Optimized sealing process

Abstract

The present application provides an optimized sealing process. A method of sealing a component assembly includes applying a first sealant bead to a first component, the first sealant bead having a first width and a first height in a cross-sectional view, where the first width is greater than the first height. The method further includes applying a second sealant bead over the first sealant bead, the second sealant bead having a second width and a second height in the cross-sectional view, thereby creating a sealant stack. The second width is equal to or less than the second height, and the second width is less than the first width. The method further includes disposing a second component over the sealant stack such that the sealant stack is positioned between the first component and the second component. Further, the method includes securing the second component to the first component, where the sealant stack is squeezed therebetween to create a liquid-tight seal via rheological flow of the first and second sealant beads.

Description

Technical Field

[0001] The present disclosure relates to an optimized liquid-tight sealing process, for example, for interfaces between adjacent components. Background Art

[0002] Sealing processes generally involve applying a sealing substance (sealant) to block the passage of fluids, dust, sound, and heat through openings in materials. Sealing of components typically forms a mechanical closure at the interface between adjacent components or substrates. Sealants can be weak or strong, flexible or rigid, temporary or permanent. Although most sealants are not adhesives technically, some sealants have adhesive or structural properties.

[0003] Sealants may have electrical isolation or conductive properties and can provide thermal and / or acoustic insulation. Sealants can also be used for simple smoothing of surface transitions or filling gaps between two or more components. Sealants often need to perform multiple such functions simultaneously. Although sealants generally do not have high strength, they can be particularly effective in waterproof components as they can keep moisture either inside or outside the components or assemblies in which they are used.

[0004] When a sealant fills the gap between components, a barrier is formed due to the physical properties of the sealant and its adhesion to adjacent components. Once applied, the sealant is intended to maintain its adhesion and its sealing performance within the necessary time frame when subjected to expected service and environmental conditions. Sealant formulations and application processes have been carefully developed to achieve the desired performance characteristics. Summary of the Invention

[0005] A method of sealing a component assembly, the method comprising providing a first component having a first outer surface. The method further comprises: applying a first bead of sealant to the first component, which in a cross-sectional view has a first width and a first height. The first width is greater than the first height. The method further comprises: applying a second bead of sealant above the first bead of sealant, which in a cross-sectional view has a second width and a second height, thereby generating a sealant stack. The second width is equal to or less than the second height, and the second width is less than the first width. The method further comprises: disposing a second component having a second outer surface above the generated sealant stack such that the sealant stack is positioned between the first outer surface and the second outer surface. Additionally, the method comprises: fastening the second component to the first component, wherein the sealant stack is squeezed therebetween. When the second component is fastened to the first component, the resulting component assembly is liquid-tightly sealed via the rheological flow of the first bead of sealant and the second bead of sealant.

[0006] The first height may be equal to or less than the second height.

[0007] The first sealant bead and the second sealant bead may be formed of a common polymeric material.

[0008] The second width may be proportional to the viscosity of the polymeric material.

[0009] Specifically, the polymeric material may be a polysulfide.

[0010] At least one of the first outer surface and the second outer surface may be characterized by an uneven profile, thereby creating an irregular gap between the first component and the second component. Then, the sealant stack may be disposed in the irregular gap, and the second sealant bead may help fill the irregular gap created by the uneven profile, thereby sealing the component assembly.

[0011] In a cross-sectional view, securing the second component to the first component may include: installing and tightening a first fastener on one side of the first sealant bead and installing and tightening a second fastener on the opposite side of the first sealant bead.

[0012] The liquid-tight seal of the component assembly may be characterized by no redundant fillets and fairing seals between the first component and the second component.

[0013] The component assembly may be part of an aircraft wing that defines a fuel reservoir.

[0014] The first component may be an aircraft wing skin or an aircraft wing spar, and the second component may be another aircraft wing component.

[0015] Also disclosed is a fay-sealed component assembly that employs the above-disclosed sealant stack extruded between the first component and the second component to seal the irregular gap therebetween.

[0016] When taken in conjunction with the accompanying drawings and the appended claims, the above features and advantages of the present disclosure, as well as other features and advantages, will become apparent from the following detailed description of the embodiments and the best mode for carrying out the disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 is a schematic perspective view of a fay-sealed component assembly according to the present disclosure, specifically depicted as part of an aircraft wing, where one of the components is shown as an aircraft wing skin and the other component is shown as an aircraft wing spar.

