BONDED ASSEMBLIES AND METHODS FOR IMPROVING BOND STRENGTH OF A JOINT

• US 20110059290A1
• Filed: 09/08/2009
• Published: 03/10/2011
• Est. Priority Date: 09/08/2009
• Status: Abandoned Application

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Allan, Adrian, Gage, Raymond
• Application Number:
  US12/555,633
• Publication Number:
  US 20110059290A1
• Time in Patent Office: Days
• US Class Current: 428/99
• CPC Class Codes: B23K 1/0018 Brazing of turbine parts
• CPC Class Codes: B23K 1/20 Preliminary treatment of work or areas to be soldered, e.g. in respect of a galvanic coating preparation of surfaces in particular ways, see the relevant classes for the treatments or the materials treated, e.g. C04B, C23C
• CPC Class Codes: B23K 2101/001 Turbines
• CPC Class Codes: B23K 28/02 Combined welding or cutting procedures or apparatus
• CPC Class Codes: B29C 65/483 Reactive adhesives, e.g. chemically curing adhesives
• CPC Class Codes: B29C 65/5057 positioned between the surfaces to be joined B29C65/5035 takes precedence
• CPC Class Codes: B29C 66/1122 Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/301 Three-dimensional joints, i.e. the joined area being substantially non-flat B29C66/5223, B29C66/5224, B29C66/5225 take precedence
• CPC Class Codes: B29C 66/30321 making use of protrusions belonging to at least one of the parts to be joined
• CPC Class Codes: B29C 66/30325 making use of cavities belonging to at least one of the parts to be joined
• CPC Class Codes: B29C 66/43 Joining a relatively small portion of the surface of said articles B29C66/45 takes precedence
• CPC Class Codes: B29C 66/474 said single elements being substantially non-flat
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/721 Fibre-reinforced materials B29C66/729 takes precedence
• CPC Class Codes: B29C 66/742 to metals or their alloys
• CPC Class Codes: B29C 66/7461 Ceramics
• CPC Class Codes: B29K 2063/00 Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
• CPC Class Codes: B29L 2031/082 Blades, e.g. for helicopters
• CPC Class Codes: B29L 2031/085 Wind turbine blades
• CPC Class Codes: B29L 2031/3076 Aircrafts blades, propellers B29L2031/08
• CPC Class Codes: C09J 2400/163 : in the substrate
• CPC Class Codes: C09J 5/00 : Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers
• CPC Class Codes: F01D 5/282 : Selecting composite materials, e.g. blades with reinforcing filaments
• CPC Class Codes: F04D 29/324 : Blades
• CPC Class Codes: F05D 2240/303 : related to the leading edge of a rotor blade
• CPC Class Codes: F16B 11/006 : by gluing gluing of plastics material B29C65/48
• CPC Class Codes: Y02P 70/50 : Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y02T 50/60 : Efficient propulsion technologies, e.g. for aircraft
• CPC Class Codes: Y10T 428/24008 : including fastener for attaching to external surface

Abstract

Bonded assemblies and methods for improving the bond strength of a joint are provided. The joint may be formed between bonding surfaces of a first and a second component. The first component has a bonding surface adapted to be bonded to a bonding surface of a second component. A plurality of features may be formed in at least one of the bonding surfaces. The bonding surfaces are bonded together to form the joint. A bonding material layer between the bonding surfaces may form the joint or the first and second components may be co-cured to form the joint. A chemical and mechanical bond between the bonding surfaces is formed with the plurality of features forming the mechanical bond and increasing the bond area of the chemical bond. The features may be openings and/or protrusions such as holes, slots, and bosses.

Claims

1. A method for improving the bond strength of a joint between bonding surfaces of a first and a second component, comprising the steps of:

providing a first component having a bonding surface adapted to be bonded to a bonding surface of a second component, at least one of the bonding surfaces including a plurality of features; and

bonding the bonding surfaces together to form a joint between the bonding surfaces;

wherein the step of bonding comprises forming a chemical and mechanical bond between the bonding surfaces with the plurality of features forming the mechanical bond.

2. The method of claim 1, wherein the plurality of features comprise at least one of a plurality of protrusions, openings, or recesses, or a combination thereof.

3. The method of claim 2, wherein the plurality of features have size dimensions within about two orders of magnitude of the bonding layer thickness.

4. The method of claim 3, wherein the plurality of protrusions comprise at least one of a plurality of bosses or pins, or a combination thereof.

5. The method of claim 3, wherein the plurality of openings comprise at least one of a plurality of holes or slots, or a combination thereof.

6. The method of claim 3, wherein the plurality of features further comprise at least one undercut portion on at least one of the plurality of features.

7. The method of claim 1, wherein the step of bonding comprises the step of depositing bonding material between the bonding surfaces and pressing the bonding surfaces together to form a bonding material layer between the bonding surfaces.

8. The method of claim 7, wherein the step of depositing bonding material comprises depositing at least one of an adhesive material, a metallic bond material, or a ceramic bond material, or a combination thereof.

9. The method of claim 1, wherein the step of bonding the bonding surfaces together comprises:

depositing a fiber-reinforced composite material over at least the bonding surface of the first component to form the second component comprised of the fiber-reinforced composite material; and

curing the fiber-reinforced composite material to form a co-cured joint having improved bond strength with at least a portion of the fiber-reinforced composite material cured between the bonding surfaces.

10. The method of claim 9, wherein the first component comprises a metal sheet having two bonding surfaces and the second component comprises a composite airfoil, and the step of bonding comprises forming a bond between the two bonding surfaces of the metal sheet and the bonding surface of the composite airfoil to form a metallic leading edge on the composite airfoil.

11. A method of forming a joint having improved bond strength, the method comprising the steps of:

providing a first component having a bonding surface with a plurality of features therein; and

bonding a second component to the first component around said plurality of features to form the joint having improved bond strength through the formation of a chemical and mechanical bond.

12. The method of claim 11, wherein the plurality of features comprise at least one of a plurality of protrusions, openings, or recesses, or a combination thereof.

13. The method of claim 12, wherein the plurality of features have size dimensions within about two orders of magnitude of the bonding layer thickness.

14. The method of claim 13, wherein the plurality of protrusions comprise at least one of a plurality of bosses or pins, or a combination thereof.

15. The method of claim 13, wherein the plurality of openings comprise at least one of a plurality of holes or slots, or a combination thereof.

16. The method of claim 13, wherein the plurality of features further comprise an undercut portion on at least one of the plurality of features.

17. The method of claim 11, wherein the step of bonding the bonding surfaces together comprises the step of depositing bonding material between the bonding surfaces and pressing the bonding surfaces together to form a bonding material layer between the bonding surfaces.

18. The method of claim 11, wherein the step of bonding the second component comprises:

depositing a fiber-reinforced composite material over at least the bonding surface of the first component to form the second component comprised of the fiber-reinforced composite material; and

curing the fiber-reinforced composite material to form a co-cured joint with a chemical and mechanical bond between the first and second components.

19. A bonded assembly, comprising:

a first component having a bonding surface;

a second component having a bonding surface bonded to the bonding surface of the first component, at least one of the first or second components, or both, having a plurality of features formed in the respective bonding surface.

20. The bonded assembly of claim 19, further comprising a bonding material layer between the bonding surfaces of the first and second components to form a chemical and mechanical bond between the first and second components.