Mould-Based UV Curing for Aircraft Fuel Tank Sealing
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Solution Overview
Problem
The conventional manual process of sealing aircraft fuel tanks is time-consuming and inefficient, requiring multiple layers of sealant with varying compositions and curing times, which can lead to lengthy operations and potential leakage issues.
Innovation Solution
A method and apparatus using a digitally designed and additive manufactured mould part to create a mould cavity, where a sealant is introduced and cured with electromagnetic radiation, such as UV light, to efficiently apply a seal to the surface of aircraft fuel tanks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual sealing process with multiple layers of sealant is used, then sealing reliability is improved, but operation time increases significantly
Solution Approach 1:
The sealant is introduced into the mould cavity in a pre-defined configuration before curing. The mould part is positioned against the surface to create a mould cavity that pre-determines the sealant distribution, thickness, and coverage area, eliminating the need for manual manipulation and multiple layers during the sealing operation.
Solution Approach 2:
The manual mechanical process of applying and smoothing sealant with brushes is replaced by introducing sealant into a mould cavity where it is held in position by the mould geometry. The electromagnetic radiation curing process replaces the need for mechanical manipulation and extended curing times associated with traditional multi-layer applications.
2Adaptability or versatility
If multiple layers of sealant with different compositions are applied, then sealing adaptability is improved, but process complexity increases
Solution Approach 1:
The mould part is configured with specific features such as varying cavity depths, recesses, and protrusions that create different sealant thicknesses and configurations in different areas of the seal. This allows different regions of the same seal to have different properties (e.g., thickness, compliance) without requiring different sealant compositions or multiple application steps.
Solution Approach 2:
The mould part serves multiple functions: it defines the seal geometry, controls sealant distribution, ensures proper positioning on the surface, and facilitates curing by allowing electromagnetic radiation passage. This single multi-functional tool replaces the need for multiple specialized tools and processes for applying different sealant layers.
3Ease of operation
If sealant is applied manually and manipulated with tools, then ease of operation is maintained, but manufacturing precision decreases
Solution Approach 1:
The mould part creates a precise replica or copy of the desired seal geometry directly onto the surface. By introducing sealant into the mould cavity and curing it in place, the exact seal shape, thickness, and positioning are replicated without requiring manual manipulation, ensuring high manufacturing precision while simplifying the operation to merely positioning the mould and initiating curing.
4Device complexity
If traditional sealing process is used, then equipment complexity is kept simple, but productivity decreases
Solution Approach 1:
The curing process is accelerated by using electromagnetic radiation (UV or visible light) that can cure the sealant rapidly compared to traditional air-curing sealants. The mould part configuration optimizes the curing parameters by allowing radiation passage while maintaining sealant containment, enabling fast cure times and high productivity with relatively simple equipment consisting of the mould part and a light source.
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
This approach reduces the workload on human operators, enhances sealing efficiency, improves leakage prevention, and allows for faster, more repeatable, and controlled application of sealant, with reduced risk of unintended application and post-sealing cleaning, while enabling the formation of complex features.
Implementation Method 1
The sealant may be an electromagnetic radiation curing sealant. The step of curing the sealant may comprises illuminating the sealant with electromagnetic radiation by causing electromagnetic radiation to pass through the mould part onto the sealant within the mould cavity.
Data Source
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AI summary
A method and apparatus for applying a seal to a structure, for example sealing an aircraft fuel tank. The method comprises: providing a mould part (600); positioning the mould part (600) against a surface (203) of the structure thereby to create a mould cavity (700) between the mould part (600) and the surface (203); introducing a sealant into the mould cavity (700); curing the sealant within the mould cavity (700) thereby to apply the seal to the surface (203); and removing the mould part (600) from the surface (203) with the seal applied thereto. The sealant may be a UV curing sealant and curing the sealant may comprise passing UV light through the mould part (600).