[0018] Figure 2 According to the present disclosure Figure 1 Schematic close-up cross-sectional elevation view of a component assembly shown in , depicting a sealant stack including two sealant beads of different sizes disposed in an interface between assembly components.

[0019] Figure 3 According to the present disclosure Figure 1 A schematic close-up cross-sectional elevation view of a component assembly shown in , depicting two rows of fasteners arranged on opposite sides of a sealant stack and compressing the sealant stack.

[0020] Figure 4 According to the present disclosure Figure 1 Schematic close-up cross-sectional side view of a component assembly shown in , depicting a sealant stack being arranged in an irregular gap between a first component and a second component due to one of the components having an unevenly contoured outer surface.

[0021] Figure 5 An example is given for a Figures 1 to 4 A flow chart of a method for sealing a component assembly is shown in FIG. DETAILED DESCRIPTION

[0022] The embodiments of the present disclosure described herein are intended to be used as examples. Other embodiments may take various alternative forms. Additionally, these drawings are generally schematic diagrams and are not necessarily drawn to scale. Some features may be exaggerated or minimized to show the details of specific components. Therefore, the specific structural and functional details disclosed herein should not be interpreted as limiting, but only as a representative basis for teaching those skilled in the art to use the present disclosure in various ways.

[0023] Certain terms that may be used in the following description are for reference only and are not intended to be limiting. For example, terms such as "above" and "below" refer to directions referenced in the accompanying drawings. Terms such as "front," "rear," "before," "after," "left," "right," "rear," "side," "upward," "downward," "top," and "bottom" describe the orientation and / or position of parts of a component or element within a consistent but arbitrary reference frame, which can be clarified by reference to the text and related drawings describing the component or element in question.

[0024] In addition, terms such as "first", "second", "third", etc. may be used to describe separate components. Such terms may include the specifically mentioned words above, their derivatives, and words with similar meanings, and are used in the description of the drawings and do not represent a limitation on the scope of the disclosure defined by the appended claims. In addition, these teachings may be described herein in terms of functional and / or logical block components and / or various processing steps. It should be recognized that such block components may include multiple hardware, software, and / or firmware components configured to perform the specified functions.

[0025] Referring to the drawings, in which like reference numerals represent like components, Figure 1 an assembly 10 having adjacent components (a first component 12 and a second component 14) is shown. The assembly 10 includes a joint or interface 10A that is hermetically sealed between the component 12 and the component 14 (as Figure 1 shown). As will be described in detail below, the hermetically sealed interface 10A may be configured as a liquid-tight seal. Generally, the first component 12 and the second component 14 are fastened and fixed to each other, for example, via appropriate fasteners (e.g., bolts, rivets, etc.), or clamped in an appropriate manner to produce a rigid assembly. Although not limited to Figure 1 the specific example shown, the component assembly 10 may be a part of an aircraft wing 16 that defines an internal fuel reservoir 18. As Figure 1 further shown in the embodiment of, the first component 12 may be an aircraft wing skin, and the second component 14 may be an aircraft wing spar (shown in a flanged configuration), and vice versa.

[0026] As Figure 2 shown, the first component 12 may be a bottom component and includes a first or top outer surface 12A. The component assembly 10 also includes a first bead of sealant 20 applied to the first component 12, specifically to the first outer surface 12A. As Figure 3 visible in the cross-sectional view shown, the first bead of sealant 20 is defined by a first width 20-1 and a first height 20-2. The size of the first width 20-1 is larger than the size of the first height 20-2. The first component 12 also includes a second bead of sealant 22 applied above or on top of the first bead of sealant 20. In Figure 3 the cross-sectional view shown, the second bead of sealant 22 is defined by a second width 22-1 and a second height 22-2. As Figure 3 shown, the second bead of sealant 22 applied above the first bead of sealant 20 creates a sealant stack 24. Before the second component 14 is fastened thereto and thereby produces the final assembly 10, the first component 12 with the sealant stack 24 disposed thereon constitutes a component sub-assembly 10' (as Figure 3 and Figure 4 shown).

