Overpress Nubs for Uniform Resin Layer Application
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Solution Overview
Problem
Existing methods for assembling aircraft understructures using liquid resin are inefficient due to uneven coverage, material wastage, air entrapment, difficulty in applying resin to vertical surfaces, and the need for labor-intensive processes like sanding and reworking, leading to increased costs and construction time.
Innovation Solution
A method involving an overpress with protruding nubs is used to apply and cure liquid resin on a frame member, ensuring uniform coverage and easy removal, with optional features like translucent materials for visibility and clamps for secure application, reducing waste and the need for sanding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If liquid resin is applied by hand directly to the aircraft understructure, then the resin can be applied to the surface, but the resin coverage becomes uneven and requires reworking
Solution Approach 1:
A resin distribution tool is introduced as an intermediary device between the resin source and the understructure surface. The tool includes a reservoir for holding liquid resin and a distribution mechanism with channels and outlets that evenly dispense resin across the surface, eliminating the uneven coverage problem associated with manual application.
Solution Approach 2:
The resin application process transitions from manual control to controlled dispensing through the distribution tool. The tool regulates resin flow parameters such as distribution pattern, thickness, and coverage area, ensuring consistent application without requiring manual skill or multiple reworking passes.
2Reliability
If too much liquid resin is applied to ensure adequate coverage, then coverage is sufficient, but material is wasted and machining time increases
Solution Approach 1:
The distribution tool precisely controls resin application parameters including flow rate, distribution pattern, and layer thickness. This ensures that the minimum adequate coverage is achieved without excess material application, eliminating both under-coverage and over-coverage problems simultaneously.
Solution Approach 2:
The manual mechanical application method is replaced with a controlled dispensing system that uses the tool's internal channels and outlets to automatically distribute resin. This substitution provides precise metering and distribution, preventing material waste while ensuring adequate coverage.
3Ease of operation
If liquid resin is applied wet using a wooden tongue depressor, then the resin can be spread on the surface, but air pockets are trapped reducing structural properties
Solution Approach 1:
The distribution tool serves as an intermediary that replaces the wooden tongue depressor method. The tool's design with channels and controlled outlets allows resin to be deposited in a manner that minimizes air entrapment, while the spreading function is maintained through the tool's geometry and resin flow control.
Solution Approach 2:
The distribution tool replicates and improves upon the manual spreading function. Instead of using a tongue depressor that traps air, the tool uses a controlled distribution mechanism that deposits resin smoothly without creating air pockets, thereby maintaining ease of operation while improving structural integrity.
4Adaptability or versatility
If liquid resin is applied to a vertical or overhead structure, then the resin can be applied to the surface, but the resin slumps due to viscosity causing unacceptable surface
Solution Approach 1:
The distribution tool is designed to be adaptable to different surface orientations including vertical and overhead positions. The tool can be positioned and oriented to match the understructure geometry, and the resin distribution mechanism adjusts to maintain proper flow characteristics regardless of gravity's direction, preventing slumping on vertical surfaces.
Solution Approach 2:
The tool provides localized resin distribution tailored to specific surface areas and orientations. By positioning the distribution outlets close to the target surface and controlling resin flow locally, the system maintains precise thickness control and prevents gravity-induced slumping even on vertical or overhead structures.
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 method enhances efficiency and dependability, reducing assembly costs by ensuring uniform resin coverage, minimizing waste, and allowing for parallel work during curing, while eliminating the need for sanding and reducing reworking requirements.
Implementation Method 1
the liquid resin is applied by hand directly to the aircraft understructure and is allowed to cure
Implementation Method 2
Since the liquid resin forms a skin, or amine carbonate, when exposed to air
Data Source
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Figure 6~7
AI summary
A method for placing a resin layer or shim on a frame member (25) uses an overpress (20). The overpress has an inner surface (32) with protruding nubs (34). The operator places a bead of liquid resin (36) on the inner surface of the overpress (20), then clamps the overpress to the frame member (25). The clamps (42) force the nubs of the overpress into contact with the frame member and allows the nubs to define a clearance between the overpress and the frame member. The liquid resin (36) spreads throughout the clearance and cures. After the resin has cured, the overpress is removed from the frame member, leaving a layer of cured resin bound to the frame member. This layer is then machined to a desired thickness.