Insulation sealing system

An insulation insert comprises a hollow cylinder formed of a closed cell foam, a first adhesive layer on a first face of the hollow cylinder, a flange of the closed cell foam extending from the hollow cylinder, and a second adhesive layer on a second face of the flange.

BACKGROUND INFORMATION

The present disclosure relates generally to insulation blankets in aircraft and, more specifically, to installing insulation blankets in an aircraft. Yet more specifically, the present disclosure relates to sealing a penetration of an insulation blanket using an insulation sealing system during installation of the insulation blanket.

During flight, temperatures outside of an aircraft are significantly lower than the temperatures inside the aircraft. Insulation blankets are present inside the fuselage of the aircraft to protect passengers and crew within the aircraft from the outside temperatures.

Aircraft systems, such as ducts, tubes, and wire bundles, run through aircraft. These aircraft systems have attach points onto stringers of the airframe of the aircraft.

These attach points create penetrations through the insulation blankets to connect to the stringers. These penetrations through the insulation blankets are potential sources of water ingress into the insulation blankets, which can result in undesirable conditions.

Therefore, it would be desirable to have a method and apparatus that take into account at least some of the issues discussed above, as well as other possible issues. For example, it would be desirable to have attach points for aircraft systems that deter water ingress into insulation blankets.

SUMMARY

An illustrative embodiment of the present disclosure provides an insulation sealing system. The insulation sealing system comprises an insulation insert and a stringer clip. The insulation insert comprises a hollow cylinder formed of a closed cell foam, a first adhesive layer on a first face of the hollow cylinder, a flange of the closed cell foam extending from the hollow cylinder, and a second adhesive layer on a second face of the flange. The stringer clip has a mounting post configured to provide an interference fit with a hole of the hollow cylinder.

Another illustrative embodiment of the present disclosure provides an insulation insert. The insulation insert comprises a hollow cylinder formed of a closed cell foam, a first adhesive layer on a first face of the hollow cylinder, a flange of the closed cell foam extending from the hollow cylinder, and a second adhesive layer on a second face of the flange.

Yet another illustrative embodiment of the present disclosure provides a method. A first hole having a first diameter is punched through a first face of an insulation blanket and a filler of the insulation blanket. A second hole having a second diameter is punched through a second face of the insulation blanket, wherein the second hole is concentric with the first hole, and wherein the second diameter is smaller than the first diameter. An insulation insert is installed within the first hole, the insulation insert comprising a hollow cylinder formed of a closed cell foam, a first adhesive layer on a first face of the hollow cylinder, a flange of the closed cell foam extending from the hollow cylinder, and a second adhesive layer on a second face of the flange.

A further illustrative embodiment of the present disclosure provides a method. A hollow cylinder is punched from a sheet of closed cell foam. A disc is punched from a second sheet of closed cell foam. The hollow cylinder is bonded to the disc to form an insulation insert comprising the hollow cylinder, a first adhesive layer on a first face of the hollow cylinder, a flange extending from the hollow cylinder, and a second adhesive layer on a second face of the flange, wherein the flange is formed by the disc.

DETAILED DESCRIPTION

The illustrative embodiments recognize and take into account one or more different considerations. For example, the illustrative embodiments recognize and take into account that it is desirable to design attach points through insulation blankets that deter or prevent water from entering through these attach points.

The illustrative embodiments recognize and take into account that designs for attach points currently exist. The illustrative embodiments recognize and take into account that some conventional attach points are installed completely within an aircraft. In these examples, the conventional attach points are installed through an insulation blanket at the stringers of the aircraft.

The illustrative embodiments recognize and take into account that some conventional attach points are partially installed outside an aircraft. For example, a conventional attach point may have a penetration through the insulation blanket formed and sealed outside of the aircraft.

The illustrative embodiments recognize and take into account that pre-sealed penetration locations may take an undesirably large amount of engineering time to pre-design the insert/penetration locations. The illustrative embodiments recognize and take into account that pre-sealed penetration locations result in less design change flexibility. The illustrative embodiments recognize and take into account that changes to aircraft systems design may result in changes to the desired penetration locations. The illustrative embodiments recognize and take into account that with pre-sealed penetration locations in insulation blankets, these changes to the insulation blankets may not be possible on the fly. The illustrative embodiments recognize and take into account that with pre-sealed penetration locations in insulation blankets, the design of the insulation blanket may be more difficult than desired to change.

