Thrust Reverser Composite Repair for FAA-Compliant Corrosion Damage
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Solution Overview
Problem
Current methods for repairing corrosion damage on airplane parts, particularly thrust reverser systems, are costly and time-consuming, often requiring complete replacement to meet FAA certification standards, which is inefficient and impractical.
Innovation Solution
A method involving the removal of the affected part, installation of synthetic fiber material sandwiched between film adhesive layers, addition of doublers, heat curing, edge sealing, and reinstallation of the outer skin, using materials like Kevlar and epoxy adhesives, to effectively repair corrosion damage while meeting FAA requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complete part replacement is performed to meet FAA certification standards, then reliability and compliance are improved, but cost and time consumption increase significantly
Solution Approach 1:
The repair process segments the thrust reverser part into removable sections, allowing the damaged area to be accessed and treated independently while maintaining the integrity of the overall structure. This enables localized repair rather than complete replacement.
Solution Approach 2:
The patent employs composite materials including synthetic fiber materials (such as Kevlar), film adhesives, and resin edge seals to create a repair structure that meets FAA certification standards. These composite materials provide the necessary strength and corrosion resistance to ensure reliability without requiring complete part replacement.
2Reliability
If complete part replacement is performed to meet FAA certification standards, then reliability and compliance are improved, but cost increases significantly
Solution Approach 1:
The repair method recovers and reuses the existing part structure by applying composite repair materials to the damaged areas. This approach discards only the minimal damaged portions while recovering and retaining the majority of the original part, significantly reducing material costs compared to complete replacement.
Solution Approach 2:
The use of composite materials provides a cost-effective alternative to replacing entire expensive thrust reverser parts. The composite repair structure meets FAA certification requirements while using less expensive materials than the original metal components.
3Reliability
If traditional replacement methods are used, then FAA certification requirements are met, but productivity decreases due to time-consuming processes
Solution Approach 1:
The method includes preliminary preparation steps such as removing the outer skin before applying the composite repair materials. This preliminary action exposes the damaged area and prepares the surface for efficient repair application, streamlining the overall process while ensuring compliance.
Solution Approach 2:
The repair process utilizes parameter changes including heat curing of the film adhesive and resin edge seal to achieve proper bonding and structural integrity. These controlled parameter changes (temperature, time) ensure FAA compliance while optimizing the repair process for 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
This method allows for cost-effective and efficient repair of corrosion damage on thrust reverser parts, ensuring compliance with FAA certification without the need for complete part replacement, thereby reducing costs and time associated with traditional replacement methods.
Implementation Method 1
The ply of synthetic fiber material being sandwiched between a layer of film adhesive on each side of the ply of synthetic fiber material
Implementation Method 2
The method also includes heat curing the layers of film adhesive
Implementation Method 3
applying an edge seal to gaps between the one or more doublers and the inner surface or outer surface of the part
Data Source
AI summary
Systems and methods for repairing corrosion damage of a part of a thrust reverser assembly. The method includes removing the part having an inner surface and an outer surface. The method also includes removing an outer skin from the inner surface and the outer surface of the part. The method further includes installing a ply of synthetic fiber material onto an area of the inner surface or the outer surface of the part. The method also includes installing one or more doublers onto the ply of synthetic fiber material and heat curing layers of film adhesive. The method further includes applying an edge seal to gaps between the one or more doublers and the inner surface or outer surface of the part. The method also includes installing the outer skin to the inner surface and the outer surface of the part and installing the part to the thrust reverser assembly.