Patent ID: 6258431
Filing Date: 2001-07-10
Classification: B29C,Y02T,Y10T

Abstract:
A system for filling a gap between adjoining coplanar first and second sheet members, each having opposed inner and outer surfaces, mounted on an outer surface of a common substrate and having juxtaposed first and second edge surfaces, respectively, said system comprising;a permanent gap filler member of predetermined shape and size for eventual reception in the gap for partially filling the gap, the permanent gap filler member having an abutting surface which, when received in the gap is in contiguous engagement with the first edge surface of the first sheet member a mounting surface for contiguous engagement with the outer surface of the common substrate, and a minor gap surface opposite said abutting surface;a temporary gap filler tool including a substitute gap filler element having substantially the same predetermined size and shape of the permanent gap filler member, the substitute gap filler element having an abutting surface for contiguous engagement, before said permanent gap filler member is mounted in the gap, with the first edge surface of the first sheet member, a minor gap surface facing opposite said abutting surface, and means for releasably attaching said temporary gap filler tool to said first sheet member so that said abutting surface of said substitute gap filler element is contiguously engaged with the first edge surface of the first sheet member in the same manner as said permanent gap filler member wherein said means for releasably attaching said temporary gap fillet tool includes a pair of spaced apart flange members projecting away from the abutting surface such that the flange members are in contiguous slidable engagement, respectively, with the inner and outer surfaces of the first sheet member, thereby defining a minor gap existing between said temporary gap filler element and the second edge surface of the second sheet member;fairing material in the minor gap existing between said substitute gap filler element and the second edge surface of the second sheet member initially laid down as a slurry, then cured to hardened forming having a substitute second edge surface contiguous with the minor gap surface of the substitute gap filler element;said permanent gap filler member being fixedly attached to the outer face of the common substrate upon removal of said temporary gap filler tool from the first sheet member with the abutting surface in continuous engagement with the first edge surface of the first sheet member and with said minor gap surface in contiguous engagement with said substitute second edge surface of said fairing member;whereby the entire gap is filled.