Joint assembly with interstitially filled protrusions and related method of manufacturing a joint assembly

Abstract

The invention is a joining assembly with protrusions having a gap and a related method of manufacturing a joining assembly. An assembly including a first part and a second part. The second part includes a non-lap surface facing a base surface, a plurality of lap surfaces shown at protrusions, which are gapped if necessary or as necessary, and a plurality of second through holes. A width of each of the plurality of protrusions is equal to or greater than 2(r+Ttanθ), where r is a maximum radial dimension of an outermost portion of a fastener in contact with the first part or the second part, T is a distance from a point of contact between the fastener and the first part or the second part to a lap surface of a corresponding protrusion, and θ is an angle between a central axis of a corresponding second through hole and an outermost load vector originating at the point of contact between the fastener and the first part or the second part.

Description

Technical Field

[0001] This disclosure generally relates to joining two or more parts together to form an assembly, and more specifically to joining assemblies that reduce or eliminate gaps, and methods for forming joining assemblies for aircraft. Background Technology

[0002] A mating assembly is defined by at least two parts attached together at their overlapping surfaces. Sometimes, unintentional gaps form between these overlapping surfaces. It is common practice to narrow sufficiently wide gaps to meet the specific overlapping surface clearance requirements of certain industries, such as aerospace. Wide gaps are reduced by filling them, which involves positioning filler pieces within the gap. Filling gaps can be time-consuming, difficult, and expensive. For example, in conventional assembly techniques, if a gap exceeds a predetermined threshold, all gaps between overlapping surfaces must be measured individually and filled. Access to the gap can be difficult, thus complicating gap measurement and filler piece installation. Furthermore, the parts forming conventional mating assemblies often have large overlapping surfaces, increasing the time and labor required to measure and fill the gaps between them. Therefore, for a given mating assembly, it is desirable to reduce the area of ​​the overlapping surfaces and the amount of filler. Summary of the Invention

[0003] The subject matter of this application provides examples of a joining assembly and a method for manufacturing the joining assembly that overcome the shortcomings of the joining assemblies and joining assembly manufacturing techniques discussed above. Therefore, the subject matter of this application has been developed in response to the shortcomings of the prior art, particularly conventional joining assemblies and conventional techniques for manufacturing joining assemblies.

[0004] This document discloses an assembly including a first part and a second part. The first part includes a base surface and a plurality of first through-holes formed in the base surface and extending through the first part. The second part is directly attached to the base surface of the first part. Additionally, the second part includes a non-overlapping surface facing the base surface, a plurality of protrusions, and a plurality of second through-holes. The plurality of protrusions are spaced apart from each other, wherein each protrusion projects from the non-overlapping surface, and each protrusion defines an overlapping surface that engages with a corresponding portion of the base surface of the first part. Each of the plurality of second through-holes is formed in the overlapping surface of a corresponding one of the plurality of protrusions and is coaxially aligned with a corresponding one of the plurality of first through-holes. The assembly further includes a plurality of fasteners, wherein each fastener passes through a corresponding one of the plurality of first through-holes and a corresponding one of the plurality of second through-holes coaxially aligned with the corresponding one of the plurality of first through-holes. Each of the plurality of protrusions has a width equal to or greater than 2(r + Ttanθ), where r is the maximum radial dimension of the outermost portion of the fastener that contacts the first or second part through the corresponding second through hole, T is the distance between the contact point between the outermost portion of the fastener and the first or second part and the overlapping surface of the corresponding protrusion, and θ is the angle between the central axis of the corresponding second through hole and the outermost load vector that begins at the contact point between the outermost portion of the fastener and the first or second part. The foregoing subject matter of this paragraph characterizes Example 1 of this disclosure.

[0005] The total surface area of ​​the overlapping surfaces of the multiple protrusions does not exceed 18% of the total surface area of ​​the non-overlapping surfaces. The foregoing subject matter of this paragraph characterizes Example 2 of the present disclosure, wherein Example 2 also includes the subject matter according to Example 1 above.

[0006] The total surface area of ​​the overlapping surfaces of the multiple protrusions does not exceed 7% of the total surface area of ​​the non-overlapping surfaces. The foregoing subject matter of this paragraph characterizes Example 3 of the present disclosure, wherein Example 3 also includes subject matter according to any one of Examples 1-2 above.

[0007] The thickness of each of the plurality of protrusions is between 0.025 inches and 0.035 inches (inclusive of the endpoints). The foregoing subject matter of this paragraph characterizes Example 4 of this disclosure, wherein Example 4 also includes the subject matter according to any one of Examples 1-3 above.

[0008] The maximum distance between the base surface of the first part and the non-overlapping surface of the second part is equal to the thickness of each of the plurality of protrusions. The foregoing subject matter of this paragraph characterizes Example 5 of the present disclosure, wherein Example 5 also includes the subject matter according to Example 4 above.

[0009] Each of the plurality of fasteners includes a bolt and a nut. The bolt includes a head and a body extending from the head. The nut engages with the body of the bolt to secure a first part and a second part together between the head of the bolt and the nut. The variable r is equal to the smaller of the maximum radial dimension of the outermost portion of the head that contacts the first part or the second part, or the maximum radial dimension of the outermost portion of the nut that contacts the first part or the second part. The foregoing subject matter of this paragraph characterizes the present disclosure of Example 6, which also includes the subject matter according to any one of Examples 1-5 above.

[0010] The variable θ is at most 25 degrees. The foregoing subject matter of this paragraph characterizes Example 7 of this disclosure, which also includes subject matter according to any one of Examples 1-6 above.

[0011] The variable θ is at most 17 degrees. The foregoing subject matter of this paragraph characterizes Example 8 of this disclosure, wherein Example 8 also includes the subject matter based on Example 7 above.

[0012] The component further includes at least one gap filler sheet inserted between the base surface and the overlapping surface of at least one of the plurality of protrusions. The foregoing subject matter of this paragraph characterizes Example 9 of the present disclosure, wherein Example 9 also includes the subject matter according to any one of Examples 1-8 above.

[0013] The gap between the base surface and the overlapping surface of at least one of the plurality of protrusions is greater than 0.005 inches. The thickness of at least one gap filler is substantially equal to the gap. The foregoing subject matter of this paragraph characterizes Example 10 of the present disclosure, wherein Example 10 also includes the subject matter according to Example 9 above.

[0014] At least one sprue is inserted between the base surface and one or more overlapping surfaces of the plurality of protrusions. The foregoing subject matter of this paragraph characterizes Example 11 of the present disclosure, wherein Example 11 also includes the subject matter according to any one of Examples 9-10 above.

[0015] No sprue is inserted between the base surface of the first part and the non-overlapping surface of the second part. The foregoing subject matter of this paragraph characterizes Example 12 of the present disclosure, wherein Example 12 also includes the subject matter according to any one of Examples 9-11 above.

[0016] The central axis of each of the plurality of second through holes passes through the geometric center of the corresponding one of the plurality of protrusions. The foregoing subject matter of this paragraph characterizes Example 13 of the present disclosure, wherein Example 13 also includes the subject matter according to any one of Examples 1-12 above.

