Bonding assembly having a shimmed boss and related method of fabricating the bonding assembly

Abstract

To provide a joint assembly method of an aircraft for reducing or eliminating shimming.SOLUTION: An assembly comprises a first part 102 and a second part 110. The second part 110 comprises a non-faying surface 112 facing a base surface 120, a plurality of faying surfaces 118 manifested at bosses 116, and a plurality of second through-holes 114. The bosses 116 are shimmed if required. A width of each of the bosses 116 is equal to or greater than 2(r+T tanθ), where r is a maximum radial dimension of an outermost peripheral portion of a fastener 122, the outermost peripheral portion being in contact with the first part 102 or the second part, T is the distance from the point of contact, between the outermost peripheral portion of the fastener 122 and the first part 102 or the second part 110, to a faying surface of a corresponding boss 116, and θ is an angle between a central axis of the corresponding second through-hole 114 and an outermost load vector initiating at the point of contact between the outermost peripheral portion of the fastener 122 and the first part or the second part 110.SELECTED DRAWING: Figure 5A

Description

Technical Field

[0001] The present disclosure relates generally to joining two or more components together to form an assembly, and more particularly to aircraft joining assemblies and processes for forming joining assemblies that reduce or eliminate shimming.

Background Art

[0002] A joining assembly is defined by at least two components attached together at a joint surface. Unintended gaps often form between the joint surfaces. To meet the requirements of the joint surface gaps, often the sufficiently wide gaps are narrowed. Those requirements are specific to some industries such as the aerospace industry. The wide gaps are narrowed by shimming the gaps. Shim shimming includes placing a shim in the gap. Shim shimming the gap can be time consuming, difficult, and costly. For example, in conventional assembly techniques, if the gap exceeds a predetermined threshold, all gaps between the joint surfaces must be individually measured and shimmed. Access to the gap can be difficult, and thus the measurement of the gap and the installation of the shim become complicated. Further, the components forming the conventional joining assembly often have a joint surface with a large area. This increases the time and labor required to measure the gap between the joint surfaces and to shim that gap. Therefore, it is desirable to reduce the area of the joint surface and the amount of shimming for a given joining assembly.

Summary of the Invention

[0003] The subject matter of this application provides embodiments of a joining assembly and a method of making the joining assembly that overcome the above-described disadvantages of prior art joining assemblies and joining assembly manufacturing techniques. Thus, the subject matter of this application has been developed in accordance with the current state of the art in the relevant field, and in particular in accordance with the disadvantages of conventional joining assemblies and conventional techniques for making joining assemblies.

[0004] An assembly comprising a first component and a second component is disclosed herein. The first component includes a base surface and a plurality of first through-holes formed in the base surface and extending through the first component. The second component is directly attached to the base surface of the first component. Further, the second component includes a non-bonding surface facing the base surface, a plurality of bosses, and a plurality of second through-holes. The plurality of bosses are spaced apart from each other, each boss protrudes from the non-bonding surface, and each boss defines a bonding surface that engages a corresponding portion of the base surface of the first component. Each of the plurality of second through-holes is formed within a corresponding one of the bonding surfaces of the plurality of bosses and is coaxially aligned with a corresponding one of the plurality of first through-holes. The assembly further includes a plurality of fasteners, each fastener passing through a corresponding one of the plurality of first through-holes and a corresponding one of the plurality of second through-holes, and a corresponding one of the plurality of second through-holes is coaxially aligned with a corresponding one of the plurality of first through-holes. The width of each of the plurality of bosses is 2(r + Ttanθ) or more, where r is the maximum radius dimension of the outermost peripheral portion of the fastener, the fastener passes through the corresponding second through-hole, the outermost peripheral portion contacts the first component or the second component, T is the distance from the contact point between the outermost peripheral portion of the fastener and the first component or the second component to the bonding surface of the corresponding boss, and θ is the angle between the central axis of the corresponding second through-hole and the outermost load vector starting at the contact point between the outermost peripheral portion of the fastener and the first component or the second component. The foregoing subject matter of this paragraph characterizes Example 1 of the present disclosure.