The illustrative embodiments recognize and take into account that conventional designs for attach points may not completely prevent water ingress. The illustrative embodiments recognize and take into account that it would be desirable to present a design for attach points with better sealing capabilities.

The illustrative embodiments also recognize and take into account that at least one of installation time or installation difficulty for conventional attach points may be undesirably high. The illustrative embodiments recognize and take into account that it would be desirable to present a design for attach points that have at least one of: fewer installation steps, less installation time, or less installation difficulty.

The illustrative embodiments recognize and take into account that some existing attach points are formed of solid plastic. The illustrative embodiments also recognize and take into account that it is desirable to reduce weight of an aircraft. The illustrative embodiments recognize and take into account that decreasing the weight of an aircraft increases the fuel efficiency of an aircraft. The illustrative embodiments recognize and take into account that decreasing the weight of an aircraft may increase the capacity for additional cargo or passengers.

Turning now toFIG. 1, an illustration of a block diagram of a manufacturing environment in which an insulation sealing system is used is depicted in accordance with an illustrative embodiment. Manufacturing environment100is an environment in which insulation blanket102is installed within aircraft104. Insulation blanket102has filler106between first face108and second face110.

Insulation blanket102is both sealed and secured to stringer112using insulation sealing system114. Insulation sealing system114seals penetration115through insulation blanket102. In some illustrative examples, insulation sealing system114forms attachment point117for an aircraft system, such as at least one of a duct, a tube, or a wire bundle.

This example also may include item A, item B, and item C, or item B and item C. Of course, any combination of these items may be present. In other examples, “at least one of” may be, for example, without limitation, two of item A, one of item B, and ten of item C; four of item B and seven of item C; or other suitable combinations.

Closed cell foam122is selected to meet standards for at least one of strength, water permeability, and fireproofing. It is desirable for closed cell foam122to be waterproof. It is also desirable for closed cell foam122to be fireproof. Closed cell foam122is any desirable material, such as polyvinylidene fluoride (PVDF).

In some illustrative examples, flange128is disc134bonded to hollow cylinder120. In these illustrative examples, disc134is bonded to hollow cylinder120using any desirable method. In some illustrative examples, disc134is bonded to hollow cylinder120using second adhesive layer130. In other illustrative examples, disc134is bonded to hollow cylinder120using a different bonding material than second adhesive layer130.

In some illustrative examples, disc134is a uniform disc of closed cell foam122without any openings. In some other illustrative examples, disc134has hole136extending through disc134. In these illustrative examples, hole136is concentric with disc134. In some of these illustrative examples, hole136has diameter138configured to receive a fastener.

In some illustrative examples, disc134comprises perforated circle140concentric with disc134. In these illustrative examples, perforated circle140extends partially through closed cell foam122of disc134. When present, perforated circle140increases the uses of insulation insert116. In some illustrative examples, when disc134comprises perforated circle140, hole136is enlarged by removing perforated circle140from disc134. In some illustrative examples, when disc134comprises perforated circle140, hole136is created by removing perforated circle140from disc134.

Hollow cylinder120has hole144with diameter142. In some illustrative examples, diameter142of hole144of hollow cylinder120is configured to provide an interference fit with mounting post145of stringer clip118.

Insulation insert116includes removable adhesive cover146contacting first adhesive layer124. As depicted, removable adhesive cover146has protruding tab148. To adhere hollow cylinder120to second face110of insulation blanket102, removable adhesive cover146is removed from insulation insert116exposing first adhesive layer124. When present, protruding tab148aids in removal of removable adhesive cover146by an operator. In some illustrative examples, protruding tab148is not present.

Insulation insert116also includes second removable adhesive cover150. As depicted, second removable adhesive cover150has protruding tab152, wherein second removable adhesive cover150contacts second adhesive layer130. To adhere flange128to first face108of insulation blanket102, second removable adhesive cover150is removed from insulation insert116exposing second adhesive layer130. When present, protruding tab152aids in removal of second removable adhesive cover150by an operator. In some illustrative examples, protruding tab152is not present.

