Composite Part Edge Seal Layout for Confined-Space Assembly
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Solution Overview
Problem
Existing edge sealing methods for composite parts, such as those in aircraft wing boxes, require post-assembly sealing and cleanup operations within confined spaces, which are difficult and time-consuming, and do not adequately protect against fuel leakage and high-energy electrical discharges.
Innovation Solution
A prepackaged edge seal arrangement integrated into the part design, comprising a polymer edge seal, a cover, and a seal bead within a recess, which forms a seal between the part and the structure upon assembly, eliminating the need for additional sealing operations and providing protection against fluid leakage and corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If precured seals are applied to cut edges before assembly, then the exposed edges are protected, but additional sealing operations are required after assembly which are difficult and time-consuming
Solution Approach 1:
The seal arrangement is pre-installed on the part before assembly, with the seal bead positioned in a recess and the cover protecting it during assembly. This preliminary action eliminates the need for difficult post-assembly sealing operations inside fuel tanks, as the seal is already in place and ready to function upon assembly.
Solution Approach 2:
The seal arrangement employs a nested structure where the cover encloses and protects the seal bead within a recess. This nested configuration allows the seal components to be pre-assembled in a compact form that integrates seamlessly into the part structure, eliminating the need for separate post-assembly sealing operations.
2Reliability
If additional seal details are applied from within fuel tanks after assembly, then sealing is achieved, but the operations are difficult due to confined space
Solution Approach 1:
The seal bead is pre-positioned in a recess and the cover is pre-installed on the part before assembly. This preliminary configuration allows the sealing function to be achieved without requiring workers to access the confined interior of fuel tanks after assembly, thereby eliminating the operational difficulties associated with confined space work.
Solution Approach 2:
Instead of applying seals from the interior of fuel tanks after assembly (the conventional approach), the invention inverts the sequence by pre-installing the seal arrangement on the part exterior before assembly. This inversion transforms an inaccessible sealing operation into a readily accessible pre-assembly operation.
3Reliability
If multiple sealing operations are performed, then comprehensive sealing is achieved, but the process complexity increases
Solution Approach 1:
The invention merges multiple sealing functions into a single integrated seal arrangement that includes the seal bead in a recess and the protective cover. This unified design provides comprehensive sealing coverage while eliminating the need for multiple separate sealing operations, thereby reducing process complexity.
Solution Approach 2:
The seal arrangement serves multiple functions simultaneously: the seal bead provides the sealing barrier, the recess contains and positions the seal bead, and the cover protects the seal bead during assembly. This multi-functional integration achieves comprehensive sealing while simplifying the overall process.
Data Source
AI summary
A seal arrangement is provided for sealing an exposed edge of a composite laminate part having a fay surface configured to be joined to a structure. The seal arrangement includes a precured edge seal covering the exposed edge and a cover covering the edge seal. A seal bead located within a recess in the fay surface of the part forms a seal between the part and the structure.