# US 10,119,421 B2 · Bonding method

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- Number: US 10,119,421 B2
- Document ID: US10119421B2
- Status: Granted
- Kind: B2
- Application number: 15/209,161
- Filed: 2016-07-13
- Published: 2017-02-16
- Granted: 2018-11-06
- Earliest claimed: 2015-08-12
- Assignees: ROLLS-ROYCE plc
- Applicants: ROLLS-ROYCE plc
- Inventors: Mark J Hicklin; Stephen O Osiyemi; Ewan F Thompson
- Web page: https://patentgrep.com/patent/US10119421B2

## CPC

- F01D 25/243: {Flange connections; Bolting arrangements (F01D25/265 takes precedence)}
- B29C 65/18: using heated tools
- B29C 65/48: using adhesives {, i.e. using supplementary joining material; solvent bonding}
- B29C 65/4835: {Heat curing adhesives}
- B29C 66/1122: {Single lap to lap joints, i.e. overlap joints (B29C66/45, B29C66/472, B29C66/52272 take precedence)}
- B29C 66/53241: {said articles being tubular and said substantially annular single elements being of finite length relative to the infinite length of said tubular articles (making T-shaped pieces by joining tubular articles B29C66/52241)}
- B29C 66/612: {Making circumferential joints}
- B29C 66/634: {using an inflatable core}
- B29C 66/72525: {comprising honeycomb cores}
- B29C 66/81433: {being toothed, i.e. comprising several teeth or pins (comprising a single tooth B29C66/81429), or being patterned}
- B29C 66/81455: {being a fluid inflatable bag or bladder, a diaphragm or a vacuum bag for applying isostatic pressure (inflatable element positioned between the joining tool and a backing-up part B29C66/82421)}
- B29C 66/82421: {using an inflatable element positioned between the joining tool and a backing-up part}
- B29C 66/8322: {Joining or pressing tools reciprocating along one axis}
- F01D 11/127: {with a deformable or crushable structure, e.g. honeycomb}
- F01D 21/045: {special arrangements in stators or in rotors dealing with breaking-off of part of rotor}
- F01D 25/24: Casings (modified for heating or cooling F01D25/14); Casing parts, e.g. diaphragms, casing fastenings (casings for rotary machines or engines in general F16M {; special arrangements in stators dealing with breaking-off of part of rotor F01D21/045})
- F01D 25/285: {Temporary support structures, e.g. for testing, assembling, installing, repairing; Assembly methods using such structures}
- F02C 7/045: having provisions for noise suppression
- B29C 66/7212: {characterised by the composition of the fibres}
- B29C 66/81457: {comprising a block or layer of deformable material, e.g. sponge, foam, rubber (pressing elements supported or backed-up by resilient material B29C66/8161)}
- B29L 2031/3076: {Aircrafts (blades, propellers B29L2031/08)}
- B29L 2031/7504: {Turbines}
- F05D 2220/32: in gas turbines
- F05D 2230/00: Manufacture
- F05D 2230/23: by permanently joining parts together
- F05D 2230/68: using auxiliary equipment for lifting or holding
- F05D 2260/962: by means of "anti-noise"
- F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- F02C: GAS-TURBINE PLANTS; AIR INTAKES FOR JET-PROPULSION PLANTS; CONTROLLING FUEL SUPPLY IN AIR-BREATHING JET-PROPULSION PLANTS (construction of turbines F01D; jet-propulsion plants F02K; construction of compressors or fans F04; generating combustion products of high pressure or high velocity F23R; using gas turbines in compression refrigeration plants F25B11/00)
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS

## Abstract

A method is provided of bonding a first component to a second component. The method includes: locating the first component against the second component to form an interface between the components, a curable adhesive being provided at the interface; locating a pressurizable, fluid-filled bladder against the first component such that the first component is sandwiched between the second component and the bladder; locating a backing member against the bladder such that the bladder is sandwiched between the backing member and the first component; pressurizing the bladder such that a consolidating pressure is exerted by the bladder on the first component to conform the first component to the second component; and curing the adhesive while the first component is conformed to the second component by the consolidating pressure.

## Claims

### Claim 1

A method of manufacturing a component, the method comprising bonding a first component to a second component including:
locating the first component against the second component to form an interface between the components, a curable adhesive being provided at the interface;
locating a pressurisable, fluid-filled bladder against the first component such that the first component is sandwiched between the second component and the bladder;
locating a backing member against the bladder such that the bladder is sandwiched between the backing member and the first component;
pressurising the bladder such that a consolidating pressure is exerted by the bladder on the first component to conform the first component to the second component;
curing the adhesive while the first component is conformed to the second component by the consolidating pressure; and
locating a compliant layer between the fluid-filled bladder and the first component, the compliant layer carrying an arrangement of spaced, rigid protuberances which project from the side of the layer facing the first component, the protuberances including summits that are configured such that only the summits are in contact with the first component when the bladder is pressurized to concentrate the consolidating pressure exerted by the bladder on the first component at the locations of the protuberances.

### Claim 2 (depends on 1)

The method according to claim 1, wherein the bladder is pressurised by forcing further fluid into the bladder, expansion of the bladder being constrained by the backing member.

### Claim 3 (depends on 1)

The method according to claim 1, wherein the bladder is pressurised by forcing the backing member against the bladder to squeeze the bladder between the backing member and the first component.

### Claim 4 (depends on 1)

The method according to claim 1, wherein one or more supports extend from the compliant layer to the backing member to hold the compliant layer in position.

### Claim 5 (depends on 1)

The method according to claim 1, wherein the method further includes locating a mould release layer and/or a puncture protection sheet on the first component between the first component and the bladder.

### Claim 6 (depends on 1)

The method according to claim 1, wherein the method further includes locating one or more heating mats adjacent the components, and heating the components during the curing of the adhesive using the mats.

### Claim 7 (depends on 1)

The method according to claim 1, wherein the first component is an acoustic liner or an abradable liner, and the second component is a gas turbine engine fan casing.

### Claim 8 (depends on 1)

A method of manufacturing a gas turbine engine comprising manufacturing one or more components using the method according to claim 1.

### Claim 9

A method of bonding a first component to a second component, the method comprising:
locating the first component against the second component to form an interface between the components, a curable adhesive being provided at the interface;
locating a pressurisable, fluid-filled bladder against the first component such that the first component is sandwiched between the second component and the bladder;
locating a backing member against the bladder such that the bladder is sandwiched between the backing member and the first component;
pressurising the bladder such that a consolidating pressure is exerted by the bladder on the first component to conform the first component to the second component;
curing the adhesive while the first component is conformed to the second component by the consolidating pressure; and
supporting a weight of a compliant layer between the fluid-filled bladder and the first component with one or more telescoping supports that extend from the compliant layer to the backing member.