When insulation insert116is installed in insulation blanket102, insulation insert116is adhered to first face108and second face110of insulation blanket102. First adhesive layer124is exposed to adhere first face126of hollow cylinder120to second face110. Second adhesive layer130is exposed to adhere second face132of disc134to first face108.

First adhesive layer124adheres first face126of hollow cylinder120to an inner surface of second face110. The inner surface of second face110is within insulation blanket102. Portions of the inner surface of second face110contact filler106.

Second adhesive layer130adheres second face132of disc134to an outer surface of first face108. The outer surface of first face108is an exterior of insulation blanket102.

When insulation insert116is installed, hollow cylinder120is contained within insulation blanket102. When insulation insert116is installed, hollow cylinder120is held within first hole154. First hole154has first diameter156. First hole154extends through a portion of insulation blanket102. First hole154extends through first face108and filler106.

Second hole158extends through a portion of insulation blanket102. As depicted, second hole158extends through second face110. Second hole158has second diameter160. Second diameter160is smaller than first diameter156of first hole154. Second diameter160is configured to receive mounting post145of stringer clip118.

In some illustrative examples, first hole154and second hole158are created in separate processes. In some other illustrative examples, first hole154and second hole158are created substantially simultaneously. In some illustrative examples in which first hole154and second hole158are created substantially simultaneously, first hole154and second hole158are created using dual cutter162.

Stringer clip118is secured to stringer112using tension. Stringer clip118has mounting post145configured to provide an interference fit with hole144of hollow cylinder120.

By installing insulation sealing system114during installation of insulation blanket102within aircraft104, a location of insulation insert116is selected on the fly. By installing insulation sealing system114during installation of insulation blanket102within aircraft104, a location of insulation insert116may be changed from an intended location based on variations during installation of insulation blanket102. By installing insulation sealing system114during installation of insulation blanket102within aircraft104, a location of insulation insert116may be changed based on design changes to aircraft systems.

Installing insulation sealing system114may involve fewer steps than installing conventional sealing systems. Installing insulation sealing system114may be less labor intensive than installing conventional sealing systems.

Insulation blanket102is pressed against stringer clip118. First hole154and second hole158are cut into insulation blanket102. Insulation insert116is adhered to insulation blanket102. In some illustrative examples, first adhesive layer124is adhered to second face110and second adhesive layer130is adhered to first face108substantially simultaneously. In some illustrative examples, first adhesive layer124is adhered to second face110prior to adhering second adhesive layer130to first face108. In some illustrative examples, first adhesive layer124is adhered to second face110prior to removing second removable adhesive cover150from second adhesive layer130.

Insulation insert116may be manufactured in any desirable fashion. In one illustrative example, insulation insert116is formed from sheet of closed cell foam164having thickness166and second sheet of closed cell foam168having thickness170.

In some illustrative examples, hollow cylinder120is punched from sheet of closed cell foam164. In these illustrative examples, a height of hollow cylinder120is the same as thickness166. First adhesive layer124is applied to hollow cylinder120in any desirable manner. In some illustrative examples, sheet of closed cell foam164includes adhesive172. In these illustrative examples, when hollow cylinder120is cut from sheet of closed cell foam164, first adhesive layer124is formed from adhesive172. In other illustrative examples, first adhesive layer124is applied to hollow cylinder120after punching hollow cylinder120from sheet of closed cell foam164.

In some illustrative examples, disc134is punched from second sheet of closed cell foam168. In these illustrative examples, a height of disc134is the same as thickness170. Second adhesive layer130is applied to disc134in any desirable manner. In some illustrative examples, second sheet of closed cell foam168includes adhesive174. In these illustrative examples, when disc134is cut from second sheet of closed cell foam168, second adhesive layer130is formed from adhesive174. In other illustrative examples, second adhesive layer130is applied to disc134after punching disc134from second sheet of closed cell foam168.

For example, removable adhesive cover146may not include protruding tab148, and second removable adhesive cover150may not include protruding tab152. As another example, at least one of hole136or perforated circle140may not be present in disc134. As yet another example, although disc134and hollow cylinder120are both depicted as being formed of closed cell foam122, in some illustrative examples, disc134and hollow cylinder120may be formed of different materials.