[0027] Referring to Figure 3 the sealant stack 24 shown, the second width 22-1 is sized equal to or less than (i.e., not greater than) the second height 22-2. Additionally, the second width 22-1 is less than the first width 20-1. Further, the first height 20-2 may be sized equal to or less than the second height 22-2. The first sealant bead 20 and the second sealant bead 22 may be formed of a common polymeric material (e.g., polysulfide) to withstand prolonged immersion in a liquid (e.g., aircraft fuel). The size of the second width 22-1 may be proportional to the viscosity of the selected bead material. Additionally, the dimensional ratios (i.e., respective widths and heights) of the first sealant bead 20 and the second sealant bead 22 may also be selected based on the sealant viscosity. For example, a wider second width 22-1 may be selected for a sealant with a lower viscosity. The stacked sealant beads 20, 22 form a continuous seal tape around the seal interface 10A at the joint between components 12 and 14.

[0028] As shown, the second component 14 may be arranged as the top component and includes a second or bottom outer surface 14A. In the component assembly 10, the sealant stack 24 is positioned between the first outer surface 12A and the second outer surface 14A. When the second component 14 is fastened to the first component 12 (wherein the sealant stack 24 is squeezed therebetween), a liquid-tight seal 26 is created in the component assembly 10 (as Figure 1 shown). When the first component 12 and the second component 14 are fastened together, most of the sealant material remains between them. However, some of the sealant material (primarily the sealant material of the first sealant bead 20) may be extruded from the interface 10A when the joint is sealed.

[0029] Generally, the sealant material is a shear-thickening rheological fluid, i.e., the viscosity of the sealant increases with an increase in the shear strain rate. In other words, when the sealant material is loaded inside the component assembly interface, its viscosity and compressibility decrease. In the case where the sealant is trapped between adjacent components, a hydrolock situation may occur, deforming or pilling the component structure. To avoid hydrolysis and deformation of the component structure in the joint, the width 22-1 of the second sealant bead 22 is less than the width 20-1 of the first sealant bead 20, while the height 22-2 is greater than the first height 20-2. Additionally, the width 20-1 of the first sealant bead 20 is greater than its height 20-2. This relative sizing of the sealant beads 20, 22 facilitates the reliable extrusion of some of the sealant material, also accounting for gap variations (discussed in detail below), and avoids hydrolock and deformation of the component structure in the joint. Additionally, the total height of the sealant stack 24 may be greater than the maximum height of the gap in the interface 10A, allowing for reliable gap filling.

[0030] Thus, the component assembly 10 is sealed via the rheological flow of the first sealant bead 20 and the second sealant bead 22. Specifically, in the cross-sectional view shown in Figure 3 , the second component 14 can be fastened to the first component 12 via a first fastener 28 on one side (as shown on the left side) 24-1 of the sealant stack 24 and a second fastener 30 on the opposite side (as shown on the right side) 24-2 of the sealant stack. Additionally, in a side view or top view of the component assembly 10 along the longitudinal axis X (as shown in Figure 2 ), the first fastener 28 can be one of the first row 28’ of fasteners, and the second fastener 30 can be one of the second row 30’ of fasteners, which are arranged along the stacked sealant beads 20, 22 to create a liquid-tight seal 26 assembly.

[0031] As shown in Figure 4 , at least one of the first outer surface 12A and the second outer surface 14A can be characterized by having an uneven profile 32 in the cross-sectional view or along the longitudinal axis X. Such an uneven profile 32 of either the first outer surface 12A or the second outer surface 14A may create irregular or inconsistent gaps 34 between the first component 12 and the second component 14, i.e., gap variations in the interface 10A. Despite the irregular gaps 34, the liquid-tight seal 26 can be maintained via the configuration of the sealant stack 24 disposed therein, particularly due to the rheological flow of the first sealant bead 20 and the second sealant bead 22. Additionally, the liquid-tight seal 26 of the component assembly 10 can be maintained even in the absence of the usual redundant fillets and fairing seals in the art between the first component 12 and the second component 14. Thus, the component assembly 10 can be configured as an unfaired and unfilled joint seal assembly.

[0032] The size of the irregular gap 34 can be used to determine the range of the first sealant bead height 20-2 and the second sealant bead height 22-2. The nominal gap thickness can typically be borne by the first sealant bead 20, while the gap variations and surface irregularities can be borne by the second sealant bead 22. For example, the first sealant bead height 20-2 can be equal to the average gap thickness. The second sealant bead height 22-2 can be equal to the maximum possible gap thickness at any position in the joint. The ratio between the width and height of the first sealant bead 20 and the second sealant bead 22 may be related to the viscosity rheological change of the tested sealant material under load. For example, a sealant material with a lower viscosity under a specific load will allow the use of a second sealant bead 22 with a relatively higher width 22-1 compared to its height and a first sealant bead 20 with a relatively higher width 20-1 compared to its height. Additionally, in such an embodiment, the width 22-1 of the second sealant bead 22 can be closer to a 1:1 ratio with respect to the size of its height 22-2.