[0017] The component further includes at least one gap filler sheet inserted between the base surface and the overlapping surface of at least one of the plurality of protrusions. The first part is made of a fiber-reinforced polymeric material. The second part is made of a metallic material. The foregoing subject matter of this paragraph characterizes Example 14 of the present disclosure, wherein Example 14 also includes the subject matter according to any one of Examples 1-13 above.

[0018] The width of each of the plurality of protrusions is equal to 2(r+Ttanθ). The foregoing subject matter of this paragraph characterizes Example 15 of the present disclosure, wherein Example 15 also includes the subject matter according to Example 14 above.

[0019] This document also discloses an aircraft that includes the components of Example 1. The foregoing subject matter of this paragraph characterizes Example 16 of this disclosure.

[0020] The aircraft includes a wing. A first part includes the skin panel of the wing. A second part includes the internal ribs of the wing. The foregoing subject matter of this paragraph characterizes the present disclosure of Example 17, which also includes the subject matter according to Example 16 above.

[0021] The aircraft includes a wing. A first part includes the skin panel of the wing. A second part includes the external fittings of the wing. The foregoing subject matter of this paragraph characterizes Example 18 of this disclosure, wherein Example 18 also includes the subject matter according to Example 16 above.

[0022] This document further discloses a method for manufacturing an assembly. The method includes indexing a second part onto a first part. The second part includes a non-overlapping surface and a plurality of protrusions. Each protrusion defines an overlapping surface that directly engages with a base surface of the first part. The method also includes, after the second part is indexed onto the first part, measuring a gap between the base surface and the overlapping surfaces of at least one of the plurality of protrusions. The method further includes, if the gap is greater than a predetermined threshold, inserting at least one chuck into the gap between the base surface and the overlapping surfaces of at least one of the plurality of protrusions, and fastening the first part to the second part, wherein the at least one chuck is inserted between the base surface and the overlapping surfaces of at least one of the plurality of protrusions. The method further includes, if the gap is less than or equal to the predetermined threshold, maintaining a chuck-free engagement between the base surface and the overlapping surfaces of at least one of the plurality of protrusions. The foregoing subject matter of this paragraph characterizes Example 19 of this disclosure.

[0023] Each of the plurality of protrusions has a width equal to or greater than 2(r + Ttanθ), where r is the maximum radial dimension of the outermost portion of the fastener in contact with the first or second part, passing through one of the plurality of second through holes in the second part; T is the distance between the contact point between the outermost portion of the fastener and the first or second part and the overlapping surface of the corresponding protrusion; and θ is the angle between the central axis of the corresponding second through hole and the outermost load vector originating from the contact point between the outermost portion of the fastener and the first or second part. The method further includes not measuring a second gap between the base surface and the non-overlapping surfaces of the second part. The foregoing subject matter of this paragraph characterizes Example 20 of this disclosure, wherein Example 20 also includes the subject matter according to Example 19 above.

[0024] The features, structures, advantages, and / or characteristics of the subject matter described in this disclosure can be combined in any suitable manner in one or more instances, including embodiments and / or implementations. Numerous specific details are provided in the following description to provide a thorough understanding of the examples of the subject matter of this disclosure. Those skilled in the art will recognize that the subject matter of this disclosure can be practiced without a particular example, embodiment, or implementation of one or more specific features, details, components, materials, and / or methods. In other instances, additional features and advantages may be recognized in certain examples, embodiments, and / or implementations, which are not present in all examples, embodiments, or implementations. Furthermore, in some instances, well-known structures, materials, or operations have not been shown or described in detail to avoid obscuring aspects of the subject matter of this disclosure. The features and advantages of the subject matter of this disclosure will become more apparent from the following description and the appended claims, or may be learned through practice of the subject matter set forth below. Attached Figure Description

[0025] To facilitate a clearer understanding of the advantages of the subject matter, a more specific description of the subject matter, briefly outlined above, will be provided with reference to concrete examples shown in the accompanying drawings. These drawings depict only typical examples of the subject matter and should not be considered as limiting its scope. Through the use of the drawings, the subject matter will be described and explained with additional characteristics and details, wherein:

[0026] Figure 1A It is a perspective view of an aircraft based on one or more instances of this disclosure;

[0027] Figure 1B This is an exploded perspective view of the assembly components of an aircraft according to one or more examples of this disclosure;

[0028] Figure 2 This is based on one or more instances of this disclosure. Figure 1B A perspective view of one part of the joining assembly;

[0029] Figure 3 This is based on one or more instances of this disclosure. Figure 1B A perspective view of another part of the joining assembly;

[0030] Figure 4 This is based on one or more instances of this disclosure. Figure 3 A perspective view of a portion of the part;

[0031] Figure 5A This is a cross-sectional side view of a joining component according to one or more instances of this disclosure;

[0032] Figure 5B This is based on one or more instances of this disclosure. Figure 5A A perspective view of the fasteners of the mating components;

[0033] Figure 5C This is a cross-sectional side view of a joining component according to one or more instances of this disclosure;

[0034] Figure 5D This is based on one or more instances of this disclosure. Figure 5C A perspective view of the fasteners of the mating components;

[0035] Figure 5E This is a cross-sectional side view of a joining component according to one or more instances of this disclosure;

[0036] Figure 6 This is a cross-sectional side view of a joint assembly without a sprue, according to one or more examples of this disclosure;

[0037] Figure 7 It is a slit plate according to one or more examples of this disclosure. Figure 6 A cross-sectional side view of the joining components;

[0038] Figure 8 It is a top plan view of the parts of a joining assembly according to one or more embodiments of this disclosure; and

[0039] Figure 9 This is a schematic flowchart illustrating a method for manufacturing a mating assembly according to one or more examples of this disclosure. Detailed Implementation

[0040] Throughout this specification, references to “an instance,” “example,” or similar language mean that a particular feature, structure, or characteristic described in connection with that instance is included in at least one instance of this disclosure. Throughout this specification, the phrases “in an instance,” “in an instance,” and similar language may, but do not necessarily all refer to the same instance. Similarly, the term “implementation” is used to mean an implementation having a particular feature, structure, or characteristic described in connection with one or more instances of this disclosure; however, unless there is an explicit relevance indicating otherwise, an implementation may be associated with one or more instances.

[0041] This document discloses a mating assembly and a method for manufacturing the mating assembly, which facilitates cost and assembly time reduction by decreasing the lap surface area (e.g., the area of ​​the lap surface) of one of the parts of the mating assembly. Reducing the lap surface area of ​​the mating assembly shortens the measurement process used to determine the gap between the lap surfaces that require caulking. In one example, the mating assembly and method disclosed herein improve upon conventional assemblies and methods by substantially replacing a single lap surface caulking piece on a mating part with multiple smaller lap surface caulking pieces, where each caulking piece corresponds to a single fastener or a selected group of fasteners. Furthermore, because the surface area of ​​the lap surface is smaller, the amount of caulking material and the corresponding handling of the caulking material are reduced. Despite reducing the lap surface area of ​​the mating assembly, the load-bearing capacity of the mating assembly is maintained.

