Stock material or miscellaneous articles – Patched hole or depression
Reexamination Certificate
2000-09-05
2001-07-10
Yao, Sam-Chuan (Department: 1733)
Stock material or miscellaneous articles
Patched hole or depression
C428S220000, C244S131000, C244S133000, C052S459000
Reexamination Certificate
active
06258431
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to methods and apparatus for filling gaps of various shapes and sizes between adjoining panels and the like and, more particularly, to an improved technique using pre-cured gap fillers of predetermined shapes and sizes. Gaps require filling with materials which exhibit suitable conductivity for electromagnetic shielding and other purposes.
2. Description of the Prior Art
There have been long-standing efforts to improve known techniques for filling or covering permanent and access panel gaps by use of sealants, caulks and tapes, especially with respect to aircraft skins, although the invention is not necessarily so limited. The mentioned materials provide continuity between inconsistent widths and depths of these gaps. Maintainability of these systems significantly impacts the aircraft's mission readiness and end users have requested that cure and maintenance times be shortened to minutes or hours rather than days or weeks.
Pre-cured gap fillers offer substantial reductions in maintenance times and simplified processes. Installation in gaps of varying shapes and sizes, however, has previously prevented serious consideration of pre-cured filler concepts. This invention describes an improved process for standardizing existing gap configurations which allows for simple installation and maintenance using pre-cured gap treatments.
The following patents are generally indicative of the prior art at the time the invention was conceived.
U.S. Pat. No. 4,587,761 to Adell discloses an edge guard and method whereby the edge guard is used to substantially fill the gap between the trailing edge of a door onto which the edge guard is installed and an adjacent portion of the vehicle body. In the case of a two-door model car and the rear door of a four-door model car, the adjacent body structure is a pillar or post. In the case of the front door of a four-door model the adjacent body structure may be the front edge of the rear door. When the rear door swing is such that the front edge swings slightly forwardly when the door is opened, provision is made so that the front edge of the rear door does not hit the edge guard on the front door. The edge guard is characterized by inner and outer legs of substantially longer length than other edge guards whereby the edge guard may have a variable engagement with the door edge to permit adjustment for a range of different thicknesses of gap. A hardenable filler material is introduced during installation of an edge guard and is pliable at this stage to permit the edge guard to be adjusted. It subsequently sets to a hardened condition to provide a substantially permanent locator for the adjusted door edge guard. The edge guard is enclosed with protective insulation whose color matches that of the door and adjacent body structure whereby both the edge guard and the gap are substantially de-emphasized thereby promoting sleekness in the appearance of the automobile.
It was with knowledge of the foregoing state of the technology that the present invention has been conceived and is now reduced to practice.
SUMMARY OF THE INVENTION
The present invention relates to a system for filling a gap between adjoining coplanar first and second sheet members mounted on an outer surface of a common substrate and having juxtaposed first and second edge surfaces. A permanent gap filler member of predetermined shape and size intended for eventual permanent reception in the gap is employed for partially filling the gap. A temporary gap filler tool which includes a substitute gap filler element having substantially the same predetermined size and shape of the permanent gap filler member, has an abutting surface for contiguous engagement with the first edge surface of the first sheet member when advanced to an attached position before the permanent gap filler member is mounted in the gap, a minor gap surface facing opposite said abutting surface, and means for releasably attaching the temporary gap filler tool to the first sheet member. A minor gap is thereby defined between the temporary gap filler element and the second edge surface of the second sheet member. Fairing material is initially laid down as an epoxy resin slurry in a minor gap resulting between the substitute gap filler element and the second edge surface of the second sheet member, then cured to hardened form having a substitute second edge surface contiguous with the minor gap surface of the substitute gap filler element. Thereafter, the temporary gap filler is removed from the gap and the permanent gap filler member is inserted and bonded to the common substrate resulting in the entire gap being filled.
More specifically, with respect to access panel edges for an aircraft, for example, a silicone rubber sleeve in the shape of a parallelogram and/or other suitable geometry is slid over the access panel edge and remains in place while the rest of the gap is filled with a filler of epoxy resin or other suitable material. Sleeve configurations have a thin flashing, or flanges, on both sides to hold the sleeve in place over the panel edge. This sleeve is placed on the access panel while removed from the aircraft and then the access panel located by fastening in place. A potting material, either conductive itself or loaded with metal, metal covered spheres or oriented/random fibers or nonconductive material replaces missing material in the gap. The epoxy resin may be potted in place or cast on the aircraft as a permanent fix. Pre-cured beads of current and future conductive elastomers can now be fitted in the gap and loaded under compression when the door is fastened down.
With respect to permanent gaps, permanent panels are able to use a precured elastoiner bead or a bond in place gasket in the shape of a parallelogram and/or other geometry. The pre-cured bead can be permanently bonded in place or a gasket can be removed after the epoxy resin has cured and the pre-cured gap filler can then be pressed into the gap.
A primary feature, then, of the present invention is the provision of a novel technique for filling gaps of various shapes and sizes between adjoining panels and the like.
Another feature of the present invention is the provision of such a novel technique using pre-cured gap fillers of predetermined shapes and sizes.
Still another feature of the present invention is the provision of such a novel technique which results in a low cost retrofit.
Yet another feature of the present invention is the provision of such a novel technique which allows the use of pre-cured gap fillers.
Still a further feature of the present invention is the provision of such a novel technique which results in decreased maintenance man hours.
Yet a further feature of the present invention is the provision of such a novel technique which assures shorter cure cycles.
Still another feature of the present invention is the provision of such a novel technique which is light weight, inexpensive, and uses readily available materials.
Still a further feature of the present invention is the provision of such a novel technique which reduces employee exposure to hazardous materials and reduces the hazardous waste stream.
Still another feature of the present invention is the provision of such a novel technique which is not temperature or humidity dependent.
Yet another feature of the present invention is the provision of such a novel technique which allows for next generation materials.
Other and further features, advantages, and benefits of the invention will become apparent in the following description taken in conjunction with the following drawings. It is to be understood that the foregoing general description and the following detailed description are exemplary and explanatory but are not to be restrictive of the invention. The accompanying drawings which are incorporated in and constitute a part of this invention, illustrate one of the embodiments of the invention, and together with the description, serve to explain the principles of the inventi
Koon Robert Warner
Reis Carl Andrew
Anderson Terry J.
Hoch, Jr. Karl J.
Northrop Grumman Corporation
Yao Sam-Chuan
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