[0005] The total surface area of the bonding surfaces of the plurality of bosses is 18% or less of the total surface area of the non-bonding surface. The foregoing subject matter of this paragraph characterizes Example 2 of the present disclosure, and Example 2 also includes the subject matter according to Example 1 described above.

[0006] The total surface area of the bonding surfaces of the plurality of bosses is 7% or less of the total surface area of the non-bonding surface. The foregoing subject matter of this paragraph characterizes Example 3 of the present disclosure, and Example 3 also includes the subject matter according to Example 1 or 2 described above.

[0007] The thickness of each of the plurality of bosses is included between 0.025 inches and 0.035 inches. The foregoing subject matter of this paragraph characterizes Example 4 of the present disclosure, and Example 4 also includes the subject matter according to any one of Examples 1 to 3 described above.

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

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

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

[0011] The variable θ is at most 17 degrees. The foregoing subject matter of this paragraph characterizes Example 8 of the present disclosure, and Example 8 also includes the subject matter according to Example 7 described above.

[0012] The assembly further includes at least one shim disposed between the base surface and the joint surface of at least one of the plurality of bosses. The foregoing subject matter of this paragraph characterizes Example 9 of the present disclosure, and Example 9 also includes the subject matter according to any one of Examples 1 to 8 described above.

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

[0014] At least one shim is disposed between the base surface and the joint surfaces of two or more of the plurality of bosses. The foregoing subject matter of this paragraph characterizes Example 11 of the present disclosure, and Example 11 also includes the subject matter according to Example 9 or 10 described above.

[0015] No shim is disposed between the base surface of the first component and the non-joint surface of the second component. The foregoing subject matter of this paragraph characterizes Example 12 of the present disclosure, and Example 12 also includes the subject matter according to any one of Examples 9 to 11 described above.

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

[0017] The assembly further includes at least one shim disposed between the base surface and the joint surface of at least one of the plurality of bosses. The first component is made of a fiber-reinforced polymer material. The second component is made of a metal material. The foregoing subject matter of this paragraph characterizes Example 14 of the present disclosure, and Example 14 also includes the subject matter according to any one of Examples 1 to 13 described above.

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

[0019] An aircraft including the assembly of Example 1 is also disclosed herein. The foregoing subject matter of this paragraph characterizes Example 16 of the present disclosure.

[0020] The aircraft includes a main wing. The first component includes the outer panel of the main wing. The second component includes the internal rib of the main wing. The foregoing subject matter of this paragraph characterizes Embodiment 17 of the present disclosure, and Embodiment 17 also includes the subject matter according to the foregoing Embodiment 16.

[0021] The aircraft includes a main wing. The first component includes the outer panel of the main wing. The second component includes the external attachment of the main wing. The foregoing subject matter of this paragraph characterizes Embodiment 18 of the present disclosure, and Embodiment 18 also includes the subject matter according to the foregoing Embodiment 16.

[0022] A method of fabricating an assembly is further disclosed herein. The method indexes a second component to a first component. The second component includes a non-joint surface and a plurality of bosses. Each boss defines a joint surface that directly engages with the base surface of the first component. The method also includes measuring a gap between the base surface and at least one joint surface of the plurality of bosses after the second component is indexed to the first component. The method further includes, when the gap is greater than a predetermined threshold, disposing at least one shim between the base surface and at least one joint surface of the plurality of bosses, and fastening the first component to the second component with at least one shim disposed between the base surface and at least one joint surface of the plurality of bosses. The method further includes maintaining a shimless engagement between the base surface and at least one joint surface of the plurality of bosses when the gap is less than or equal to the predetermined threshold. The foregoing subject matter of this paragraph characterizes Embodiment 19 of the present disclosure.