[0042] refer to Figure 1A and 1B According to some examples, the joining assembly 100 is shown in an exploded view. The joining assembly 100 includes a first part 102 and one or more second parts, such as second part 110A and second part 110B. The first part 102 includes the structure 104 to which the second parts 110A and 110B are attached. According to some examples, such as Figure 1A and 1B As shown, the joining assembly 100 is the aircraft 117 or the wing 101 of the aircraft 117 or a part of the wing 101 of the aircraft 117 or the aircraft 117, and the structure 104 is the skin panel 103 of the aircraft 117 or the wing 101 of the aircraft 117.

[0043] In the illustrated example, the second part 110A is either the engine attachment external accessory 113 or another external accessory attached to the outer surface of a skin panel of an aircraft or wing assembly. External accessories are configured to facilitate the attachment of external components—such as engines, landing gear, stabilization and control devices, auxiliary fuel tanks, etc.—to the aircraft or wing assembly. For example, see reference... Figure 1A and 1BThe second part 110A helps to secure the engine 105 to the wing 101 at position 107. Typically, large-diameter shear pins are used to secure external components. These shear pins are offset from the wingbox monocoque structure. Therefore, in addition to reaction momentum, reaction force is also a capability required for static equilibrium. By definition, the shear reaction force is parallel to and directly translated to the skin or spars mid-surface of the monocoque structure, which has sufficient capacity to react to and dissipate the shear. Typically, reaction momentum manifests as a reaction force with a vector component, which can be described as parallel (shear) and perpendicular (tension / compression) to the coordinate system of the local monocoque structure mid-surface.

[0044] Additionally, in the illustrated example, the second part 110B is an internal rib 111 of the wing 101, attached to the upper and lower skin panels 103 of the wing 101 and the internal surfaces of the front and rear spars (not shown). The internal rib 111 extends through the wing along the chord direction and stabilizes the closed-hole torque box, reacting against external and internal pressure loads, and helps to connect the spaced longitudinal spars extending along the wingspan direction. Furthermore, the vertical vector component from the second part 110A passes through the skin panel and is reacted by the second part 110B. The vertical vector component reacted by the internal rib 111 is then carried to the spar via the internal rib 111. Although shown as the external fitting 113 and internal rib 111 of the wing 101 or wing assembly, in other examples, the second part 110A and the second part 110B are attached to other parts of the aircraft, such as stabilizers, fuselages, etc. Furthermore, although the second part 110A and the second part 110B are depicted as external fitting 113 and internal rib 111, respectively, in other instances, the second part 110A and the second part 110B are any of a variety of other parts attached to the aircraft, wherein the parts are configured to transfer loads on the aircraft.

[0045] like Figure 2 As shown, the second part 110A includes a non-overlapping surface 112 and a plurality of protrusions 116 projecting from the non-overlapping surface 112. The protrusions 116 (e.g., padding) are spaced apart from each other around the non-overlapping surface. In some instances, at least some of the protrusions 116 are spaced at the same distance, while in others they are spaced differently. In some instances, the number of protrusions 116 and the spacing of the protrusions 116 relative to each other are based on a predicted distribution of the transmitted load on the second part 110A. For example, to accommodate a non-uniform transmitted load distribution, the second part 110A may have more protrusions 116 per unit area at locations on the second part 110A where it is predicted to experience higher transmitted loads than at other locations.

[0046] Each protrusion 116 includes an overlapping surface 118, which is defined as the furthest surface of the protrusion 116 furthest from the non-overlapping surface 112. In other words, each protrusion 116 of the overlapping surface 118 is offset from the non-overlapping surface 112 by a distance equal to the height (H) of the protrusion 116 (see, for example, Figure 5A Furthermore, the protrusions 116 define a space between the non-overlapping surface 112 of the second part 110A and the base surface 120 of the first part 102. The overlapping surface 118 of each protrusion 116 is configured to directly engage (e.g., contact) the base surface of the first part 102. Therefore, as used herein, an overlapping surface is a surface configured to directly engage the base surface of a mating part, and a non-overlapping surface is a surface configured away from the mating part or not to directly engage with the surface of the mating part. The shape of the overlapping surface 118 of each protrusion 116 depends on the shape of the base surface of the mating part to which the overlapping surface 118 is configured to directly engage. Therefore, when the base surface of the mating part is flat, the overlapping surface 118 is flat, and when the base surface is wavy, the overlapping surface 118 is wavy to match the shape of the base surface.

[0047] The outer periphery of the protrusion 116 defines the shape of the protrusion 116. Figure 2 In the example shown, the protrusion 116 has a circular shape. However, in other examples, the protrusion 116 has a non-circular shape, such as a rectangle, square, triangle, or other polygonal shape. In the example shown, the shape of the protrusion 116 is constant along its height. In other words, according to some examples, the outer peripheral wall defining the shape of the protrusion 116 is perpendicular to the portion of the protrusion 116 that protrudes from the non-overlapping surface 112 of the second part 110A.

[0048] The second part 110A also includes a plurality of through holes. Each of the through holes is formed in the overlapping surface 118 of a corresponding one of the protrusions 116 and extends entirely through the corresponding protrusion 116 and the non-overlapping surface from which the protrusion 116 protrudes. In other words, each through hole passes through the corresponding one of the protrusions 116 and the portion of the second part 110A below the corresponding protrusion 116.

[0049] Similar to the second part 110A, such as Figure 3 and 4As shown, the second part 110B includes a plurality of protrusions 116 and a plurality of through holes. The protrusions 116 and through holes of the second part 110B are configured to be the same as those of the second part 110A. Therefore, the description of the protrusions 116 and through holes of the second part 110A also applies to the protrusions 116 and through holes of the second part 110B. However, unlike the second part 110A, which has a single continuous non-overlapping surface 112, the second part 110B includes a plurality of discontinuous or spaced-apart non-overlapping surfaces 112. Each of the non-overlapping surface 112 or non-overlapping surface segments includes at least two protrusions 116 projecting therefrom and at least two through holes, each through hole passing through one of the two protrusions 116 respectively.

[0050] refer to Figure 5A This shows an example of the engagement assembly 100. The engagement assembly 100 is similar to... Figure 1B The joining components 100, wherein the same numbers refer to the same features. For example, Figure 5A The joining assembly 100 includes a first part 102 and a second part 110 attached to the first part. The second part 110 includes features similar to those of second parts 110A and 110B. Therefore, the features of second parts 110A and 110B, and the related descriptions of those features, also apply to the second part 110. In some instances, Figure 5A The second part 110 represents either the second part 110A or the second part 110B.

[0051] like Figure 5A As shown, the first part 102 of the engagement assembly 100 includes a base surface 120 and a plurality of through holes formed in the base surface 120. The through holes extend entirely from the base surface 120 through the first part 102 to a non-facing surface 121 of the first part 102 opposite to the base surface 120. As used herein, the non-facing surface 121 is the surface of the first part 102 that faces away from the second part 110.

