Manifold Heating Tool for Uniform Adhesive Curing in Tight Spaces
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Solution Overview
Problem
The assembly of tiltrotor aircraft wings is complex and labor-intensive due to the need for precise alignment and fastening of composite materials, which requires extensive time and increases part count, leading to warping and dimensional issues, especially in confined spaces with limited access.
Innovation Solution
A heating tool with a manifold and diverging chamber provides uniform airflow for localized heating of surfaces, allowing for efficient curing of adhesives and assembly of composite components, reducing assembly time and part count by aligning the ventilation path with the surface contour and using an alignment member for precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional heating methods are used for curing adhesives in confined spaces, then heating can be applied, but uniform heating is difficult to achieve and assembly time increases
Solution Approach 1:
The heating system is segmented into multiple heating zones along the airflow path, allowing different regions to be heated independently and uniformly. The manifold divides the airflow into multiple streams that can be distributed across the bonding surface, ensuring even heat distribution in confined spaces.
Solution Approach 2:
The heating tool provides localized heating control by adjusting airflow distribution and temperature at different positions along the bonding surface. This allows precise temperature management in specific areas, achieving uniform heating while reducing overall assembly time.
2Strength
If complex fastening systems are used to assemble wing components, then structural strength is improved, but assembly complexity and part count increase
Solution Approach 1:
The adhesive bonding process merges multiple fastening functions into a single bonding operation. The heating tool enables direct adhesive curing without requiring separate fastening steps, reducing part count and assembly complexity while maintaining structural strength through proper adhesive formulation and curing control.
3Reliability
If traditional adhesive curing methods are used in confined spaces, then bonding can be achieved, but alignment precision deteriorates due to warping
Solution Approach 1:
Components are pre-aligned and pre-bonded in a controlled sequence before final adhesive curing. The heating tool applies gradual, uniform heat to minimize thermal stress and warping during the bonding process, maintaining alignment precision throughout the curing operation in confined spaces.
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 heating tool facilitates faster and more precise assembly of tiltrotor wing components by ensuring uniform heating and alignment, reducing assembly time by 32% and minimizing warping, while also simplifying the assembly process and reducing the need for complex fastening systems.
Implementation Method 1
a heating tool includes a heat source having a discharge outlet; a manifold including an intake conduit configured to releasably connect to the discharge outlet of the heat source and a chamber coupled to the intake conduit having a ventilation path
Implementation Method 2
provide heating to a surface
Data Source
AI summary
In one aspect, a heating tool includes a heat source having a discharge outlet; and a manifold including an intake conduit configured to releasably connect to the discharge outlet of the heat source and a chamber coupled to the intake conduit having a ventilation path. The chamber includes a diverging portion configured to provide uniform airflow through the ventilation path to provide heating to a surface. In an embodiment, the chamber has a first portion and a second portion configured for assembly and disassembly. A method of curing an aircraft component is provided.