Sandwich Structure Repair Kit for On-Site Floor Panels
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Solution Overview
Problem
Existing methods for repairing sandwich structures, such as aircraft floor panels, are time-consuming, costly, and require removal from the vehicle for permanent repairs, while temporary repairs do not fully restore structural integrity and resistance to mechanical and chemical stresses.
Innovation Solution
A method and kit for repairing sandwich structures that allow on-site repair by localizing damage, removing the damaged section, filling the cavity with a foam filling material, and securing a cover layer with fixing elements that extend through the layers, ensuring structural integrity and chemical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If permanent repair methods are used according to prior art, then structural integrity is restored, but the repair process is time-consuming and requires removal from the vehicle
Solution Approach 1:
The repair system is segmented into modular components: a repair kit containing all necessary materials (filling material, cover layer, fixing elements) and a portable repair device. This allows the repair process to be divided into discrete, manageable steps that can be performed on-site without removing the sandwich structure from the vehicle, thereby reducing repair time while maintaining structural integrity.
Solution Approach 2:
The repair kit is prepared in advance with all necessary components pre-assembled and ready for use. The fixing elements are pre-configured with appropriate lengths and the filling material is pre-packaged in accessible containers. This preliminary preparation eliminates the need for time-consuming on-site assembly and material handling during the actual repair process.
2Reliability
If permanent repair methods are used according to prior art, then structural integrity is restored, but labor and material costs increase
Solution Approach 1:
The repair system is designed to be self-contained and self-sufficient. The repair kit includes all necessary materials and the portable device provides all required functions (drilling, filling, fixing) in one integrated unit. This eliminates the need for expensive specialized repair facilities, external equipment rental, and highly skilled labor, thereby significantly reducing both labor and material costs while maintaining structural integrity.
3Loss of time
If temporary repair methods are used, then repair time is reduced, but structural integrity and resistance to stresses are not fully restored
Solution Approach 1:
The system uses adjustable parameters to optimize the repair process: the filling material can be selected based on viscosity and expansion properties, the cover layer can be customized to match the original panel specifications, and the fixing elements can be chosen with appropriate lengths and thread configurations. These parameter adjustments allow the repair to achieve full structural integrity while maintaining a quick, on-site process.
Solution Approach 2:
The repair utilizes composite material construction: the filling material (e.g., expanding foam) provides structural support and fills voids, the cover layer (e.g., fiber-reinforced plastic) restores the protective and aesthetic surface, and the fixing elements (e.g., screws or anchors) provide mechanical fastening. This multi-material approach ensures full structural integrity is restored while keeping the process quick and on-site feasible.
4Productivity
If on-site repair is enabled, then removal from vehicle is avoided, but repair complexity increases
Solution Approach 1:
The portable repair device merges multiple functions into a single integrated unit: it combines the drilling mechanism, filling material dispensing system, and fixing element installation capabilities in one portable apparatus. This consolidation reduces the number of separate tools and equipment needed on-site, simplifying the repair system while maintaining high repair efficiency.
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
Provides fast, reliable, and durable repairs that maintain structural properties, reducing labor and material costs by allowing repairs to be conducted on-site without removing the damaged panel.
Implementation Method 1
filling the cavity with a foam filling material
Data Source
AI summary
A method and a repair kit for repairing a sandwich structure, in particular a floor panel in a vehicle, such as an aircraft, the sandwich structure having a top layer and a bottom layer defining an intermediate space between them which is at least partially filled out with a core material, the method comprising the steps of localizing a damaged section of the sandwich structure, such as a hole in the top layer and the underlying core material; removing the damaged section to create a repair cavity while preserving the bottom layer; filling up the repair cavity with a filling material; covering the filled-up repair cavity with a cover layer; and fixing the cover layer with at least one fixing element extending through the cover layer and the filling material and/or the core material next to the filling material.