[0052] The through-holes of the first part 102—which can be considered as first through-hole 132—and the through-holes of the second part 110—which can be considered as second through-hole 114—are alignable. More specifically, the central axis 142 of each first through-hole 132 is coaxially aligned with the central axis 142 of a corresponding second through-hole 114. The second through-hole 114 extends entirely from the lap surface 118 of the protrusion 116 through the second part 110 to the non-facing surface 130 of the second part 110. As used herein, the non-facing surface 130 is the surface of the second part 110 that faces away from the first part 102. The first part 102 and the second part 110 are secured together by a plurality of fasteners 122. Each fastener 122 includes a bolt 123 (e.g., a screw) and a corresponding nut 128 that engages with the bolt 123, but other fastener arrangements may be used. Each coaxially aligned first through-hole 132 and second through-hole 114 is configured to receive a corresponding one of the plurality of bolts 123 of the engagement assembly 100. Therefore, each of the plurality of bolts 123 passes through a corresponding one of the plurality of coaxially aligned first through holes 132 and second through holes 114. The dimensions of the first through holes 132 and second through holes 114 are determined to nestably hold the bolts 123 such that the bolts 123 remain coaxially aligned with the central axis 142 of the first through holes 132 and second through holes 114 when received in the through holes.

[0053] Bolt 123 includes a head 124 and a body 126 extending from the head 124. In some instances, the first through hole 132 includes a countersunk hole portion 134 formed in the non-facing surface 121 of the first part 102, configured to nestably receive the head 124 of a corresponding bolt 123 (which is... Figure 5A (In the case of countersunk head). The nestable engagement between the head 124 of bolt 123 and the countersunk portion 134 of the first through hole 132 allows the head 124 to be flush with or below the non-facing surface 121 and prevents the head 124, thereby preventing the bolt 123 from moving along the central axis 142 of the through hole in the direction toward the second part 110. Movement of bolt 123 along the central axis 142 of the through hole in the direction toward the first part 102 is prevented by engagement with the nut 128, which is fixed to the body 126 of bolt 123, and with the non-facing surface 130 of the second part 110. In some instances, the body 126 is externally threaded, and the internally threaded nut 128 threadedly engages the body 126 to secure the nut 128 to the body 126. Although the countersunk hole portion 134 is shown as part of the first through hole 132 forming the first part 102 and the nut 128 is shown as engaging with the non-facing surface 130 of the second part 110, in other instances, the countersunk hole portion 134 forms part of the second through hole 114 of the second part 110 and the nut 128 engages with the non-facing surface 121 of the first part 102.

[0054] Additionally, in some instances, such as Figure 5C As shown, the head 124 of bolt 123 is not countersunk, but rather non-countersunk, such as a round head, button head, or saucer head. Figure 5C In some examples, the first through hole 132 is not countersunk, such that the head 124 of the bolt 123 rests on the non-counterface surface 121 of the first part 102. Therefore, in some examples, neither the first through hole 132 nor the second through hole 114 is countersunk, and the head 124 of the bolt 123 engages with the non-counterface surface of the corresponding one of the first part 102 or the second part 110.

[0055] With the first through hole 132 coaxially aligned with the corresponding second through hole 114, and the bolt 123 passing through the corresponding coaxially aligned first through hole 132 and second through hole 114, the nut 128 is secured to the body 126 of the corresponding bolt 123 and tightened relative to the body 126, so that the overlapping surface 118 of the protrusion 116 of the second part 110 is tightened against the base surface 120 of the first part 102 to form the engagement assembly 100. When the engagement assembly 100 is formed, no portion of the non-overlapping surface 112 of the base surface 120 contacts the base surface 120 of the first part 102. In practice, in some instances, the non-overlapping surface 112 is offset from the base surface 120 by at least the height (H) of the protrusion 116. In some instances, the height (H) of the protrusion 116 is between 0.025 inches and 0.035 inches (including the endpoints). In some other instances, the maximum distance between the base surface 120 and the non-overlapping surface 112 is equal to the height (H) of the protrusion 116. Therefore, in the case of forming the joining assembly 100, the only surface in contact between the second part 110 and the first part 102 is the overlapping surface 118 of each of the protrusions 116.

[0056] To illustrate possible alternative instances of the joining component 100, Figure 5E An optional example of the engagement assembly 100 is shown. Figure 5A The joining components 100 are the same. Figure 5E The engagement assembly 100 includes a first part 102 and a second part 110, wherein the second part 110 includes a protrusion 116. However, with Figure 5A The joining components 100 are different. Figure 5E The engagement assembly 100 includes an additional second part 110 with a protrusion 116, which is attached to the opposite side of the first part 102. In other words, Figure 5EThe engagement assembly 100 includes two second parts 110 attached to the first part 102 on opposite sides of the first part 102. Thus, the first part 102 is sandwiched between the two second parts 110. Fasteners 122 are configured to secure the two second parts 110 to the first part 102.

[0057] In some instances, the total surface area of ​​the overlapping surfaces 118 of the protrusion 116 is less than the total surface area of ​​the non-overlapping surfaces (one or more) 112. According to one example, and particularly with reference to... Figure 2 In the second part 110A, the overlapping surface 118 and the non-overlapping surfaces (one or more) 112 of the protrusion 116 account for approximately 6% and approximately 94% of the total surface area of ​​the second part 110 facing the first part 102, respectively. Therefore, in this example, the total surface area of ​​the overlapping surfaces 118 does not exceed 7% of the total surface area of ​​the non-overlapping surfaces (one or more) 112 of the second part 110. In another example, and specifically referring to... Figure 3 and 4 In the second part 110B, the overlapping surface 118 and the non-overlapping surfaces (one or more) 112 of the protrusion 116 account for 15% and 85% of the total surface area of ​​the second part 110 facing the first part 102, respectively. Therefore, in this additional example, the total surface area of ​​the overlapping surfaces 118 does not exceed 18% of the total surface area of ​​the non-overlapping surfaces (one or more) 112 of the second part 110.

[0058] The percentage of the surface area of ​​the second part 110, which faces and directly engages with the first part 102, is significantly lower than (e.g., as low as 94%) than that of conventional components, particularly those used in aerospace applications. However, the lower surface area directly engaging with the first part 102 does not negatively impact the engagement assembly 100, particularly the ability of the second part 110 of the engagement assembly 100 to handle loads (e.g., clamped compressive loads) transmitted through the engagement assembly 100, compared to conventional components. (See reference...) Figure 5A As described in more detail, load transfer between two parts attached together by fasteners occurs primarily through the fasteners and the tightly surrounding structure supporting the fasteners. Therefore, positioning the protrusion 116 and the corresponding overlapping surface 118 at the second through-hole 114 allows the second part 110 to fully transfer loads (e.g., through the engagement assembly 100) using such a large percentage of the non-overlapping surfaces (one or more) 112 facing the first part 102. Figure 5A (Indicated by arrow 191 in the image).

