Vacuum-Driven Sealant Distribution for Aircraft Wing Box Sealing

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Solution Overview

Problem

Conventional methods for sealing aircraft wing box structures are inefficient and pose ergonomic challenges due to the need for technicians to maneuver in confined spaces, leading to time-consuming and potentially hazardous procedures.

Innovation Solution

A method and system involving the creation of channels within structural components, placement of a retainer flap to form a cavity, and evacuation of air through one channel to force a sealant into the cavity through another channel, ensuring a fluid-tight seal between structural components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a technician manually applies sealant to the interface between structural components, then the seal can be formed, but the process is time-consuming and causes ergonomic issues

Engineering Contradiction:

Improveease of sealingVSAvoidsealing time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical application of sealant with a vacuum-based system. A vacuum source creates negative pressure to automatically draw sealant through channels and onto the interface between structural components, eliminating the need for technicians to manually apply sealant in confined spaces.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses vacuum pressure (a pneumatic principle) to control the flow of sealant. By creating a pressure differential between the vacuum source and atmospheric pressure, the system automatically transports sealant through designated channels and deposits it precisely at the sealing interface without manual intervention.

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Ease of manufacture

If a technician manually applies sealant to the interface between structural components, then the seal can be formed, but the technician may bump into structural components and the process becomes hazardous

Engineering Contradiction:

Improveease of sealingVSAvoidsafety hazard

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces vacuum pressure as an intermediary force to mediate the sealant application process. Instead of direct manual contact between the technician and the confined sealing space, the vacuum system acts as an intermediary that automatically performs the sealing function from a safe distance.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If sealant is applied manually to numerous locations throughout the wing box, then all interfaces can be sealed, but the process becomes increasingly time-consuming

Engineering Contradiction:

Improveseal completenessVSAvoidsealing efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent segments the sealant distribution system into multiple independent channels, each leading to a specific sealing location. This segmentation allows simultaneous or sequential activation of multiple channels to seal numerous interfaces concurrently, dramatically improving productivity while maintaining complete coverage of all required locations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent enables continuous sealant application by maintaining constant vacuum pressure across all active channels. The vacuum source continuously draws sealant through the channel network and deposits it at all sealing interfaces without interruption, eliminating the start-stop nature of manual application and maximizing sealing efficiency.

Inventive Principle:

Principle #20Continuity of useful action

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 approach enhances efficiency and safety by allowing for a more ergonomic and effective sealing process, preventing fluid leaks and improving ergonomic conditions for technicians.

Implementation Method 1

evacuating the cavity through the first channel, thereby forcing the retainer flap against the second structural component

Methodology Applied

Scientific EffectVacuum: Vacuum

Implementation Method 2

evacuating the cavity through the first channel, thereby forcing the retainer flap against the second structural component

Methodology Applied

Scientific EffectPressure differential: Pressure Gradient

Implementation Method 3

forcing a sealant to flow through the second channel into the cavity

Methodology Applied

Scientific EffectPressure-driven flow: Pressure Gradient

Data Source

PatentUS11780557B2System and method for forming a seal between structural components

Publication Date: 2023.10.10 THE BOEING CO

AI summary

A method for forming a seal between structural components includes placing a retainer flap on a first side of a first structural component over a first channel within the first structural component and over a second channel within the first structural component such that the retainer flap, the first side of the first structural component, and a second structural component form a cavity. The first channel extends between the first side of the first structural component and a second side of the first structural component that is opposite the first side. The second channel extends between the first side of the first structural component and the second side of the first structural component. The method also includes evacuating the cavity through the first channel, thereby forcing the retainer flap against the second structural component and forcing a sealant to flow through the second channel into the cavity.