Multilayer riblet applique and methods of producing the same

• US 10,105,877 B2
• Filed: 07/08/2016
• Issued: 10/23/2018
• Est. Priority Date: 07/08/2016
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Rawlings, Diane C., Keough, Bruce K., Olli, Larry K., Burg, Alan G., Kestner, James M., Granger, George Michael, McGarvey, James Charles
• Primary Examiner(s): Sengupta, Sonya M
• Application Number:
  US15/205,460
• Publication Number:
  US 20180009136A1
• Time in Patent Office: 837 Days
• Field of Search: 156 8911
• CPC Class Codes: B29C 39/123 Making multilayered articles
• CPC Class Codes: B29C 39/146 for making multilayered articles
• CPC Class Codes: B29C 39/148 characterised by the shape of the surface
• CPC Class Codes: B29C 39/16 between endless belts
• CPC Class Codes: B29C 39/18 incorporating preformed parts or layers, e.g. casting around inserts or for coating articles B29C39/206 takes precedence
• CPC Class Codes: B29C 39/38 Heating or cooling
• CPC Class Codes: B29C 41/30 incorporating preformed parts or layers, e.g. moulding around inserts or for coating articles
• CPC Class Codes: B29C 41/32 Making multilayered or multicoloured articles
• CPC Class Codes: B29C 41/46 Heating or cooling
• CPC Class Codes: B29C 65/7894 of continuously moving sheets or webs
• CPC Class Codes: B29D 2009/00 IPC7 Producing layered products
• CPC Class Codes: B29K 2101/12 Thermoplastic materials
• CPC Class Codes: B29L 2007/00 Flat articles, e.g. films or sheets B29L2024/00 takes precedence
• CPC Class Codes: B29L 2009/00 Layered products
• CPC Class Codes: B29L 2031/3076 Aircrafts blades, propellers B29L2031/08
• CPC Class Codes: B29L 2031/756 Microarticles, nanoarticles
• CPC Class Codes: B32B 15/06 of natural rubber or synthetic rubber
• CPC Class Codes: B32B 15/08 of synthetic resin
• CPC Class Codes: B32B 15/088 comprising polyamides
• CPC Class Codes: B32B 2037/243 Coating
• CPC Class Codes: B32B 2255/10 : on synthetic resin layer or on natural or synthetic rubber layer
• CPC Class Codes: B32B 2255/26 : Polymeric coating
• CPC Class Codes: B32B 2307/402 : Coloured
• CPC Class Codes: B32B 2307/412 : Transparent
• CPC Class Codes: B32B 2307/51 : Elastic
• CPC Class Codes: B32B 2307/748 : Releasability
• CPC Class Codes: B32B 2371/00 : Polyethers, e.g. PEEK, i.e. polyether-etherketone; PEK, i.e. polyetherketone
• CPC Class Codes: B32B 2375/00 : Polyureas; Polyurethanes
• CPC Class Codes: B32B 2398/20 : Thermoplastics
• CPC Class Codes: B32B 25/042 : of natural rubber or synthetic rubber
• CPC Class Codes: B32B 25/14 : comprising synthetic rubber copolymers B32B25/18 and B32B25/20 take precedence
• CPC Class Codes: B32B 25/16 : comprising polydienes homopolymers or poly-halodienes homopolymers B32B25/12 takes precedence
• CPC Class Codes: B32B 25/20 : comprising silicone rubber
• CPC Class Codes: B32B 2605/18 : Aircraft blades, propellers B32B2603/00
• CPC Class Codes: B32B 27/08 : of synthetic resin
• CPC Class Codes: B32B 27/283 : comprising polysiloxanes
• CPC Class Codes: B32B 27/285 : comprising polyethers
• CPC Class Codes: B32B 27/288 : comprising polyketones
• CPC Class Codes: B32B 27/34 : comprising polyamides
• CPC Class Codes: B32B 3/30 : characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B32B 33/00 : Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
• CPC Class Codes: B32B 37/0053 : Constructional details of laminating machines comprising rollers; Constructional features of the rollers
• CPC Class Codes: B32B 37/02 : characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
• CPC Class Codes: B32B 37/10 : characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
• CPC Class Codes: B32B 37/203 : One or more of the layers being plastic
• CPC Class Codes: B32B 37/24 : with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate B32B37/15 takes precedence
• CPC Class Codes: B64C 21/10 : using other surface properties, e.g. roughness
• CPC Class Codes: B64C 2230/26 : by using rib lets or hydrophobic surfaces
• CPC Class Codes: Y02T 50/10 : Drag reduction

