Aircraft Wing Manhole Cover Assembly With Integrated Gasket Curing
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Solution Overview
Problem
The current method for applying covers to aircraft wing manholes is time-consuming and costly due to manual installation of gaskets, requiring dedicated geometries, frequent repairs for thickness tolerance issues, and the use of sealants, which also has a negative environmental impact.
Innovation Solution
A method involving a skin with manholes, gaskets made from thermoplastic materials like recycled polyamide with continuous thickness, and plugs adapted to the cover thickness, cured together in an autoclave, eliminating the need for manual installation and dedicated measurements, and using recycled materials for gaskets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual installation of gaskets is used, then customization and fit precision are improved, but application time and labor costs increase
Solution Approach 1:
The patent merges the gasket and cover into a single integrated component manufactured as one piece. This eliminates the need for separate gasket installation while maintaining the sealing function, thereby reducing application time without sacrificing fit precision.
Solution Approach 2:
The integrated cover-gasket component serves multiple functions simultaneously: it provides structural coverage and sealing in one element. This universal design eliminates the need for separate gasket installation steps while maintaining customization capabilities through varied cover designs.
2Manufacturing precision
If dedicated gasket geometries are manufactured per part, then thickness tolerance requirements are met, but manufacturing complexity and costs increase
Solution Approach 1:
By combining the gasket function with the cover structure, the patent eliminates the need for separate dedicated gasket geometries. The sealing function is integrated into the cover design itself, reducing manufacturing complexity while maintaining thickness tolerance through standardized cover manufacturing processes.
Solution Approach 2:
The patent extracts the gasket as a separate component and integrates its sealing function directly into the cover structure. This eliminates the need for separate gasket manufacturing and installation, simplifying the overall manufacturing process while maintaining precision requirements.
3Reliability
If gaskets are installed one by one manually, then proper positioning and sealing are ensured, but application time and recurrent costs increase
Solution Approach 1:
The patent merges the gasket and cover into a single component, eliminating the need for manual installation of separate gaskets. This integration maintains sealing quality while dramatically reducing application time and recurrent maintenance costs.
Solution Approach 2:
The sealing function is preliminarily integrated into the cover manufacturing process itself. By pre-incorporating the gasket function during cover production, the patent ensures proper sealing is achieved without requiring subsequent manual installation steps.
4Strength
If chemical sealants are used to bond gaskets, then bonding strength is improved, but environmental impact and process complexity increase
Solution Approach 1:
The patent extracts and eliminates the chemical sealant from the assembly process by integrating the gasket function directly into the cover. This eliminates harmful chemical substances while maintaining bonding strength through mechanical integration.
Solution Approach 2:
By eliminating chemical sealants in favor of an integrated mechanical design, the patent removes substances that require environmental management and disposal, reducing harmful factors while maintaining functional performance.
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 reduces application time and costs, minimizes repairs, and enhances environmental sustainability by integrating gaskets and plugs with the wing cover, ensuring precise thickness and mechanical joint, while eliminating the need for sealants and secondary bonding processes.
Implementation Method 1
curing the aircraft wing with the cover, the cover comprising the skin, the gasket or gaskets and the plug or plugs
Implementation Method 2
the curing is made in an autoclave
Implementation Method 3
the, or each, gasket, preferably with a continuous thickness, is made from a thermoplastic material, e.g., from recycled polyamide, by injection
Data Source
AI summary
A method for applying a cover to an aircraft wing including placing a skin provided with one or more manholes on the aircraft wing; placing a gasket for the, or each, manhole of the skin; placing a plug in the, or each, manhole; and curing the aircraft wing with the cover, the cover comprising the skin, the gasket or gaskets and the plug or plugs. The aircraft wing includes a cover applied by the described method including a skin, one or more gaskets and one or more plugs.