[0059] refer to Figure 5AThe residence volume of the clamping compressive load (e.g., indicated by arrow 191) between the first part 102 and the second part 110 is shown by dashed lines 162 and 160. In other words, the integration of the clamping compressive load—which manifests as compressive loads on the lap surface 118 and the base surface 120—averages and conversely balances the fastener tensile preload. The fastener tensile preload is generated by the bolt elongation caused by applying torque to the nut. The fastener tensile preload is specified to target zero clearance under specific load conditions, e.g., no clearance at or below the design limit load. The residual clamping compressive contact load generated by the fastener tensile preload from the torque of the nut applied to the assembled structure at the fastener location must be overcome by a load that manifests as a pull-away of the assembled structure before the compressive contact between the lap surface and the joint gap disappears. All relevant component build-up load vectors from the first part 102 to the second part 110 lie within the truncated conical region 190 defined by dashed line 160 (see, e.g., Figure 5B The clamping compression load vector from the second part 110 to the first part 102 lies within a truncated conical region (similar to truncated conical region 190) defined by dashed line 162. The truncated conical region is coaxial or concentric with the central axis 142, such that dashed lines 160 and 162 extend 360 degrees around the central axis 142 of the first through hole 132 and the second through hole 114 to each define a truncated conical maximum load transfer range corresponding to a region of the same shape.

[0060] The load transfer from the first part 102 to the second part 110 originates at the interface between the head 124 of the bolt 123 and the first through hole 132. Therefore, the dashed line 160 extends from the outer periphery of the head 124 at an angle θ to the central axis 142 of the first through hole 132. Similarly, the load transfer from the second part 110 to the first part 102 originates at the interface between the nut 128 and the non-facing surface 130 of the second part 110. Therefore, the dashed line 162 extends from the outer periphery of the nut 128 at the non-facing surface 130 at an angle θ to the central axis 142 of the first through hole 132. In this way, the maximum load transfer range of the truncated cone between the first part 102 and the second part 110 has a maximum span of twice the angle θ. In one example, the angle θ is at most 25 degrees. According to another example, the angle θ is at most 17 degrees. According to yet another example, the angle θ is at most 15 degrees.

[0061] To provide a structure sufficient to accommodate the range of loads transmitted between the first part 102 and the second part 110 at a given fastener 122, the width (W) of the corresponding protrusion 116 is at least as wide as the maximum range of the transmitted load along the height of the protrusion 116. Therefore, as Figure 5AAs shown, the width (W) of the protrusion 116 is sufficient such that all transmitted loads within the maximum transmitted load range (e.g., between dashed lines 160 and 162) pass through the protrusion 116. Because the maximum transmitted load range can be symmetrical in a plane parallel to and passing through the central axis 142 of the first through hole 132 and the second through hole 114, in some instances, each protrusion 116 is symmetrical in the same plane. Furthermore, in some instances, the central axis 142 of the first through hole 132 and the second through hole 114 passes through the geometric center of the protrusion 116 corresponding to the first through hole 132 and the second through hole 114. Therefore, in some instances, the protrusion 116 is concentric with the second through hole 114 extending through it.

[0062] For any type of fastener 122, in some instances, the width (W) of each of the plurality of protrusions 116 is equal to or greater than 2(r + Ttanθ). This equation is derived from the cross-sectional shape of the maximum load-bearing range, which, as mentioned above, is a truncated cone. In this equation, r is the maximum radial dimension of the outermost portion of the fastener 122 that contacts the first part 102 or the second part 110 and passes through the corresponding second through hole 114, and T (e.g., Figure 5A In this context, T1 or T2 is the distance from the contact point between the outermost portion of the fastener 122 and the first part 102 or the second part 110 to the overlapping surface 118 of the corresponding protrusion 116, and θ is the angle between the central axis 142 of the corresponding second through hole 114 and the outermost load vector originating at the contact point between the outermost portion of the fastener 122 and the first part 102 or the second part 110. The outermost portion of the fastener 122 in contact with the first part 102 or the second part 110 has the largest radial dimension, regardless of the cross-sectional shape of the outermost portion of the fastener 122. In other words, the term "radial dimension" does not imply or requires a circular cross-section. Rather, as used herein, the radial dimension is a dimension that extends vertically away from the central axis of the fastener 122.

[0063] In some instances where the fasteners 122 include bolts 123 and nuts 128, the width (W) of each protrusion 116 is equal to or greater than the minimum of 2(r1+T1tanθ) or 2(r2+T2tanθ). Figure 5A As shown, variable r1 is the maximum radial dimension of the head 124 of the bolt 123 of the fastener 122 that contacts the first part 102. For example... Figure 5AAs shown, variable r2 is the maximum radial dimension of the nut 128 of the fastener 122 that contacts the second part 110. Therefore, in some instances, the width (W) of each protrusion 116 is equal to or greater than 2(r + Ttanθ), where r is equal to the smaller of the maximum radial dimension of the outermost portion of the head 124 that contacts the first part 102 or the second part 110, or the maximum radial dimension of the outermost portion of the nut 128 that contacts the first part 102 or the second part 110. The head 124 or nut 128 has a circular cross-section, the maximum radial dimension r1 of the head 124 is the radius of the head 124 that contacts the first part 102, and the maximum radial dimension r2 of the nut 128 is the radius of the nut 128. In embodiments where one or both of the head 124 and the nut 128 have a non-circular cross-section (e.g., hexagonal), the maximum radial dimension r1 of the head 124 is half the maximum width of the head 124, and the maximum radial dimension r2 of the nut 128 is half the maximum width of the nut 128. By applying the equations presented above, the corresponding width (W) of the protrusion 116 will be large enough to capture the transmitted load vector emanating from both the head 124 and the nut 128.

[0064] like Figure 5A As depicted, distance T1 is the thickness of the first part 102 and distance T2 is the total thickness of the second part 110, which includes the distance between the non-overlapping surface 112 and the non-facing surface 130 and the height H of the protrusion 116.

[0065] The variable θ is the angle between the central axis 142 of the corresponding second through hole 114 and the outermost load vector originating from the outermost portion of the fastener 122 and the contact point between the first part 102 or the second part 110. Therefore, as... Figure 5A As shown in the figure, the variable θ is the angle θ between the central axis 142 and either the dashed line 160 or the dashed line 162.

[0066] Because the overlapping surface 118 of the joining component 100 is reduced compared to conventional components, in some instances, the possibility of gaps requiring caulking is reduced to zero. However, referring to... Figure 6According to some examples, as described above, after the second part 110 is attached to the first part 102, a gap that needs to be filled may exist between the base surface 120 of the first part 102 and the overlapping surface 118 of the protrusion 116. This gap is not intentionally incorporated into the design of the mating assembly 100. However, due to manufacturing tolerances and other manufacturing constraints, a gap may form between the base surface 120 and the overlapping surface 118 after the initial formation of the mating assembly 100. In some industries, such as the automotive and aerospace industries, the gap between the overlapping surfaces of two parts can be adjusted. In such industries, the gap between the overlapping surfaces cannot exceed certain predetermined maximum thresholds. In the aircraft industry, the predetermined maximum threshold may be 0.005 inches. If the gap between the two overlapping surfaces exceeds the predetermined maximum threshold, then the gap needs to be closed below the predetermined maximum threshold for implementation in, for example, the operating structure of a vehicle or aircraft.

