# US 8,784,604 B2 · Method and apparatus for out-of-autoclave adhesive shear bonding of structures

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- Number: US 8,784,604 B2
- Document ID: US8784604B2
- Status: Granted
- Kind: B2
- Application number: 13/272,393
- Filed: 2011-10-13
- Published: 2013-04-18
- Granted: 2014-07-22
- Earliest claimed: 2011-10-13
- Assignees: Textron Innovations Inc.
- Applicants: Paul Oldroyd; James Donn Hethcock; Robert Clive Fews
- Inventors: Paul Oldroyd; James Donn Hethcock; Robert Clive Fews
- Web page: https://patentgrep.com/patent/US8784604B2

## CPC

- B29C 66/5221: {for forming coaxial connections, i.e. the tubular articles to be joined forming a zero angle relative to each other}
- B29C 65/22: Heated wire {resistive ribbon, resistive band or resistive strip (electrical insulating support therefor B29C66/81871)}
- B29C 65/4835: {Heat curing adhesives}
- B29C 65/5021: {being multi-layered}
- B29C 65/5057: {positioned between the surfaces to be joined (B29C65/5035 takes precedence)}
- B29C 65/7838: {from the inside, e.g. of tubular or hollow articles (B29C66/3242 takes precedence)}
- B29C 65/7841: {Holding or clamping means for handling purposes (clamping means for the purpose of applying pressure on the parts to be joined, in the area to be joined B29C66/81; work holders in general B25B; devices for holding or positioning work for welding metal B23K37/04)}
- B29C 66/112: {Single lapped joints}
- B29C 66/1122: {Single lap to lap joints, i.e. overlap joints (B29C66/45, B29C66/472, B29C66/52272 take precedence)}
- B29C 66/131: {Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area}
- B29C 66/326: {Shaping the burr, e.g. by the joining tool}
- B29C 66/53245: {said articles being hollow}
- B29C 66/543: {joining more than two hollow-preforms to form said hollow articles}
- B29C 66/612: {Making circumferential joints}
- B29C 66/63: {Internally supporting the article during joining (B29C66/49 takes precedence)}
- B29C 66/721: {Fibre-reinforced materials (B29C66/729 takes precedence)}
- B29C 66/8248: {Pressure application by weights (by the own weight of the joining tool B29C66/8282)}
- B29C 66/836: {Moving relative to and tangentially to the parts to be joined, e.g. transversely to the displacement of the parts to be joined, e.g. using a X-Y table (B29C66/65 takes precedence)}
- B29C 66/91221: {of the parts to be joined}
- B29C 66/91231: {of the joining tool}
- B29C 66/91421: {of the joining tools}
- B29C 66/71: {characterised by the composition of the plastics material of the parts to be joined (welding bar compositions B29C65/125)}
- B29C 66/7212: {characterised by the composition of the fibres}
- B29C 66/961: {involving a feedback loop mechanism, e.g. comparison with a desired value}
- B29L 2031/3082: {Fuselages}
- B29L 2031/3088: {Helicopters}
- B64C 1/12: Construction or attachment of skin panels
- B64C 2001/0072: {from composite materials}
- F16B 11/006: {by gluing (gluing of plastics material B29C65/48)}
- Y02T 50/40: Weight reduction
- Y10T 156/1089: of discrete laminae to single face of additional lamina
- 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)
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B64C: AEROPLANES; HELICOPTERS
- F16B: DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING (couplings for transmitting rotation F16D)
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

The shear bonding method is configured to facilitate bonding of structures in an out-of-autoclave environment. The shear bonding method includes bonding a plurality of frame members to the interior of a tapered tailboom. The frames are located on a bayonet type tool. An adhesive pack is applied to each frame. The bayonet type tool is inserted into the tailboom until the adhesive packs come into contact with the interior walls of the tailboom. Conductive heating tiles are applied to the tailboom. The conductive heating tiles are controlled to achieve and maintain viscosity of the adhesive packs. During this period the bayonet tool is actuated so that the frames are translated in relation to the tailboom. The heating tiles are then controlled to achieve and maintain the adhesive at a requisite curing temperature.

## Claims

### Claim 1

A method of bonding a frame to a skin, the method comprising:
applying an adhesive pack to a faying surface of the frame;
securing the frame on a tool, the tool comprising a shaft;
securing a skin to a skin fixture on the tool;
performing a smear bonding procedure, the smear bonding procedure comprising:
translating the skin relative to the frame until the adhesive pack is in contact with an interior surface of the skin;
applying heat from an exterior of the skin so as to at least partially turn the adhesive pack viscous;
consolidating the adhesive pack by translating the skin relative to the frame so as to compressively smear the adhesive pack; and
curing the adhesive pack when the frame is in a final position relative to the skin.

### Claim 2 (depends on 1)

The method according to claim 1, wherein the step of applying an adhesive pack to the faying surface of the frame includes heating the frame to promote tackiness between the adhesive pack and the frame.

### Claim 3 (depends on 1)

The method according to claim 1, wherein the adhesive pack includes a plurality of adhesive film layers.

### Claim 4 (depends on 1)

The method according to claim 1, wherein the adhesive pack includes a noodle formed by rolling up excess of the adhesive film layer, the noodle being configured to form an adhesive fillet between the frame and the skin.

### Claim 5 (depends on 1)

The method according to claim 1, wherein compression during the step of consolidating the adhesive packs by translating the skin relative to the frame is produced by the skin being tapered.

### Claim 6 (depends on 1)

The method according to claim 1, wherein the skin is a tapered tailboom.

### Claim 7 (depends on 1)

The method according to claim 1, wherein at least one of the skin and the frame are of a composite material.

### Claim 8 (depends on 1)

The method according to claim 1, wherein the step of securing the frame on a tool includes translating an inner shaft relative to the shaft in order to actuate a locking mechanism so as to secure the frame to the tool.

### Claim 9 (depends on 1)

The method according to claim 1, wherein the step of translating the skin relative to the frame is performed using an actuator control system configured to accurately translate the skin fixture and skin while the shaft remains stationary.

### Claim 10 (depends on 1)

The method according to claim 1, wherein the step of applying heat from an exterior of the skin comprises selectively controlling a heat transfer tile, the heat transfer tile being located on an outer surface of the skin.

### Claim 11 (depends on 1)

The method according to claim 1, wherein the step of applying heat from an exterior of the skin includes using a computer to automatically dictate a heating level applied by a heat transfer tile located on the exterior of the skin.

### Claim 12 (depends on 1)

The method according to claim 1, further comprising:
using a computer to interpret data from a thermocouple located between the frame and the skin.

### Claim 13 (depends on 1)

The method according to claim 1, wherein the step of curing the adhesive pack includes applying heat so as to sustain a cure temperature at a curing duration.

### Claim 14 (depends on 1)

The method according to claim 1, wherein the adhesive pack includes an adhesive film layer.

### Claim 15 (depends on 1)

The method according to claim 1, wherein the adhesive pack includes an adhesive paste layer.

### Claim 16 (depends on 1)

The method according to claim 1, wherein the step of applying heat includes applying heat from an exterior of the skin.

### Claim 17 (depends on 1)

The method according to claim 1, wherein the step of consolidating the adhesive pack by translating the skin is achieved by a weight coupled to the skin so that gravity acts to translate the skin.

### Claim 18 (depends on 1)

The method according to claim 1, wherein the frame is exterior to the skin.