[0033] The sealant stack 24 can help promote the rheological flow of the first sealant bead 20 into the wider space within the irregular gap 34 and control the extrusion of the first sealant bead from the narrower space. At the same time, the second sealant bead 22 helps fill the general space along the longitudinal axis X between the first component 12 and the second component 14. For example, since the sealant stack 24 is disposed in the irregular gap 34, the first sealant bead 20 will fill most of the interface 10A. Then, the second sealant bead 22 will flow into the adjacent irregular gap and facilitate filling the irregular gap 34 generated by the uneven profile 32. Thus, when the sealant stack 24 is squeezed during the fastening process, the first sealant bead 20 and the second sealant bead 22 cooperate to seal the component assembly 10 without causing deformation of the interface components and / or the sealant water seal. Therefore, squeezing the sealant stack 24 is intended to completely seal the interface 10A and provide a reliable leak-free performance for the component assembly 10.

[0034] Figure 5 A method 100 for sealing a component assembly 10 is shown, where the component assembly 10 is, for example, an assembly that is part of an aircraft wing 16 having an aircraft wing skin and an aircraft wing spar and defining an internal fuel reservoir 18, and will be described below with reference to Figures 1 to 4 the structure shown therein. The method 100 begins at block 102, where a first component 12 is provided. After block 102, the method proceeds to block 104. In block 104, the method includes applying a first sealant bead 20 to the first component 12. As described above, in a cross-sectional view, the first sealant bead 20 has a first width 20-1 and a first height 20-2, where the magnitude of the first width is greater than the magnitude of the first height.

[0035] As described above with respect to Figures 1 to 4 The first sealant bead 20 and the second sealant bead 22 can be formed of a common polymeric material such as polysulfide. Additionally, the magnitude of the width of the second sealant bead (second width 22-1) and the dimensional ratio of the first sealant bead 20 and the second sealant bead 22 can be proportional to the viscosity of the sealant material. The method continues from block 104 to block 106. In block 106, the method includes applying a second sealant bead 22 having a second width 22-1 and a second height 22-2 in a cross-sectional view above the first sealant bead 20, thereby generating a sealant stack 24. As described above with respect to Figure 3 and Figure 4 The sealant stack 24 applied to the first component 12 generates a component sub-assembly 10'. As described above, the second width 22-1 is equal to or less than the second height 22-2 and is less than the first width 20-1.

[0036] After block 106, the method proceeds to block 108. In block 108, the method includes: disposing a second component 14 above the generated sealant stack 24 such that the sealant stack is positioned between a first outer surface 12A and a second outer surface 14A. After block 108, the method proceeds to block 110. In block 110, the method includes: fastening the second component 14 to the first component 12, wherein the sealant stack 24 is squeezed therebetween. Thus, the squeezed sealant stack 24 provides a liquid-tight seal of the component assembly 10 via the rheological flow of the first sealant bead 20 and the second sealant bead 22. In embodiments where the first outer surface 12A and / or the second outer surface 14A feature the previously described uneven profile 32, the resulting irregular gaps 34 will be reliably filled by the squeezed sealant between the first component 12 and the second component 14. As described above with respect to Figures 1 to 4 As described, fastening the second component 14 to the first component 12 may include: installing and tightening a first row 28' of fasteners on one side of the first sealant bead 20 and installing and tightening a second row 30' of fasteners on the opposite side thereof.

[0037] The method may proceed from block 110 to block 112. In block 112, the method includes: cleaning sealant material that may have extruded from the mating seal interface 10A and from various locations such as the irregular gaps 34. After block 112, the method may proceed to block 114 for completing the component assembly 10. After block 112 or 114, the method may proceed to block 116 for incorporating the component assembly 10 into a larger assembly such as an aircraft wing 16. Overall, method 100 is intended to generate a liquid-tight component assembly via two sealant beads of different proportions (i.e., the second sealant bead 22 applied above the first sealant bead 20) to generate the sealant stack 24. Such a liquid-tight interface is specifically formed via the rheological flow of the first sealant bead 20 and the sealant bead 22. The above-described liquid-tight seal interface may be particularly beneficial when constructing an aircraft wing having connected wing spars and wing skins and configured to define a fuel reservoir.

