Deformable Sealing Plug for Narrow Wing Box Cavities

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Solution Overview

Problem

Existing methods for plugging cavities in aircraft wing boxes, such as those between the wing box and central box, are ergonomically challenging and inefficient due to the need for access on both sides and high injection pressures, especially in confined spaces, and are not suitable for narrower wing boxes.

Innovation Solution

A deformable sealing plug with a deformable envelope and a rod that can be pulled to exert compressive force, expelling a viscous seal through orifices to fill and seal the cavity, allowing for easy and quick plugging of cavities of various shapes and sizes from one side, with the seal polymerizing for complete leaktightness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If sealant mastic containing foam particles is injected into the cavity, then the cavity can be plugged, but the method requires access on both sides of the cavity and considerable injection pressure

Engineering Contradiction:

Improveaccess requirementVSAvoidinjection pressure

Core Design Contradiction:

Ease of operationVSStress or pressure

Solution Approach 1:

Instead of injecting sealant from both sides as in conventional methods, the invention inverts the approach by inserting a deformable envelope from one side only, then deforming it in-place to expel sealant unidirectionally into the cavity, eliminating the need for bilateral access and reducing pressure requirements

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The deformable envelope acts as an intermediary device that facilitates sealant delivery. It is inserted through a narrow opening, deformed to expand within the cavity, and expels sealant through controlled orifices, serving as a mediator between the operator and the cavity plugging process

Inventive Principle:

Principle #24Intermediary (Mediator)

2Use of energy by moving object

If the wing box size is reduced to improve aircraft performance, then fuel efficiency improves, but the cavity plugging operation becomes more difficult

Engineering Contradiction:

Improvefuel efficiencyVSAvoidcavity access

Core Design Contradiction:

Use of energy by moving objectVSEase of operation

Solution Approach 1:

The envelope is made of flexible, deformable material that can be compressed into a compact form for insertion through narrow openings in reduced-size wing boxes, then expanded in-place to perform the plugging function, adapting to confined spaces without requiring large access openings

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The envelope transitions from a compressed, insertable state to an expanded, functional state within the cavity. This dynamic transformation allows the same component to navigate narrow access points while effectively filling larger cavity volumes in reduced-size wing boxes

Inventive Principle:

Principle #15Dynamics

3Reliability

If sealant mastic is injected from the inside of the wing box, then leaktightness requirements are met, but the operation becomes lengthy and awkward due to preparation steps

Engineering Contradiction:

ImproveleaktightnessVSAvoidoperation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The envelope is pre-loaded with sealant and prepared outside the wing box, then inserted as a complete unit. The deformable structure is pre-configured to expel sealant through controlled orifices, eliminating time-consuming on-site preparation steps while ensuring leaktightness through the reliable envelope-sealant system

Inventive Principle:

Principle #10Preliminary action

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 solution enables efficient, one-sided plugging of cavities with reduced operational complexity and labor, suitable for various shapes and sizes, and maintains leaktightness without requiring significant injection pressure or extensive preparation, improving ergonomics and adaptability for narrower wing boxes.

Implementation Method 1

an envelope configured to be able to be deformed incompressibly... when the envelope is deformed by the head of the rod

Methodology Applied

Scientific EffectDeformation: Deformation

Implementation Method 2

envelope configured to be able to be deformed incompressibly

Methodology Applied

Scientific EffectIncompressibility:

Implementation Method 3

The viscous seal corresponds to a sealant mastic which is polymerizable at ambient temperature

Methodology Applied

Scientific EffectPolymerization: Photopolymerisation

Data Source

PatentUS20250100714A1Deformable sealing plug and process for plugging a cavity using such a sealing plug

Publication Date: 2025.03.27 AIRBUS OPERATIONS (SAS)

AI summary

A sealing plug for leaktightly plugging a cavity. The sealing plug comprises an incompressibly deformable envelope delimiting a hollow internal space and provided with at least one orifice, a rod which can slide through the envelope, a first end of the rod that is provided with a head being able to deform the envelope when a second end of the rod is pulled, and a viscous seal arranged in the internal space of the envelope so as to be expelled from the envelope through the orifice when the envelope is deformed.