Aircraft Windshield Moisture Sensor for Seal Monitoring

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Solution Overview

Problem

Aircraft windshields experience decreased efficiency and eventual failure due to moisture ingress between laminated layers, leading to premature degradation and the need for emergency maintenance, as existing technologies lack effective real-time monitoring of moisture seals.

Innovation Solution

Integration of moisture sensors with electrolyte members between electrodes in the laminated windshield, connected to sensor electronics to measure electrical properties and detect moisture levels, allowing for scheduled maintenance rather than emergency repairs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If moisture seals are used to prevent moisture ingress in laminated windshields, then the structural integrity is maintained, but the seals fail over time due to lack of monitoring leading to delamination and accessory damage

Engineering Contradiction:

Improvemoisture seal performanceVSAvoidservice time until failure

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The moisture sensor is installed within the laminate structure during manufacturing, positioned to detect moisture ingress at the moisture seal interface before delamination occurs. This preliminary monitoring arrangement enables early detection of seal failures, allowing maintenance to be scheduled before structural damage happens to the windshield or accessories.

Inventive Principle:

Principle #10Preliminary action

2Device complexity

If no monitoring system is installed, then the windshield structure remains simple, but moisture ingress goes undetected causing premature degradation and emergency maintenance

Engineering Contradiction:

Improvewindshield structureVSAvoidwindshield functionality

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The moisture sensor utilizes a thin film electrolyte layer sandwiched between two electrodes, integrated within the laminate structure. This thin-film approach provides effective moisture detection capability while minimizing the increase in overall windshield complexity and maintaining structural integrity.

Inventive Principle:

Principle #30Flexible shells and thin films

3Measurement precision

If moisture sensors are integrated into the windshield, then real-time monitoring of moisture ingress is enabled, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvemoisture detection capabilityVSAvoidwindshield fabrication

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The moisture sensor components (electrodes and electrolyte layer) are merged into the existing windshield laminate structure during the manufacturing process. The sensor is positioned between laminate layers, combining the structural function of the windshield with the monitoring function of the sensor in a single integrated assembly, thereby reducing separate manufacturing steps.

Inventive Principle:

Principle #5Merging (Combining)

4Productivity

If the windshield lacks moisture monitoring, then maintenance costs are lower initially, but emergency repairs increase overall expenses and downtime

Engineering Contradiction:

Improveoperational efficiencyVSAvoidmaintenance resources

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

The moisture sensor provides continuous feedback on the condition of the moisture seal by detecting moisture ingress between laminate layers. This feedback mechanism enables condition-based maintenance scheduling, allowing operators to service the windshield proactively before delamination occurs, thereby maintaining higher operational efficiency and preventing costly emergency repairs.

Inventive Principle:

Principle #23Feedback

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

The solution enables real-time monitoring of moisture ingress, preventing premature degradation and extending the service life of the windshield by allowing for timely maintenance and reducing the risk of structural failures.

Implementation Method 1

The moisture sensor includes, among other things, an electrolyte member between a first electrode and a second electrode wherein the electrolyte material is in electrical contact with the first and second electrodes and maintains the first and the second electrodes spaced from one another and out of the surface contact with one another

Methodology Applied

Scientific EffectElectrolyte: Electrolyte

Implementation Method 2

the electrical potential between the electrodes and/or current supplied through a calibrated load within the sensor electronics measures the amount of moisture within the laminated windshield in the area of the moisture sensor

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS9975646B2Aerospace transparency having moisture sensors

Publication Date: 2018.05.22 PPG INDUSTRIES OHIO INC

AI summary

A transparency, e.g. an aircraft laminated windshield, includes one or more moisture sensors to monitor moisture penetration to monitor performance of the moisture barrier. At least one of the moisture sensors includes an electrolyte between and in ionic contact with two electrically conductive electrodes. Measuring the potential between the first and second electrode and/or the current through the electrodes to determine the amount of moisture within the laminated windshield in the area of the moisture sensor. With the information provided by the moisture sensors performance of the windshield is available to schedule timely repair or replacement of the windshield that is performing outside of acceptable limits.