Shape Memory Polymer Duct Coupling for Easier Aircraft Installation
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Solution Overview
Problem
Aircraft ducting made from molded plastics and rubbers requires expensive tooling and long lead times, making repairs and replacements difficult due to their complex shapes and the need for significant disassembly.
Innovation Solution
Utilizing shape memory polymer materials for ducting that can be additively manufactured, allowing for the integration of shape memory interconnecting ends that can be configured and heated to couple with existing ductwork, reducing disassembly and installation time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional molded plastics and rubbers are used for ducting, then the ducts can be manufactured with complex shapes, but the manufacturing requires expensive tooling and long lead times
Solution Approach 1:
The patent changes the material parameter from conventional molded plastics to shape memory polymers, which can be additively manufactured. This parameter change enables complex duct shapes to be produced without expensive mold tooling, significantly reducing manufacturing lead times while maintaining the capability to create convoluted geometries through digital modeling and additive processes
Solution Approach 2:
The patent replaces the mechanical molding process with additive manufacturing. Instead of using expensive mold tooling and mechanical injection processes, the ducts are built layer-by-layer from digital models using shape memory polymer materials, eliminating the need for costly tooling while maintaining complex shape capabilities
2Strength
If conventional molded ducts are used, then the ducts can maintain structural integrity, but repair and replacement require significant disassembly and long times
Solution Approach 1:
The patent divides the duct system into modular sections that can be independently manufactured, installed, and replaced. The additive manufacturing process creates self-contained duct segments with integrated coupling features, allowing individual sections to be repaired or replaced without requiring disassembly of the entire duct system, thus improving ease of repair while maintaining overall structural integrity
Solution Approach 2:
The patent incorporates coupling features and connection interfaces directly into the duct segments during additive manufacturing. These pre-integrated coupling elements are built in during fabrication, eliminating the need for separate assembly operations or extensive disassembly during repair, thereby significantly reducing repair time while maintaining structural integrity
3Productivity
If shape memory polymer materials are used, then installation time is reduced through heating to activate shape memory properties, but the material requires heating above transition temperature to change shape
Solution Approach 1:
The patent utilizes the phase transition properties of shape memory polymers, which undergo a reversible transformation between a rigid high-temperature phase and a compliant low-temperature phase. During installation, the polymer is heated above its glass transition temperature to become compliant for routing through contorted paths, then cooled to regain its permanent shape and structural integrity, enabling fast installation without compromising the material's load-bearing capability
Solution Approach 2:
The patent changes the temperature parameter of the shape memory polymer during installation. By temporarily increasing the temperature above the glass transition point, the material transitions from a rigid state to a compliant state, allowing it to be deformed and routed easily. After installation, cooling restores the material to its rigid permanent shape, providing both installation speed and structural integrity
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
This solution enables faster and more efficient installation and repair of ducting by allowing duct portions to be coupled and shaped using shape memory properties, reducing the need for extensive disassembly and tooling, and facilitating the creation of complex shapes that can be easily adapted to fit within aircraft systems.
Implementation Method 1
heating a shape memory polymer material that is at least part of the first duct portion above a transition temperature of the shape memory polymer material, the material to change shape toward a permanent shape
Implementation Method 2
the heating the shape memory polymer presses an end of the first duct portion against an end of the second duct portion
Data Source
AI summary
Ducting and/or duct couplings can be formed from shape memory polymer material, with the material for example being additively manufactured. The use of shape memory polymer material for one or more of the duct portions may allow for easier installation of the ducting, for example allowing the ducting to be warped and/or bent to fit into or through places that are hard to reach or hard to maneuver through, with the ducting then heated to cause it to return to a predetermined memory shape. The coupling of duct portions together may be accomplished by the duct portions including a shape memory polymer material, with for example ends of the duct portions fitted together, and then heated to use a shape memory property of the material to effect coupling. Heating of the shape memory polymer material also softens the material, allowing it to move to a previously set shape.