In some non-depicted illustrative examples, a cylindrical standoff may be present within hollow cylinder120. In some illustrative examples, the cylindrical standoff is bonded within hollow cylinder120.

FIGS. 2-4are illustrations of one example of a physical implementation of an insulation insert. In the illustrative examples, the same reference number may be used in more than one figure. This reuse of a reference numeral in different figures represents the same element in the different figures.

Turning now toFIG. 2, an illustration of a top perspective view of an insulation insert is depicted in accordance with an illustrative embodiment. Insulation insert200is a physical implementation of insulation insert116ofFIG. 1. Insulation insert200may be installed in an insulation blanket, such as insulation blanket102ofFIG. 1.

Insulation insert200comprises hollow cylinder202, first adhesive layer204, flange206, and second adhesive layer208. Hollow cylinder202is formed of a closed cell foam. First adhesive layer204is on first face210of hollow cylinder202.

Flange206is formed of a closed cell foam. Flange206extends from hollow cylinder202. Second adhesive layer208is on second face212of flange206.

As depicted, hollow cylinder202has hole214. Diameter216of hole214of hollow cylinder202is configured to provide an interference fit with a mounting post of a stringer clip, such as mounting post145of stringer clip118ofFIG. 1.

Turning now toFIG. 3, an illustration of a bottom perspective view of an insulation insert is depicted in accordance with an illustrative embodiment. View300is a bottom perspective view of insulation insert200ofFIG. 2. As depicted, flange206is disc302adhered to hollow cylinder202.

Turning now toFIG. 4, an illustration of an exploded view of an insulation insert is depicted in accordance with an illustrative embodiment. View400is an exploded view of insulation insert200ofFIG. 2. As depicted, second adhesive layer208extends across second face212of flange206to bond hollow cylinder202to disc302.

The illustration of insulation insert200inFIGS. 2-4is not meant to imply physical or architectural limitations to the manner in which an illustrative example may be implemented. For example, disc302may not have hole304. In some illustrative examples, disc302may have a perforated circle in place of hole304. As another example, disc302may have a perforated circle in addition to hole304.

Turning now toFIG. 5, an illustration of a perspective exploded view of an insulation sealing system and an insulation blanket is depicted in accordance with an illustrative embodiment. View500includes insulation blanket502and insulation sealing system504. Insulation sealing system504includes insulation insert506and stringer clip508.

Stringer clip508is connected to stringer510using tension. Stringer clip508has mounting post512. Mounting post512may be used to form an attach point for an aircraft system, such as a duct, a tube, or a wire bundle.

Insulation insert506comprises hollow cylinder514and flange516extending from hollow cylinder514. Flange516is formed by disc518bonded to hollow cylinder514. In this illustrative example, disc518does not have a hole extending through disc518. As depicted, perforations519are present in disc518.

Hollow cylinder514is inserted into first hole520in insulation blanket502. A first adhesive layer on hollow cylinder514is adhered to second face521of insulation blanket502. A second adhesive layer on flange516is adhered to first face522of insulation blanket502.

First hole520extends through first face522and filler524of insulation blanket502. Second hole526extends through second face521. Mounting post512of stringer clip508extends through second hole526. Mounting post512is configured to have an interference fit with a hole extending through hollow cylinder514of insulation insert506.

Turning now toFIG. 6, an illustration of a cross-sectional exploded view of an insulation sealing system and an insulation blanket is depicted in accordance with an illustrative embodiment. View600is a cross-sectional view of insulation sealing system504and insulation blanket502ofFIG. 5.

As depicted, perforations519in disc518extend partially through disc518. In some illustrative examples, a portion of disc518may be removed by “punching out” the perforated material.

The illustration of insulation insert506inFIGS. 5-6is not meant to imply physical or architectural limitations to the manner in which an illustrative example may be implemented. For example, a hole may be present in disc518in addition to perforations519in disc518. In other illustrative examples, perforations519are not present.