[0067] One method for closing gaps to meet gap specifications is to fill the gaps. Filling involves placing one or more filler pieces (e.g., thin strips of material) within the gap to effectively close it. Because only those gaps that do not meet a predetermined maximum threshold need to be filled, gaps are typically measured to determine if they meet the predetermined maximum threshold. The more overlapping surfaces to measure, the greater the time, effort, and cost required to meet gap specifications. Therefore, due to the relatively low ratio of overlapping surface 118 to non-overlapping surface 112 of the second part 110, measuring the gap of the second part 110 to ensure gap compliance requires less time, effort, and money compared to conventional assemblies with a higher ratio of overlapping to non-overlapping surfaces.

[0068] like Figure 6 As shown in the diagram, according to one example, after attaching the first part 102 to the second part 110, a gap G1 exists between the overlapping surface 118 of one protrusion 116 and the base surface 120 of the first part 102, and a gap G2 exists between the overlapping surface 118 of another protrusion 116 and the base surface 120 of the first part 102. Gap G1 may have the same or different dimensions as gap G2. (See reference...) Figure 8After detecting and measuring gaps G1 and G2, if the gap is greater than a predetermined maximum threshold, then one or more sizing pads 140 are placed in gap G1 and one or more sizing pads 140 are placed in gap G2. In some instances, the thickness of a single sizing pad 140 or a combination of sizing pads 140 located in gap G1 is substantially equal to the size of gap G1. Similarly, in some instances, the thickness of a single sizing pad 140 or a combination of sizing pads 140 located in gap G2 is substantially equal to the size of gap G2. However, it should be recognized that in some instances, the thickness of a single sizing pad 140 or multiple sizing pads 140 is such that after the sizing pads 140 are placed therein, any remaining gap in gap G1 or gap G2 does not exceed the predetermined maximum threshold. In instances where multiple sizing pads 140 are located within gap G1 or gap G2, the thickness of the sizing pads 140 may be the same or different. As used herein, the term "substantially" means a deviation of less than or equal to 5%.

[0069] Based on certain examples, such as Figure 7 As shown, each grout piece 140 is located only within the gap between the overlapping surface 118 of the protrusion 116 and the base surface 120 of the first part 102. In other words, in this example, no grout piece is inserted between the base surface 120 of the first part 102 and the non-overlapping surface 112 of the second part 110. This configuration helps to save costs associated with grouting material. However, in some instances, such as... Figure 8 As shown, a single sprue 140 can extend from the overlapping surface 118 of one protrusion 116 to the overlapping surface 118 of another protrusion. Therefore, a single sprue 140 can fill the gap between the two protrusions 116 and the base surface 120 of the first part 102. Figure 8 As shown, using a single stencil 140 spanning at least two protrusions 116 also helps to keep the stencil 140 in place and prevent rotation of the stencil 140.

[0070] The first part 102 is made of any of a variety of materials. In a particular example, the first part 102 is made of a fiber-reinforced polymeric material, such as where the fibers are carbon-based fibers. In some examples, the second part 110 is made of a metallic material, which allows for the formation of the protrusion 116 using machining techniques. According to some examples, the first part 102 is made of a fiber-reinforced polymeric material and the second part 110 is made of a metallic material. The spacer 140 is made of any of a variety of materials. In one example, the spacer 140 is made of a fiber-reinforced polymeric material, which may be a carbon fiber-reinforced polymeric material.

[0071] refer to Figure 9According to some examples, the method 200 for manufacturing the joining assembly 100 as described above includes (box 202) transposing the second part 110 to the first part 102. After transposing the second part 110 to the first part 102 in box 202, method 200 includes (box 204) measuring gaps, such as gap G1 and / or gap G2 between the overlapping surfaces 118 of at least one of the base surface 120 and the protrusion 116. If, at (block 206), gap G1 or gap G2 is determined to be greater than a predetermined threshold, such as a predetermined maximum threshold, then method 200 includes (block 208) inserting at least one filler piece 140 into gap G1 or gap G2 between the base surface 120 and the overlapping surfaces 118 of at least one of the protrusions 116, and fastening the first part 102 to the second part 110, wherein at least one filler piece 140 is located in gap G1 or gap G2 between the base surface 120 and the overlapping surfaces 118 of the last of the protrusions 116. However, if, at (block 206), gap G1 or gap G2 is determined not to be greater than a predetermined threshold (e.g., less than or equal to a predetermined threshold), then method 200 includes (block 210) maintaining a filler-free engagement between the base surface 120 and the overlapping surfaces 118 of at least one of the protrusions 116.

[0072] In some instances, method 200 further includes measuring only the gap between the base surface 120 and the overlapping surface 118 of at least one of the protrusions, meaning that a second gap between the base surface 120 and the non-overlapping surface 112 is not measured. Therefore, at block 210, before fastening the first part 102 to the second part 110, in the absence of a grout 140 in the gap and no grout in the second gap between the base surface 120 and the non-overlapping surface 112, the second gap is not measured. Because grouting of the non-overlapping surfaces is not required, not measuring the second gap is acceptable, saving time, effort, and cost associated with grouting the mating assembly 100.

[0073] In some instances, method 200 further includes additional steps following the steps associated with block 208 or block 210. In one instance, after performing the steps associated with block 208 or block 210, method 200 includes drilling through holes (e.g., first through hole 132 and second through hole 114) in the parts (e.g., first through hole 132 and second through hole 114), inserting fastener 122, turning (e.g., tightening) fastener 122, pausing for a predetermined period of time, and then turning fastener 122 again.

[0074] In the above description, certain terms may be used, such as “upper,” “lower,” “upper part,” “lower part,” “horizontal,” “vertical,” “left,” “right,” “above,” “below,” etc. These terms are used, where applicable, to provide a clear description when dealing with relative relationships. However, these terms are used to imply absolute relationships, positions, and / or directions. For example, for an object, simply by flipping the object, the “upper” surface can become the “lower” surface. Nevertheless, it is still the same object. Furthermore, unless otherwise explicitly stated, the terms “including,” “comprising,” “having,” and their variations mean “including but not limited to.” Unless otherwise explicitly stated, the enumerated list of terms does not imply that any or all terms are mutually exclusive and / or mutually inclusive. Unless otherwise explicitly stated, the terms “a” and “the” also mean “one or more.” In addition, the term “multiple” can be defined as “at least two.”

[0075] Additionally, in this specification, instances of one element being "connected" to another element can include direct and indirect connections. A direct connection can be defined as one element being connected to another element and making some kind of contact with it. An indirect connection can be defined as a connection between two elements that are not in direct contact with each other, but with one or more additional elements between the connected elements. Further, as used herein, securing one element to another element can include direct and indirect securing. Also, as used herein, "proximity" does not necessarily mean contact. For example, an element may be adjacent to another element without contacting that element.

[0076] As used in this article, the phrase "at least one of..." when used with a list of items means that different combinations of one or more of the listed items can be used, and it may be necessary to use only one of the items in the list. An item can be a specific object, thing, or category. In other words, "at least one of..." means that any combination or number of items in the list can be used, but it may not be necessary to use all of the items in the list. For example, "at least one of items A, B, and C" could mean item A; item A and item B; item B; item A, item B, and item C; or item B and item C. In some cases, "at least one of items A, B, and C" could mean, for example, but not limited to, two of items A, one of items B, and ten of items C; four of items B and seven of items C; or some other suitable combination.

