Bond line control process

A method for bonding composite parts, the method comprising:

• applying an adhesive and a plurality of beads onto a first surface of a skin panel to form a layer of adhesive and beads by one of placing a mask onto the first surface of the skin panel, placing a screen onto the mask to form an exposed area on the first surface of the skin panel, and applying the adhesive and the plurality of beads onto the first surface of the skin panel through the exposed area of the screen;
• placing the screen onto the first surface of the skin panel and spreading the adhesive with the plurality of beads onto the first surface of the skin panel through the screen;
• and placing the screen onto the first surface of the skin panel, spreading the adhesive onto the first surface of the skin panel through the screen, and spreading the plurality of beads onto the first surface of the skin panel through the screen, wherein the screen has a thickness and wherein the plurality of beads has a size that causes substantially uniform thickness for the layer of adhesive and beads when applied to the first surface of the skin panel, and wherein the plurality of beads is a plurality of spheres and is comprised of a material selected from one of glass, ceramic, metal, and rubber;
• applying the adhesive onto a patch through the screen;
• placing the first surface of the skin panel with the layer of adhesive and beads in contact with a second surface of the patch to form a structure;
• placing a caul plate on the structure prior to curing the structure;
• and
• curing the structure, wherein the skin panel is comprised of a material selected from one of a composite material, a metal, aluminum, and titanium.

A method for bonding parts, the method comprising:

• applying an adhesive onto a first surface of a first part through a screen to form a layer of adhesive;
• placing the first surface of the first part with the layer of adhesive in contact with a second surface of a second part to form a structure;
• and
• curing the structure.

An apparatus comprising:

• a first part having a first surface;
• a second part having a second surface;
• and
• a layer of adhesive and a plurality of beads in contact with the first surface of the first part and the second surface of the second part.

A structure comprising:

• a first composite part having a first surface;
• a second composite part having a second surface;
• and
• a layer of adhesive and a plurality of beads in contact with the first surface of the first composite part and the second surface of the second composite part, wherein the layer of adhesive is cured to form a structural bond between the first composite part and the second composite part.

A method for bonding parts, comprising:

• placing a screen on a surface of a first part;
• applying an adhesive onto the surface of a first part to form a layer of adhesive and screen;
• placing the surface of the first part with the layer of adhesive and screen in contact with a surface of a second part;
• and
• curing the adhesive.

A method of bonding a patch on a structure, comprising:

• applying a layer of adhesive on one of the patch and the structure;
• placing the patch on the structure with the layer adhesive therebetween forcing the patch against the structure;
• and,
• controlling the thickness of the layer of adhesive by introducing at least of one of a screen and beads into the layer of adhesive.