Aircraft Window Laminate Repair via Vacuum Heating and Adhesive Injection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Window laminates, particularly aircraft window laminates, tend to delaminate over time, leading to moisture ingress and reduced transparency and structural integrity, with existing repair methods being costly and inefficient.
Innovation Solution
A method involving placing the laminate in a vacuum bag and heating it in an oven or autoclave to remove moisture, followed by injecting adhesive into delamination voids and replacing damaged polyvinyl butyral layers and embedded sensors or heating elements as needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire window laminate structure is replaced, then structural integrity and transparency are restored, but cost and time consumption increase significantly
Solution Approach 1:
The patent extracts and removes only the damaged PVB interlayer and affected glass plies from the window laminate structure, rather than replacing the entire assembly. This selective extraction allows for targeted repair of delaminated areas while preserving intact components, thereby reducing both time and material waste compared to complete replacement
Solution Approach 2:
The patent recovers and reuses intact glass plies and functional components from the original window laminate structure after removing only the damaged portions. By discarding only the degraded PVB interlayer and affected areas while recovering usable components, the repair process minimizes waste and reduces the time required compared to complete replacement
2Strength
If adhesive is injected into delaminated areas, then bonding strength is restored, but moisture already present may remain trapped
Solution Approach 1:
The patent applies preliminary action by heating the window laminate structure before adhesive injection to evaporate and remove moisture from delaminated areas. This pre-drying step ensures that moisture is eliminated before the adhesive is introduced, preventing trapped moisture from compromising the restored bonding strength
Solution Approach 2:
The patent changes the temperature parameter by heating the window laminate structure to a specific temperature range to facilitate moisture removal through evaporation. This parameter change (temperature increase) enables the elimination of harmful moisture before adhesive bonding, ensuring optimal bonding strength without trapped moisture
3Illumination intensity
If the window laminate is heated to remove moisture, then transparency is improved, but delaminated areas may expand before repair
Solution Approach 1:
The patent applies preliminary action by heating the window laminate structure to remove moisture and improve transparency before the delamination can spread. This sequential approach ensures that the heating process is completed and transparency restored before any potential delamination expansion occurs
Solution Approach 2:
The patent utilizes parameter changes by controlling the heating temperature and duration to achieve moisture removal and transparency improvement while maintaining conditions that prevent delamination spread. The heated adhesive is then applied to seal and stabilize the repaired areas, preventing further delamination expansion
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
Effectively repairs delaminated areas, removes moisture, and extends the lifespan of window laminates at a lower cost than replacing the entire structure, while maintaining transparency and structural integrity.
Implementation Method 1
placing the window laminate in a vacuum bag
Implementation Method 2
inserting it into an oven or autoclave for a specific ramp up/hold and ramp down
Implementation Method 3
The adhesive is injected into the delaminated area to fill the void between plies and prevent moisture or delamination from returning
Data Source
AI summary
A method for repairing window laminates in which two plies have become separated to create a void, and wherein moisture may have entered through an edge of the window laminate and into the void. The method includes the steps of: placing the window laminate in a vacuum bag and inserting the vacuum bag containing the window laminate into an oven or autoclave for a minimum of ten minutes at a minimum temperature of 120 degrees Fahrenheit to remove the moisture between the plies; removing the vacuum bag and window laminate from the oven, and removing the window from the vacuum bag; forcing a needle on a syringe through the edge of the window laminate in the area of the void; and injecting an adhesive in the syringe into the void to fill the void with the adhesive.