Adjustable Plasma Pulse Probe for Portable Bondline Verification

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Solution Overview

Problem

Current laser bond inspection systems are large, expensive, and require a laser and power supply, necessitating a more cost-effective and portable solution for evaluating adhesive bonds in structures.

Innovation Solution

A system using an adjustable submerged plasma probe that generates a compression wave by creating a plasma between electrodes in a liquid, eliminating the need for lasers and large power supplies, and allowing for adjustable pulse width and intensity to inspect various bond types, thicknesses, and materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If laser bond inspection systems are used to evaluate adhesive bonds, then inspection capability is achieved, but equipment size and cost increase

Engineering Contradiction:

Improvebond inspection capabilityVSAvoidequipment size

Core Design Contradiction:

Measurement precisionVSWeight of stationary object

Solution Approach 1:

The patent extracts the laser component from the inspection system and replaces it with an electrohydraulic compression wave generation system. By removing the laser and its associated optics, the system achieves bond inspection capability without the bulky equipment associated with laser-based methods.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the optical/laser-based system with a mechanical/electrohydraulic system. Instead of using laser pulses to generate compression waves, the invention uses an electrohydraulic probe that generates compression waves through electrical discharge in a liquid medium, eliminating the need for laser equipment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If laser bond inspection systems are used to evaluate adhesive bonds, then inspection capability is achieved, but equipment cost increases

Engineering Contradiction:

Improvebond inspection capabilityVSAvoidequipment cost

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent employs a relatively simple electrohydraulic probe that can be manufactured at lower cost compared to laser systems. The probe uses basic components (electrodes, liquid medium, pulse generator) that are more economical than laser sources and their required optical components, making the inspection system more cost-effective.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The replacement of the expensive laser system with a mechanical/electrohydraulic system significantly reduces equipment cost. The electrohydraulic probe uses readily available components and simpler manufacturing processes, making the overall system more economical while maintaining bond inspection capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If fixed plasma probe configuration is used, then system simplicity is maintained, but adaptability to different bond types is limited

Engineering Contradiction:

Improvesystem simplicityVSAvoidinspection of diverse bond types

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The patent incorporates adjustable parameters in the plasma probe system, including variable pulse width and intensity controls. This dynamic capability allows the same probe to adapt to different bond types, thicknesses, and materials without requiring multiple specialized probes, thus maintaining system simplicity while enhancing versatility.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent enables inspection of diverse bonded structures by allowing changes in operational parameters such as pulse width and intensity. By adjusting these parameters, the system can optimize the compression wave characteristics for different bond types, thicknesses, and materials, providing adaptability without increasing physical complexity.

Inventive Principle:

Principle #35Parameter changes

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 system reduces equipment size and cost, enabling efficient inspection of diverse bonded structures with increased portability and flexibility, replacing destructive testing and expensive laser-based methods.

Implementation Method 1

provide an electrical pulse to create a plasma in the liquid between the first and the second electrodes to generate a compression wave

Methodology Applied

Scientific EffectPlasma: Plasma

Implementation Method 2

generate a compression wave... The compression wave mechanically creates a stress load on the adhesive bond

Methodology Applied

Scientific EffectCompression wave: Shock Wave

Data Source

PatentUS12523586B2Variable plasma pulse generator for bondline strength verification

Publication Date: 2026.01.13 THE BOEING CO

AI summary

A system and method for evaluating a bond is provided. The system uses an adjustable submerged plasma probe to generate a compression wave in a first vessel containing a liquid. The system further includes a second vessel in which a vacuum is pulled to hold the first vessel against a bonded structure being inspected. The compression wave is directed to propagate from the liquid into the bonded structure to apply a known force to the bond being inspected. The adjustable submerged plasma probe allows the intensity of the compression wave to be increased or decreased at the bonded structure.