Structural Gap Filler Assembly Without Drilling Debris Cleanup

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Solution Overview

Problem

Current aircraft manufacturing processes require disassembly and cleaning of components to remove drilling debris, which increases labor and time, and introduces inefficiencies.

Innovation Solution

A method involving drilling an injection hole through two components, encapsulating drilling debris with a structural gap filler injected through the hole, and then drilling a subsequent hole through the filler and components, while maintaining clamp-up to prevent re-debris generation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If components are disassembled and cleaned to remove drilling debris, then manufacturing precision is improved, but productivity deteriorates due to increased labor and time

Engineering Contradiction:

Improvecleanliness of gap between componentsVSAvoidmanufacturing time and labor

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent converts the harmful drilling debris into a beneficial element by using it as a placeholder that maintains gap dimensions during the fastening process, eliminating the need for time-consuming cleaning operations while preserving manufacturing precision

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent introduces drilling debris as an intermediary substance between the two components that serves as a dimensional reference and spacer, allowing the assembly to proceed without disassembly and cleaning, thus improving productivity while maintaining precision

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If clamp-up is maintained between drilling operations, then productivity is improved by eliminating disassembly, but manufacturing precision may deteriorate due to potential misalignment

Engineering Contradiction:

Improvecontinuity of assembly processVSAvoidalignment of holes through components

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent performs preliminary drilling of the first hole through both components while they are clamped together, establishing a reference position that guides subsequent drilling operations, thereby maintaining alignment precision throughout the continuous process

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces the traditional mechanical alignment system (disassembly and repositioning) with a drilling-guidance system where the first drilled hole serves as a physical guide for subsequent holes, maintaining precision without breaking clamp-up

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP4353460B1Methods and structural gap filler for one-up assembly

Publication Date: 2025.04.16 THE BOEING CO

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AI summary

Methods and structural gap filler for one up assembly of structures. Drilling debris (210) generated between the first component (204) and the second component (206) during drilling (1002) of an injection hole (209) are encapsulated by injecting a structural gap filler (212) through the injection hole (209) and between the first component and the second component.