Multi-Layer Mask Forming System for Aircraft Manufacturing

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Solution Overview

Problem

The existing methods for applying protective masking materials in aircraft manufacturing are time-consuming and inefficient, leading to increased manufacturing time and overspray issues, while also requiring a large footprint in the manufacturing facility due to the need for a large flat-bed table and multiple labor-intensive steps.

Innovation Solution

A method and system for forming a mask using a multi-layered masking material that includes a first layer for printing, a second layer for adhesive properties, and a third layer for transfer, which are kiss-cut and double-kiss-cut to create a protective mask with reduced overspray and faster application time, while maintaining the same orientation throughout the process and eliminating the need for flipping the material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If a flat-bed table is used to create protective material, then the protective material can be formed, but the footprint in the manufacturing facility becomes large

Engineering Contradiction:

Improvefootprint in manufacturing facilityVSAvoidprocess to create protective material

Core Design Contradiction:

Area of stationary objectVSEase of manufacture

Solution Approach 1:

The masking material is divided into multiple layers (first layer for printing, second layer for adhesive, third layer for transfer) that can be processed independently and then combined. This segmentation allows the use of a smaller processing platform instead of a large flat-bed table, reducing facility footprint while maintaining manufacturing capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent transitions from a traditional 2D flat-bed table approach to a 3D layered structure approach. By stacking multiple functional layers vertically, the system reduces the horizontal footprint required for processing while maintaining all necessary manufacturing functions (printing, adhesive application, transfer).

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Productivity

If traditional masking material application methods are used, then protection is provided, but the process is time-consuming with multiple touch labor points

Engineering Contradiction:

Improveapplication timeVSAvoidtime for multiple touch points

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

Multiple functions (printing, adhesive application, transfer) are merged into a single integrated layered structure. This eliminates the need for multiple separate processing steps and touch points, significantly reducing application time and improving productivity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

All necessary processing (printing on first layer, adhesive application to second layer, transfer layer preparation) is completed in advance during manufacturing. The pre-assembled layered structure requires only simple application to the substrate, eliminating time-consuming on-site processing steps.

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If masking material is flipped over on the flat-bed table, then the material can be processed, but the process becomes more complex with additional steps

Engineering Contradiction:

Improvesimplicity of processingVSAvoidnumber of processing steps

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

Instead of flipping the masking material over during processing, the patent inverts the approach by having all processing occur on one side of the layered structure. The layers are designed and processed in their final orientation, eliminating the need for flipping operations and reducing process complexity.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS20240082865A1Mask forming system for protecting a structure and a method of forming a mask for the same

Publication Date: 2024.03.14 THE BOEING CO

AI summary

A mask forming system for protecting a structure and a method of forming a mask for protecting the structure includes a masking material having a first layer, a second layer, and a third layer sandwiched together. The masking material is unrolled across a platform and a plurality of features are generated in the masking material, wherein the features include printing, kiss cutting, and double-kiss cutting the masking material. Data is printed on the first layer of the masking material. The first layer of the masking material is kiss cut. The second layer of the masking material is double-kiss cut. The third layer remains uncut and unprinted on during the formation of the mask. The masking material remains in the same orientation during printing and kiss cutting of the first layer, and the masking material remains in the same orientation during double-kiss cutting of the second layer.