Abstract

Multilayer riblet applique and methods of producing the same are described herein. One disclosed example method includes applying a first high elongation polymer material to a web tool, where the web tool is to be provided from a first roll, and heating, via a first heating process, the first high elongation polymer material. The disclosed example method also includes applying a second high elongation polymer material to the first high elongation polymer material, and heating, via a second heating process, the second high elongation polymer material. The disclosed example method also includes applying, via a laminating roller, a support layer to the second high elongation polymer material.

Claims

1. A method of producing a multilayered riblet structure comprising:

applying a first high elongation polymer material to a web tool, the web tool provided from a first roll;

heating, via a first heating process associated with a first inline oven, the first high elongation polymer material as the first high elongation polymer material passes through an interior length of the first inline oven to cure the first high elongation polymer material;

applying a second high elongation polymer material to the first high elongation polymer material;

heating, via a second heating process associated with a second inline oven, the second high elongation polymer material as the second high elongation polymer material passes through an interior length of the second inline oven to cure the second high elongation polymer material; and

applying, via a laminating roller, a support layer to the second high elongation polymer material.

2. The method as defined in claim 1, further including placing the multilayered riblet structure onto a rewind roll after the support layer has been applied.

3. The method as defined in claim 1, further including:

placing the multilayered riblet structure onto a redirect reel after the support layer has been applied;

removing the web tool from the multilayered riblet structure; and

applying at least one of a masking or a liner to the multilayered riblet structure via pinch rollers.

4. The method as defined in claim 3, further including applying a masking polymer coating to the first high elongation polymer material prior to applying the at least one of the masking or the liner.

5. The method as defined in claim 3, wherein the web tool is removed via a removal roll.

6. The method as defined in claim 1, wherein the second high elongation polymer material includes a color layer.

7. The method as defined in claim 1, wherein at least one of the first or second high elongation polymer materials includes fluorosilicone.

13. The method as defined in claim 1, further including moving, via a conveyor, the first high elongation polymer material through the first inline oven and the first and second high elongation polymer material through the second inline oven.

14. The method as defined in claim 1, wherein the first and second inline ovens are partially enclosed.

8. A method of producing a multilayered riblet structure comprising:

dispensing a web tool from a first roll;

applying a first high elongation polymer material to the web tool;

applying, via a first roller, a riblet liner to the first high elongation polymer material to define a first layered construction;

placing the first layered construction onto a first rewind roll;

curing the first layered construction;

dispensing the first layered construction from the first rewind roll;

removing the riblet liner via a removal reel;

applying a second high elongation polymer material to the first high elongation polymer material;

applying, via a second roller, a support layer to the second high elongation polymer material to define a second layered construction;

placing the second layered construction onto a second rewind roll; and

curing the second layered construction.

9. The method as defined in claim 8, wherein curing at least one of the first layered construction or the second layered construction includes moving the at least one of the first layered construction or the second layered construction through an oven via a conveyor.

10. The method as defined in claim 8, further including at least partially curing the first high elongation polymer material prior to placing the first layered construction onto the first rewind roll.

11. The method as defined in claim 8, wherein the second roller includes a nip roller.

12. The method as defined in claim 8, wherein at least one of the first or second high elongation polymer materials includes fluorosilicone.

15. A method comprising:

casting a fluorosilicone riblet tip structure using web tool provided from a first roll, wherein casting the fluorosilicone riblet tip structure includes applying a first fluorosilicone material to the web tool as the web tool is unrolled from the first roll;

heating the flurosilicone riblet tip structure via a first inline oven to cure the fluorosilicone riblet tip structure;

applying a fluorosilicone layer to the fluorosilicone riblet tip structure, the fluorosilicone layer including a second fluorosilicone material;

heating the fluorosilicone layer via a second inline oven to cure the fluorosilicone layer; and

applying, via a laminating roller, a support layer adjacent to the fluorosilicone layer.

16. The method as defined in claim 15, further including:

removing the web tool; and

applying at least one of a masking or a liner to the fluorosilicone riblet tip structure.