Rear Cone Fluoroelastomer Patch Repair for Erosion Protection
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Solution Overview
Problem
Jet engine components suffer from erosion damage due to particulate matter, and existing fluoroelastomer erosion coatings require a method for repair or replacement to extend their useful life.
Innovation Solution
A method involving the removal of existing fluoroelastomer coating from a rear cone segment, forming a cured replacement coating with a layer of fluoroelastomer and fibrous reinforcement, preparing and adhering the new coating to the repair area using mechanical and chemical methods, and curing it at specific temperatures and pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fluoroelastomer erosion coatings are applied to protect engine components, then erosion protection is improved, but the coating eventually deteriorates and requires repair or replacement
Solution Approach 1:
The patent applies the discarding and recovering principle by removing deteriorated portions of the fluoroelastomer coating and replacing them with new material. The repair process involves stripping away eroded coating sections and applying fresh coating material to restore protective functionality, thereby extending the overall service life of the coated component.
Solution Approach 2:
The patent implements preliminary action through surface preparation steps performed before applying repair coating. These include cleaning, roughening, and treating the substrate surface in advance to ensure optimal adhesion of the new coating material, preventing future delamination and extending coating durability.
2Ease of repair
If existing fluoroelastomer coating is removed for repair, then coating renewal is enabled, but removal process adds time and complexity
Solution Approach 1:
The patent applies segmentation by allowing partial removal of coating only in deteriorated areas rather than complete removal. This enables targeted repair of specific eroded sections while leaving intact the remaining functional coating, significantly reducing repair time and complexity compared to full coating removal and reapplication.
Solution Approach 2:
The patent implements local quality by applying repair coating only to deteriorated areas rather than the entire component surface. This localized approach focuses resources on where protection is needed, reducing material usage, repair time, and complexity while maintaining overall coating effectiveness.
3Strength
If replacement coating with fibrous reinforcement is formed, then structural integrity is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies composite materials by combining fluoroelastomer coating with fibrous reinforcement materials to create a multi-layered composite structure. This composite construction provides enhanced mechanical strength, erosion resistance, and durability while maintaining flexibility, justifying the increased manufacturing complexity through superior performance.
Solution Approach 2:
The patent implements merging by integrating multiple functional layers (fluoroelastomer coating, fibrous reinforcement, adhesive layers) into a single unified replacement coating assembly. This combined structure leverages the complementary properties of each layer to achieve overall structural integrity and protective functionality.
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
Extends the life of jet engine components by effectively repairing and replacing erosion coatings, ensuring continued protection against erosion damage while maintaining structural integrity.
Implementation Method 1
curing it at specific temperatures and pressures
Implementation Method 2
adhering the prepared cured replacement erosion coating to the prepared repair area
Data Source
AI summary
Disclosed is a method of repairing a rear cone segment erosion coating including removing a portion of an existing fluoroelastomer coating from a rear cone segment to form a repair area; forming a cured replacement erosion coating corresponding to the repair area, wherein the cured replacement erosion coating has a layer of fluoroelastomer and a layer of fibrous reinforcement; preparing the repair area and the cured replacement erosion coating for adhesion; locating the prepared cured replacement erosion coating on the prepared repair area; and adhering the prepared cured replacement erosion coating to the prepared repair area. Also disclosed is a cured replacement erosion coating and a repaired inlet nose cone.