[0077] Unless otherwise stated, the terms “first,” “second,” etc., are used only as markers in this document and are not intended to require the order, position, or hierarchy of the items referred to by these terms. Furthermore, for example, referring to an item as “second” does not require or exclude, for example, the existence of an item as “first” or lower numbered, and / or, for example, an item as “third” or higher numbered.

[0078] As used herein, a system, device, structure, article, element, component, or hardware “configured to” perform a specified function is indeed capable of performing the specified function without any changes, and not merely has the potential to perform the specified function after further modifications. In other words, a system, device, structure, article, element, component, or hardware “configured to” perform a specified function is specifically selected, created, implemented, utilized, programmed, and / or designed for the purpose of performing the specified function. As used herein, “configured to” means an existing characteristic of the system, device, structure, article, element, component, or hardware that enables the system, device, structure, article, element, component, or hardware to perform the specified function without further modifications. For the purposes of this disclosure, a system, device, structure, article, element, component, or hardware described as “configured to” perform a particular function may additionally or alternatively be described as “suitable” and / or “operational to” perform that function.

[0079] The illustrative flowcharts included herein are generally presented as logical flowcharts. Therefore, the sequence and labeled steps depicted indicate an instance of the proposed method. Other steps and methods that are functionally, logically, or effectively equivalent to one or more steps or portions thereof of the illustrated method can be envisioned. Furthermore, the format and symbols used are provided to explain the logical steps of the method and should be understood as not limiting the scope of the method. While various arrow types and line styles may be used in flowcharts, they should be understood as not limiting the scope of the corresponding method. In practice, some arrows or other connectors may be used only to indicate the logical flow of the method. For example, an arrow may indicate a wait or monitoring period of unspecified duration between enumeration steps of the depicted method. Additionally, the order in which a particular method occurs may or may not strictly adhere to the order of the corresponding steps shown.

[0080] Furthermore, this disclosure includes implementation methods according to the following terms:

[0081] Clause 1. A component comprising:

[0082] A first part includes a base surface and a plurality of first through holes formed in the base surface and extending through the first part;

[0083] The second part, which is directly attached to the base surface of the first part, includes:

[0084] Non-overlapping surfaces facing the base surface;

[0085] A plurality of protrusions spaced apart from each other, each protrusion projecting from a non-overlapping surface, and each protrusion defining an overlapping surface that engages with a corresponding portion of the base surface of the first part; and

[0086] A plurality of second through holes, each formed in the overlapping surface of a corresponding one of the plurality of protrusions and each coaxially aligned with a corresponding one of the plurality of first through holes; and

[0087] Multiple fasteners, each fastener passing through a corresponding one of a plurality of first through holes and a corresponding one of a plurality of second through holes coaxially aligned with the corresponding one of the plurality of first through holes;

[0088] The width (W) of each of the plurality of protrusions is equal to or greater than 2(r+Ttanθ), where r is the maximum radial dimension of the outermost portion of the fastener that contacts the first or second part and passes through one of the plurality of second through holes, T is the distance between the contact point between the outermost portion of the fastener and the first or second part and the overlapping surface of the corresponding one of the plurality of protrusions, and θ is the angle between the central axis of the corresponding second through hole and the outermost load vector originating at the contact point between the outermost portion of the fastener and the first or second part.

[0089] Clause 2. For components pursuant to Clause 1, the total surface area of ​​the overlapping surfaces of the plurality of protrusions shall not exceed 18% of the total surface area of ​​the non-overlapping surfaces.

[0090] Clause 3. For components according to Clause 1 or Clause 2, the total surface area of ​​the overlapping surfaces of the plurality of protrusions shall not exceed 7% of the total surface area of ​​the non-overlapping surfaces.

[0091] Clause 4. Components according to any one of Clauses 1 to 3, wherein the height (H) of each of the plurality of protrusions is between 0.025 inches and 0.035 inches (inclusive of the endpoints).

[0092] Clause 5. The components according to Clause 4, wherein the maximum distance between the base surface of the first part and the non-overlapping surface of the second part is equal to the height (H) of each of the plurality of protrusions.

[0093] Clause 6. Components of any one of Clauses 1 to 5, wherein:

[0094] Each of the multiple fasteners includes a bolt and a nut;

[0095] A bolt includes a head and a body extending from the head;

[0096] The nut engages with the body of the bolt to secure the first and second parts together between the bolt head and the nut; and

[0097] r is equal to the smaller of the maximum radial dimension of the outermost portion of the head that contacts the first or second part, or the maximum radial dimension of the outermost portion of the nut that contacts the first or second part.

[0098] Clause 7. A component of any one of Clauses 1 to 6, wherein θ is at most 25 degrees.

[0099] Clause 8. As per the components of Clause 7, where θ is at most 17 degrees.

[0100] Clause 9. A component according to any one of Clauses 1 to 8, further comprising at least one filler sheet inserted between the base surface and the overlapping surface of at least one of the plurality of protrusions.

[0101] Clause 10. Components pursuant to Clause 9, wherein:

[0102] The gap (G1) between the base surface and the overlapping surface of at least one of the plurality of protrusions is greater than 0.005 inches; and

[0103] The thickness of at least one stencil is substantially equal to the gap (G1).

[0104] Clause 11. Components according to Clause 9 or Clause 10, wherein at least one sprue is inserted between the base surface and the overlapping surfaces of more than one of the plurality of protrusions.

[0105] Clause 12. A component pursuant to any one of Clauses 9 to 11, wherein a stencil is inserted between the base surface of the first part and the non-overlapping surface of the second part.

[0106] Clause 13. An assembly pursuant to any one of Clauses 1 to 12, wherein the central axis of each of the plurality of second through holes passes through the geometric center of the corresponding one of the plurality of protrusions.

[0107] Clause 14. The component according to any one of Clauses 1 to 13 further comprises at least one filler sheet inserted between the lap surfaces of the base surface and at least one of the plurality of protrusions, wherein:

[0108] The first component is made of fiber-reinforced polymeric material; and

[0109] The second part is made of metal.

[0110] Clause 15. The component according to Clause 14, wherein the width (W) of each of the plurality of protrusions is equal to 2(r+Ttanθ).

[0111] Clause 16. An aircraft comprising any of the components of Clauses 1 to 15.

[0112] Clause 17. Aircraft pursuant to Clause 16, wherein:

[0113] Aircraft include wings;

[0114] The first component includes the wing skin panels; and

[0115] The second component includes the internal ribs of the wing.

[0116] Clause 18. Aircraft pursuant to Clause 16, wherein:

[0117] Aircraft include wings;

[0118] The first component includes the wing skin panels; and

[0119] The second part includes the external fittings of the wing.