[0038] In addition, the present application includes embodiments according to the following examples:

[0039] 1. A method (100) of sealing a component assembly (10), the method comprising:

[0040] providing a first component (12) having a first outer surface (12A);

[0041] Apply a first sealant bead (20) to the first component, the first sealant bead having a first width (20-1) and a first height (20-2) in cross-section, wherein the first width is greater than the first height;

[0042] Apply a second sealant bead (22) above the first sealant bead, the second sealant bead having a second width (22-1) and a second height (22-2) in cross-section, thereby generating a sealant stack (24), wherein:

[0043] the second width is equal to or less than the second height; and

[0044] the second width is less than the first width;

[0045] Arrange a second component (14) having a second outer surface (14A) above the generated sealant stack such that the sealant stack is positioned between the first outer surface and the second outer surface; and

[0046] Fasten the second component to the first component, wherein the sealant stack is squeezed therebetween, thereby providing a liquid-tight seal of the component assembly via the rheological flow of the first and second sealant beads.

[0047] 2. The method according to Example 1, wherein the first height is equal to or less than the second height.

[0048] 3. The method according to Example 1, wherein the first sealant bead and the second sealant bead are formed of a common polymeric material.

[0049] 4. The method according to Example 3, wherein the second width is proportional to the viscosity of the polymeric material.

[0050] 5. The method according to Example 3, wherein the polymeric material is a polysulfide.

[0051] 6. The method according to Example 1, wherein:

[0052] at least one of the first outer surface and the second outer surface is characterized by an uneven profile (32), thereby generating an irregular gap (34) between the first component and the second component;

[0053] the sealant stack is arranged in the irregular gap; and

[0054] the second sealant bead helps to fill the irregular gap to seal the component assembly.

[0055] 7. The method according to Example 1, wherein fastening the second component to the first component includes: in the cross-sectional view, installing and tightening a first fastener (28) on one side of the first bead of sealant, and installing and tightening a second fastener (30) on the opposite side of the first bead of sealant.

[0056] 8. The method according to Example 1, wherein the liquid-tight seal of the component assembly is characterized by no redundant fillets and fairing seals between the first component and the second component.

[0057] 9. The method according to Example 1, wherein a portion of the aircraft wing (16) defines a fuel reservoir (18).

[0058] 10. The method according to Example 9, wherein the first component is one of an aircraft wing skin and an aircraft wing spar, and the second component is the other of the aircraft wing skin and the aircraft wing spar.

[0059] 11. A joined and sealed component assembly (10), the joined and sealed component assembly comprising:

[0060] A first component (12) having a first outer surface (12A);

[0061] A first bead of sealant (20) applied to the first component;

[0062] A second bead of sealant (22) applied above the first bead of sealant, wherein the second bead of sealant applied above the first bead of sealant forms a sealant stack (24);

[0063] A second component (14) disposed above the sealant stack, wherein the second component includes a second outer surface (14A) such that the sealant stack is positioned between the first outer surface and the second outer surface;

[0064] Wherein:

[0065] At least one of the first outer surface and the second outer surface is characterized by an uneven profile (32); and

[0066] The second component is fastened to the first component, wherein the sealant stack is squeezed therebetween, thereby liquid-tightly sealing the component assembly via the rheological flow of the first bead of sealant and the second bead of sealant.

[0067] 12. The joined and sealed component assembly according to Example 11, wherein the first sealant bead and the second sealant bead are formed of a common polymeric material.

[0068] 13. The joined and sealed component assembly according to Example 12, wherein the width (22-1) of the second sealant bead is proportional to the viscosity of the polymeric material.

[0069] 14. The joined and sealed component assembly according to Example 12, wherein the polymeric material is a polysulfide.

[0070] 15. The joined and sealed component assembly according to Example 11, wherein:

[0071] the uneven profile of at least one of the first outer surface and the second outer surface generates an irregular gap (34) between the first component and the second component;

[0072] the sealant stack is disposed in the irregular gap; and

[0073] the second sealant bead helps to fill the irregular gap to seal the component assembly.