In some non-depicted illustrative examples, a cylindrical standoff may be present within hollow cylinder514. In some illustrative examples, the cylindrical standoff is bonded within hollow cylinder514.

Turning now toFIG. 7, an illustration of a cross-sectional view of an insulation blanket during installation on a stringer clip is depicted in accordance with an illustrative embodiment. In view700, insulation blanket702is pressed against mounting post704of stringer clip706. Insulation blanket702is a physical implementation of insulation blanket102ofFIG. 1.

Turning now toFIG. 8, an illustration of a cross-sectional view of cutting a first hole and a second hole in an insulation blanket during installation on a stringer clip is depicted in accordance with an illustrative embodiment. In view800, dual cutter802cuts first hole804into first face806and filler808of insulation blanket702. Dual cutter802is a physical implementation of dual cutter162ofFIG. 1.

In view800, dual cutter802cuts second hole810into second face812of insulation blanket702. As depicted, first hole804has a greater diameter than second hole810. As depicted, mounting post704extends through second hole810.

Turning now toFIG. 9, an illustration of a cross-sectional view of adhering an insulation insert to an insulation blanket during installation on a stringer clip is depicted in accordance with an illustrative embodiment. In view900, insulation insert902has been installed. A first adhesive layer on first face904of hollow cylinder906of insulation insert902is applied to inside surface908of second face812of insulation blanket702. First face904of hollow cylinder906is adhered to second face812of insulation blanket702using the first adhesive layer. A second adhesive layer on second face910of flange912of insulation insert902is applied to outside surface914of first face806of insulation blanket702. Second face910of flange912is adhered to first face806of insulation blanket702using the second adhesive layer.

The illustration of insulation insert902inFIG. 9is not meant to imply physical or architectural limitations to the manner in which an illustrative example may be implemented. In this illustrative example, flange912of insulation insert902has neither perforations nor a hole. In non-depicted examples, at least one of perforations or a hole is present in the disc forming flange912. Additionally, in some non-depicted illustrative examples, a cylindrical standoff may be present within hollow cylinder906of insulation insert902.

Turning now toFIG. 10, an illustration of a top perspective view of an insulation sealing system in an insulation blanket is depicted in accordance with an illustrative embodiment. In view1000, flange1002of insulation insert1004is adhered to first face1006of insulation blanket1008. Insulation insert1004is a physical implementation of insulation insert116ofFIG. 1.

As depicted, insulation insert1004is formed of a closed cell foam and is flexible. As insulation blanket1008bends and moves, flange1002also bends and moves. Insulation insert1004seals a penetration through insulation blanket1008.

In some illustrative examples, a fastener will be inserted through insulation insert1004to attach a structure, such as a duct, a pipe, or a wiring bundle, to a stringer beneath insulation blanket1008. In these illustrative examples, the fastener pierces insulation insert1004to attach a structure to a stringer beneath insulation blanket1008. In some non-depicted illustrative examples, a hole is present. In these illustrative examples, a fastener may have an interference fit with the hole. In other non-depicted examples, perforations may be present with or without a hole.

The different components shown inFIGS. 2-10may be combined with components inFIG. 1, used with components inFIG. 1, or a combination of the two. Additionally, some of the components inFIGS. 2-10may be illustrative examples of how components shown in block form inFIG. 1may be implemented as physical structures. Turning now toFIG. 11, an illustration of a flowchart of a method for installing an insulation blanket is depicted in accordance with an illustrative embodiment. Method1100may be used to install insulation insert116ofFIG. 1into insulation blanket102ofFIG. 1. Method1100may be used to install insulation insert200ofFIGS. 2-4into an insulation blanket. Method1100may be used to install insulation insert506in insulation blanket502ofFIGS. 5-6.FIGS. 8-9may depict an insulation blanket following some operations of method1100.

Method1100punches a first hole having a first diameter through a first face of an insulation blanket and a filler of the insulation blanket (operation1102). Method1100punches a second hole having a second diameter through a second face of the insulation blanket, wherein the second hole is concentric with the first hole, and wherein the second diameter is smaller than the first diameter (operation1104). In some illustrative examples, the first hole and the second hole are punched substantially simultaneously by a dual punch tool. In other illustrative examples, the first hole and the second hole are punched in subsequent operations by two different punch tools.