[0120] Clause 19. A method of manufacturing a component, the method comprising:

[0121] The second part is transposed to the first part, wherein the second part includes a non-overlapping surface and a plurality of protrusions, and wherein each protrusion defines an overlapping surface that directly engages with the base surface of the first part;

[0122] After the second part is moved to the first part, the gap (G1) between the base surface and the overlapping surface of at least one of the plurality of protrusions is measured;

[0123] If the gap (G1) is greater than a predetermined threshold, at least one gap filler is inserted into the gap (G1) between the base surface and the overlapping surface of at least one of the plurality of protrusions, and the first part is fastened to the second part, wherein at least one gap filler is inserted between the base surface and the overlapping surface of at least one of the plurality of protrusions; and

[0124] If the gap (G1) is less than or equal to a predetermined threshold, maintain gapless meshing between the base surface and the overlapping surfaces of at least one of the plurality of protrusions.

[0125] Clause 20. The method pursuant to Clause 19, wherein:

[0126] The width (W) of each of the plurality of protrusions is equal to or greater than 2(r + Ttanθ), where r is the maximum radial dimension of the outermost portion of the fastener of the corresponding one of the plurality of second through holes passing through the second part and contacting the first or second part, T is the distance from the contact point between the outermost portion of the fastener and the first or second part to the overlapping surface of the corresponding one of the plurality of protrusions, and θ is the angle between the central axis of the corresponding one of the plurality of second through holes and the outermost load vector originating at the contact point between the outermost portion of the fastener and the first or second part;

[0127] The method further includes not measuring the second gap between the base surface and the non-overlapping surfaces of the second part.

[0128] The invention may be implemented in other specific forms without departing from the spirit or essential characteristics thereof. The examples described are to be considered illustrative rather than restrictive in all respects. All modifications falling within the equivalent meaning and scope of the claims are to be included within their scope.

Claims

1. A component (100) comprising: A first part (102) includes a base surface (120) and a plurality of first through holes (132) formed in the base surface (120) and extending through the first part (102); The second part (110), which is directly attached to the base surface (120) of the first part (102) and includes: The non-overlapping surface (112) facing the base surface (120); A plurality of protrusions (116) spaced apart from each other, each protrusion protruding from the non-overlapping surface (112), and each protrusion defining an overlapping surface (118) that engages with a corresponding portion of the base surface (120) of the first part (102); and A plurality of second through holes (114), each formed in the overlapping surface (118) of a corresponding one of the plurality of protrusions (116) and each coaxially aligned with a corresponding one of the plurality of first through holes (132); and A plurality of fasteners (122), each fastener passing through a corresponding one of the plurality of first through holes (132) and a corresponding one of the plurality of second through holes (114) coaxially aligned with the corresponding one of the plurality of first through holes (132); The width (W) of each of the plurality of protrusions (116) is equal to or greater than 2(r + Ttanθ), where r is the maximum radial dimension of the outermost portion of the fastener (122) that contacts the first part (102) or the second part (110) through a corresponding one of the plurality of second through holes (114), T is the distance from the contact point between the outermost portion of the fastener (122) and the first part (102) or the second part (110) to the overlapping surface (118) of the corresponding one of the plurality of protrusions (116), and θ is the angle between the central axis (142) of the corresponding second through hole (114) and the outermost load vector originating from the contact point between the outermost portion of the fastener (122) and the first part (102) or the second part (110). The total surface area of ​​the overlapping surfaces (118) of the plurality of protrusions (116) does not exceed 18% of the total surface area of ​​the non-overlapping surfaces (112).

2. The component (100) of claim 1, wherein the height (H) of each of the plurality of protrusions (116) is between 0.025 inches and 0.035 inches, including an end point.

3. The component (100) according to claim 1, wherein: Each of the plurality of fasteners (122) includes a bolt (123) and a nut (128); The bolt (123) includes a head (124) and a body (126) extending from the head (124); The nut (128) engages with the body (126) of the bolt (123) to secure the first part (102) and the second part (110) together between the head (124) of the bolt (123) and the nut (128); and r is equal to the smaller of the maximum radial dimension of the outermost portion of the head (124) in contact with the first part (102) or the second part (110) or the maximum radial dimension of the outermost portion of the nut (128) in contact with the first part (102) or the second part (110).

4. The component (100) according to any one of claims 1 to 3, wherein θ is at most 25 degrees.

5. The component (100) according to any one of claims 1 to 3, further comprising at least one filler piece (140) inserted between the overlapping surfaces (118) of at least one of the base surface (120) and the plurality of protrusions (116).

6. The component (100) according to any one of claims 1 to 3, further comprising at least one filler piece (140) inserted between the overlapping surfaces (118) of at least one of the base surface (120) and the plurality of protrusions (116), wherein: The first part (102) is made of fiber-reinforced polymeric material; and The second part (110) is made of metal.

7. An aircraft (117) comprising a component (100) according to any one of claims 1 to 3.

8. A method (200) for manufacturing a component (100), the method (200) comprising: The second part (110) is transposed to the first part (102), wherein: The first part (102) includes a base surface (120) and a plurality of first through holes (132) formed in the base surface (120) and extending through the first part (102); The second part (110) is directly attached to the base surface (120) of the first part (102) and includes: The non-overlapping surface (112) facing the base surface (120); A plurality of protrusions (116) spaced apart from each other, each protrusion protruding from the non-overlapping surface (112), and each protrusion defining an overlapping surface (118) that engages with a corresponding portion of the base surface (120) of the first part (102); and A plurality of second through holes (114), each formed in the overlapping surface (118) of a corresponding one of the plurality of protrusions (116) and each coaxially aligned with a corresponding one of the plurality of first through holes (132); and The total surface area of ​​the overlapping surfaces (118) of the plurality of protrusions (116) does not exceed 18% of the total surface area of ​​the non-overlapping surfaces (112); After the second part (110) is transposed to the first part (102), the gap (G1) between the base surface (120) and the overlapping surface (118) of at least one of the plurality of protrusions (116) is measured; If the gap (G1) is greater than a predetermined threshold, at least one gap filler piece (140) is inserted into the gap (G1) between the base surface (120) and the overlapping surface (118) of at least one of the plurality of protrusions (116), and the first part (102) is fastened to the second part (110), wherein the at least one gap filler piece (140) is inserted between the base surface (120) and the overlapping surface (118) of at least one of the plurality of protrusions (116); and If the gap (G1) is less than or equal to the predetermined threshold, maintain the gapless meshing between the base surface (120) and the overlapping surface (118) of at least one of the plurality of protrusions (116). Each of the plurality of fasteners passes through a corresponding one of the plurality of first through holes (132) and a corresponding one of the plurality of second through holes (114) coaxially aligned with the corresponding one of the plurality of first through holes (132); and The width (W) of each of the plurality of protrusions (116) is equal to or greater than 2(r+Ttanθ), where r is the maximum radial dimension of the outermost portion of the fastener (122) that contacts the first part (102) or the second part (110) through the corresponding one of the plurality of second through holes (114), T is the distance from the contact point between the outermost portion of the fastener (122) and the first part (102) or the second part (110) to the overlapping surface (118) of the corresponding one of the plurality of protrusions (116), and θ is the angle between the central axis (142) of the corresponding second through hole (114) and the outermost load vector starting from the contact point between the outermost portion of the fastener (122) and the first part (102) or the second part (110).

9. The method (200) according to claim 8, wherein: The method (200) further includes not measuring a second gap between the base surface (120) and the non-overlapping surface (112) of the second part (110).

Images