimensional inconsistencies, achieving the desired fit and finish without the time-consuming process of discarding and remanufacturing the original parts.
4Manufacturing precision
If a composite part is manufactured to exact specifications, then gaps are eliminated, but the manufacturing cost and time increase due to stricter quality control and potential rework
Solution Approach 1:
The patent changes the approach from achieving exact dimensional specifications during part manufacturing to achieving the desired final dimension through controlled curing of the liquid shim material. This parameter change in the curing process (temperature, time, pressure) allows for efficient manufacturing of parts with reasonable tolerances while achieving precise final dimensions, thereby maintaining productivity without sacrificing manufacturing precision.
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 solution allows for faster and more uniform curing of the liquid shim, reducing manufacturing time and costs by ensuring a precise fit between composite parts without the need for re-manufacturing, while maintaining structural integrity.
Implementation Method 1
A magnetic field is applied to the magnetically permeable material in the location. The magnetic field is configured to heat the liquid shim material to a temperature to cause the liquid shim material to become solid and form the shim.
Data Source
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AI summary
A liquid shim material (500) with a magnetically permeable material (502, 504) is applied in a location (400) for the shim between a plurality of composite parts (302, 402). A magnetic field (510) is applied to the magnetically permeable material (502, 504) in the location (400). The magnetic field (510) is configured to heat the liquid shim material (500) to a temperature to cause the liquid shim material (500) to become solid and form the shim.