Method1100installs an insulation insert within the first hole, the insulation insert comprising a hollow cylinder formed of a closed cell foam, a first adhesive layer on a first face of the hollow cylinder, a flange of the closed cell foam extending from the hollow cylinder, and a second adhesive layer on a second face of the flange (operation1106). Afterwards, method1100terminates.

In some illustrative examples, installing the insulation insert comprises adhering the first face of the hollow cylinder to the second face of the insulation blanket using the first adhesive layer and adhering the second face of the flange to the first face of the insulation blanket using the second adhesive layer (operation1108). In some of these illustrative examples, the first face of the hollow cylinder is adhered to the second face of the insulation blanket and the second face of the flange is adhered to the first face of the insulation blanket in one step. In some of these illustrative examples, the first face of the hollow cylinder is adhered to the second face of the insulation blanket, and the second face of the flange is adhered to the first face of the insulation blanket in two steps.

In some illustrative examples, method1100places the insulation blanket in contact with a stringer clip (operation1110). In some illustrative examples, installing the insulation insert comprises forming an interference fit between a diameter of a hole of the hollow cylinder and a mounting post of the stringer clip (operation1112).

In some illustrative examples, method1100removes a first removable adhesive cover with a protruding tab from the first adhesive layer prior to installing the insulation insert (operation1114). In some illustrative examples, installing the insulation insert within the first hole comprises adhering the first face of the hollow cylinder to the second face of the insulation blanket using the first adhesive layer, removing a second removable adhesive cover with a protruding tab from the second adhesive layer after adhering the first face of the hollow cylinder to the second face of the insulation blanket, and adhering the second face of the flange to the first face of the insulation blanket using the second adhesive layer (operation1116).

Turning now toFIG. 12, an illustration of a flowchart of a method for manufacturing an insulation insert is depicted in accordance with an illustrative embodiment. Method1200may be used to form insulation insert116ofFIG. 1. Method1200may be used to form insulation insert200ofFIGS. 2-4. Method1200may be used to form insulation insert506ofFIGS. 5-6. Method1200may be used to form insulation insert902ofFIG. 9. Method1200may be used to form insulation insert1004ofFIG. 10.

Method1200punches a hollow cylinder from a sheet of closed cell foam (operation1202). In some illustrative examples, the sheet of closed cell foam has a layer of adhesive and a cover contacting the layer of adhesive.

Method1200punches a disc from a second sheet of closed cell foam (operation1204). In some illustrative examples, the second sheet of closed cell foam has a second layer of adhesive and a cover contacting the second layer of adhesive.

Method1200bonds the hollow cylinder to the disc to form an insulation insert comprising the hollow cylinder, a first adhesive layer on a first face of the hollow cylinder, a flange extending from the hollow cylinder, and a second adhesive layer on a second face of the flange, wherein the flange is formed by the disc (operation1206). Afterwards, method1200terminates.

In some illustrative examples, bonding the hollow cylinder to the disc comprises adhering the hollow cylinder to the disc using the second adhesive layer (operation1208). In other illustrative examples, bonding the hollow cylinder to the disc is performed using a different material than the second adhesive layer.

In some illustrative examples, not all blocks of method1100or method1200are performed. For example, operations1108through1116ofFIG. 11may be optional. As another example, operation1208ofFIG. 12may be optional.

The illustrative examples of the present disclosure may be described in the context of aircraft manufacturing and service method1300as shown inFIG. 13and aircraft1400as shown inFIG. 14. Turning first toFIG. 13, an illustration of an aircraft manufacturing and service method is depicted in accordance with an illustrative example. During pre-production, aircraft manufacturing and service method1300may include specification and design1302of aircraft1400inFIG. 14and material procurement1304.

During production, component and subassembly manufacturing1306and system integration1308of aircraft1400takes place. Thereafter, aircraft1400may go through certification and delivery1310in order to be placed in service1312. While in service1312by a customer, aircraft1400is scheduled for maintenance and service1314, which may include modification, reconfiguration, refurbishment, and other maintenance or service.