[0074] 16. The joined and sealed component assembly according to Example 11, wherein in a cross-sectional view of the sealant stack, the second component is fastened to the first component via a first fastener (28) on one side of the first sealant bead and a second fastener (30) on the opposite side of the first sealant bead.

[0075] 17. The joined and sealed component assembly according to Example 11, wherein the liquid-tight sealed component assembly is characterized by no redundant fillets and fairing seals between the first component and the second component.

[0076] 18. The joined and sealed component assembly according to Example 11, wherein the component assembly is a part of an aircraft wing (16) that defines a fuel reservoir (18), and wherein the first component is one of an aircraft wing skin and an aircraft wing spar, and the second component is the other of the aircraft wing skin and the aircraft wing spar.

[0077] 19. A method (100) of sealing an aircraft wing (16) assembly that defines a fuel reservoir (18), the method comprising:

[0078] providing an aircraft wing skin (12) having a first outer surface (12A);

[0079] Apply a first sealant bead (20) to the aircraft wing skin, the first sealant bead having a first width (20-1) and a first height (20-2) in cross-section, wherein the first width is greater than the first height;

[0080] Apply a second sealant bead (22) above the first sealant bead, the second sealant bead having a second width (22-1) and a second height (22-2) in cross-section, thereby creating a sealant stack (24), wherein:

[0081] the second width is equal to or less than the second height; and

[0082] the second width is less than the first width;

[0083] Position an aircraft wing spar (14) having a second outer surface (14A) above the created sealant stack such that the sealant stack is positioned between the first outer surface and the second outer surface; and

[0084] Fasten the aircraft wing spar to the aircraft wing skin, wherein the sealant stack is squeezed therebetween to provide a liquid-tight seal of the aircraft wing assembly via rheological flow of the first sealant bead and the second sealant bead, wherein fastening the aircraft wing spar to the aircraft wing skin includes: in the cross-section, installing and tightening a first fastener (28) on one side of the first sealant bead and installing and tightening a second fastener (30) on the opposite side of the first sealant bead.

[0085] 20. A component sub-assembly (10'), the component sub-assembly comprising:

[0086] A first component (12), the first component having a first outer surface (12A);

[0087] A first sealant bead (20), the first sealant bead being applied to the first component, wherein in cross-section, the first sealant bead is defined by a first width (20-1) and a first height (20-2), and wherein the first width is greater than the first height;

[0088] A second sealant bead (22), the second sealant bead being applied above the first sealant bead, thereby creating a sealant stack (24), wherein:

[0089] In the cross-section, the second sealant bead is defined by a second width (22-1) and a second height (22-2);

[0090] the second width is equal to or less than the second height; and

[0091] The second width is less than the first width; and

[0092] A second component (14) arranged relative to the sealant stack and having a second outer surface (14A) and configured to be fastened to the first component in the case where the sealant stack is squeezed between the first outer surface and the second outer surface such that a liquid-tight joint seal is created between the first component and the second component via the rheological flow of the first sealant bead and the second sealant bead.

[0093] 21. The component subassembly according to example 20, wherein the first height is equal to or less than the second height.

[0094] 22. The component subassembly according to example 20, wherein the first sealant bead and the second sealant bead are formed of a common polymeric material.

[0095] 23. The component subassembly according to example 22, wherein the second width is proportional to the viscosity of the polymeric material.

[0096] 24. The component subassembly according to example 22, wherein the polymeric material is a polysulfide.

[0097] The detailed description and the drawings support and describe the present disclosure, but the scope of the present disclosure is defined only by the claims. Although some best modes and other embodiments for practicing the claimed disclosure have been described in detail, there are various alternative designs and embodiments for practicing the disclosure defined in the appended claims. Additionally, the features of the embodiments shown in the drawings or mentioned in the various embodiments of this specification are not necessarily to be understood as separate embodiments. Instead, each feature described in an example of an embodiment can be combined with one or more other desired features in other embodiments, resulting in other embodiments that cannot be described in words or with reference to the drawings. Accordingly, such other embodiments fall within the scope framework of the appended claims.