With reference now toFIG. 14, an illustration of an aircraft is depicted in which an illustrative embodiment may be implemented. In this example, aircraft1400is produced by aircraft manufacturing and service method1300inFIG. 13and may include airframe1402with a plurality of systems1404and interior1406. Examples of systems1404include one or more of propulsion system1408, electrical system1410, hydraulic system1412, and environmental system1414. Any number of other systems may be included.

Apparatuses and methods embodied herein may be employed during at least one of the stages of aircraft manufacturing and service method1300. One or more illustrative examples may be used during component and subassembly manufacturing1306, system integration1308, or maintenance and service1314ofFIG. 13. For example, insulation sealing system114ofFIG. 1may be used to form attachment point117ofFIG. 1through insulation blanket102ofFIG. 1during component and subassembly manufacturing1306. As another example, insulation sealing system114may be used to install insulation blanket102as a replacement part during maintenance and service1314ofFIG. 13.

Apparatuses and methods embodied herein may be employed in manufacturing at least one component of aircraft1400. For example, insulation blanket102may be attached to airframe1402to insulate interior1406.

The illustrative examples create a seal around a penetration through an airplane insulation blanket. The seal created by the insulation sealing system is water-tight or substantially water-tight. Installing the seal is faster and has fewer steps than conventional attach points. The illustrative examples provide enhanced sealing compared to current designs. The illustrative examples may be lighter than current designs. The illustrative examples may be less expensive than conventional attach points.

The illustrative examples provide a foam plug, or insulation insert. The foam plug may be lighter than conventional solid plastic parts. The foam plug is shaped like a “top hat”. The top of the top hat, or hollow cylinder, has a hole sized to give an interference fit with the stringer clip mounting post. Bonded onto the cylindrical “top” of the top hat is a thinner disc-shaped layer which resembles the brim of a top hat.

The plug is made of a closed cell foam, for example PVDF foam. The top of the “top hat” has an adhesive layer which can be exposed by peeling off a cover. The top of the “brim” also has an adhesive layer. If desired, the “top hat” shape allows the plug, or insulation insert, to bond to both faces of the insulation blanket in a single step.

The illustrative examples may be installed using three steps. The insulation blanket is pushed into place without mounting the grommets. A core is cut from the insulation blanket using at least one coring tool such that two cores are cut, one larger than the other. This may be done with a single dual cutter tool, or two tools.

The top hat adhesive, or first adhesive layer, is exposed and the top hat is pushed into the cylindrical hole, adhering to the back/outboard face of the insulation blanket, creating a seal there. The brim adhesive, or second adhesive layer, is exposed, and adheres to the front/inboard face of the blanket, creating a seal there. The interference fit over the stringer clip mounting post retains the insulation blanket in this location.

In some illustrative examples, the disc-shaped brim may be pre-manufactured with a hole size for a fastener, a standoff, or a spacer to be attached to the stringer clip mounting post. In some illustrative examples, the disc-shaped brim may have no hole at all, and the fasteners are installed by pressing the metal fastener against the foam disc until it penetrates. In some illustrative examples, the disc-shaped brim may have a center perforation which penetrates partly through the foam. The perforation does not penetrate all the way, as this penetration would create a leak path. The perforation provides a starting point for a fastener piercing the foam disc. In some illustrative examples, the disc-shaped brim may have a circular pattern of perforations which penetrate partly through the foam, creating a tear-out disc for a standoff or spacer to mount to the stringer clip post.

In some illustrative examples, the peel-off adhesive covers would have protruding tabs for ease of removal. This is a removal convenience for the “top” of the “top hat”, or first adhesive material. The “brim” adhesive, or second adhesive material, however, might benefit significantly from an exposed tab, because an installer would be able to peel the cover off the brim adhesive after the top hat is installed onto the stringer clip mounting post and adhered to the outboard face. By removing the cover from the brim adhesive after being adhered to the outboard face, the installer would only have to focus on bonding one face at a time instead of both faces. Adhering one face of the “top hat” at a time may improve quality by making it easier to avoid wrinkles.

The illustrative examples provide at least one of: reduce installation costs, improve water tightness, and reduce aircraft weight. The illustrative examples do not require grommets to be pre-installed onto the stringer clips, eliminating some conventional installation steps.