Claims

1. A method (100) of sealing a component assembly (10), the method comprising: Providing a first component (12) having a first outer surface (12A); applying a first sealant bead (20) to the first component, the first sealant bead having a first width (20-1) and a first height (20-2) in a cross-sectional view, wherein the first width is greater than the first height; A second sealant bead (22) is applied over the first sealant bead, the second sealant bead having a second width (22-1) and a second height (22-2) in a cross-sectional view, thereby creating a sealant stack (24), wherein: The second width is equal to or less than the second height; and The second width is smaller than the first width; placing a second component (14) having a second outer surface (14A) over the resulting sealant stack such that the sealant stack is positioned between the first outer surface and the second outer surface; and The second component is fastened to the first component, wherein the sealant stack is compressed therebetween, thereby providing a fluid-tight seal of the component assembly via rheological flow of the first and second sealant beads.

2. The method according to claim 1, wherein: The first height is equal to or smaller than the second height.

3. The method according to claim 1, wherein: The first sealant bead and the second sealant bead are formed of a common polymer material.

4. The method according to claim 3, wherein: The second width is proportional to the viscosity of the polymer material.

5. The method according to claim 1, wherein: At least one of the first outer surface and the second outer surface features an uneven profile (32) thereby creating an irregular gap (34) between the first component and the second component; The sealant stack is arranged in the irregular gap; and The second sealant bead helps fill the irregular gap to seal the component assembly.

6. The method according to claim 1, wherein: Fastening the second component to the first component includes installing and tightening a first fastener (28) on one side of the first sealant bead in the cross-sectional view and installing and tightening a second fastener (30) on an opposite side of the first sealant bead.

7. The method according to claim 1, wherein: The fluid-tight seal of the component assembly is characterized by an absence of redundant fillet and cowl seals between the first component and the second component.

8. A component assembly (10) for joint sealing, the component assembly for joint sealing comprising: a first component (12) having a first outer surface (12A); a first sealant bead (20) applied to the first component; a second sealant bead (22), the second sealant bead being applied over the first sealant bead, wherein the second sealant bead applied over the first sealant bead creates a sealant stack (24); a second component (14) disposed above the sealant stack, wherein the second component comprises a second outer surface (14A) such that the sealant stack is positioned between the first outer surface and the second outer surface; in: At least one of the first outer surface and the second outer surface is characterized by an uneven profile (32); and The second component is fastened to the first component, wherein the sealant stack is squeezed therebetween, thereby fluid-tightly sealing the component assembly via rheological flow of the first and second sealant beads.

9. A method (100) of sealing an aircraft wing (16) assembly defining a fuel reservoir (18), the method comprising: Providing an aircraft wing skin (12) having a first outer surface (12A); Applying a first sealant bead (20) to the aircraft wing skin, the first sealant bead having a first width (20-1) and a first height (20-2) in a cross-sectional view, wherein the first width is greater than the first height; A second sealant bead (22) is applied over the first sealant bead, the second sealant bead having a second width (22-1) and a second height (22-2) in a cross-sectional view, thereby creating a sealant stack (24), wherein: The second width is equal to or less than the second height; and The second width is smaller than the first width; placing an aircraft wing spar (14) having a second outer surface (14A) over the generated sealant stack such that the sealant stack is positioned between the first outer surface and the second outer surface; and The aircraft wing spar is fastened to the aircraft wing skin, wherein the sealant stack is squeezed therebetween to provide a liquid-tight seal of the aircraft wing assembly via rheological flow of the first sealant bead and the second sealant bead, wherein fastening the aircraft wing spar to the aircraft wing skin includes: in the cross-sectional view, installing and tightening a first fastener (28) on one side of the first sealant bead, and installing and tightening a second fastener (30) on an opposite side of the first sealant bead.

10. A component subassembly (10'), the component subassembly comprising: a first component (12) having a first outer surface (12A); a first sealant bead (20) applied to the first component, wherein, in a cross-sectional view, the first sealant bead is defined by a first width (20-1) and a first height (20-2), and wherein the first width is greater than the first height; A second sealant bead (22) is applied over the first sealant bead to create a sealant stack (24), wherein: In the cross-sectional view, the second sealant bead is defined by a second width (22-1) and a second height (22-2); The second width is equal to or less than the second height; and the second width is less than the first width; and A second component (14) is arranged relative to the sealant stack and has a second outer surface (14A), and is configured to be fastened to the first component with the sealant stack squeezed between the first outer surface and the second outer surface so that a liquid-tight joint seal is generated between the first component and the second component via rheological flow of the first sealant bead and the second sealant bead.

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