[0023] The width of each of the plurality of bosses is 2(r + Ttanθ) or more, where r is the maximum radius dimension of the outermost peripheral portion of the fastener, the fastener passes through a corresponding one of the plurality of second through holes of the second component, the outermost peripheral portion contacts the first component or the second component, T is the distance from the contact point between the outermost peripheral portion of the fastener and the first component or the second component to the joint surface of the corresponding boss, and θ is the angle between the central axis of the corresponding second through hole and the outermost load vector starting at the contact point between the outermost peripheral portion of the fastener and the first component or the second component. The method further includes not measuring a second gap between the base surface and the non-joint surface of the second component. The foregoing subject matter of this paragraph characterizes Example 20 of the present disclosure, and Example 20 also includes the subject matter according to Example 19 described above.

[0024] The features, structures, advantages, and / or characteristics described of the subject matter of the present disclosure may be combined in any suitable manner in one or more embodiments including embodiments and / or implementations. To facilitate a comprehensive understanding of the embodiments of the subject matter of the present disclosure, numerous specific details are provided in the following description. Those skilled in the art will recognize that the subject matter of the present disclosure may be practiced without one or more of the specific features, details, components, materials, and / or methods of a particular example, embodiment, or implementation. In other instances, additional features and advantages recognizable in a particular example, embodiment, and / or implementation may not exist in all examples, embodiments, or implementations. Further, in some instances, well-known structures, materials, or processes are not described or illustrated in detail so as not to obscure aspects of the subject matter of the present disclosure. The features and advantages of the subject matter of the present disclosure will become more apparent from the following description and the appended claims, or will be understood by practicing the subject matter as described below.

[0025] For a better understanding of the advantages of the present subject matter, a more specific description of the subject matter outlined above is provided with reference to specific embodiments shown in the accompanying drawings. It is understood that these drawings illustrate only typical embodiments of the present subject matter and should not be considered as limiting the scope of the present subject matter. The present subject matter will be described and explained in more specific and detailed manner through the use of the drawings.

Brief Description of the Drawings

[0026]

Figure 1A

Figure 1B

Figure 2

Figure 3

Figure 4

Figure 5A

Figure 5B

Figure 5C

Figure 5D

Figure 5E

Figure 6

Figure 7

Figure 8

Figure 9

DETAILED DESCRIPTION OF THE INVENTION

[0027] As used herein, when reference is made to "one embodiment", "an embodiment", or similar language, it means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. The appearances of "one embodiment", "an embodiment", or similar language throughout this specification may all refer to the same embodiment, but they do not necessarily have to. Similarly, the term "implementation form" means an implementation form having a particular feature, structure, or characteristic described in connection with one or more embodiments of the present disclosure, but unless there is an obvious correlation indicating otherwise, the implementation form may be associated with one or more embodiments.

[0028] Disclosed herein are a bonding assembly and a method of fabricating a bonding assembly that promote reduction of cost and assembly time by reducing the area of a bonding surface (e.g., the area of a bonding surface) of one of the components of the bonding assembly. By reducing the area of the bonding surface of the bonding assembly, the measurement process for specifying the gap between the bonding surfaces that require shimming is shortened. In one embodiment, the bonding assembly and method disclosed herein improve conventional assemblies and methods by essentially replacing the shim of a single bonding surface on an engaging component with shims of a plurality of smaller bonding surfaces, with each shim corresponding to a single fastener or a selected group of fasteners. Furthermore, the amount of shimming material and the corresponding processing of the shimming material are reduced because the surface area of the bonding surface is smaller. Despite the reduction in the area of the bonding surface of the bonding assembly, the load transfer capacity of the bonding assembly is maintained.

[0029] Referring to FIGS. 1A and 1B, a joining assembly 100 according to some embodiments is shown in an exploded view. The joining assembly 100 includes a first part 102 and one or more second parts such as a second part 110A and a second part 110B. The first part 102 includes a structure 104 to which the second parts 110A and 110B are attached. As shown in FIGS. 1A and 1B, according to some embodiments, the joining assembly 100 is a part of the aircraft 117 or the wing 101 of the aircraft 117, and the structure 104 is the outer panel 103 of the aircraft 117 or the wing 101 of the aircraft 117.

[0030] In the illustrated embodiment, the second part 110A is an external attachment 113 for engine attachment or other external attachment that is attached to the outer surface of the outer panel of the aircraft or wing assembly. The external attachment is configured to assist in fixing external components such as engines, landing gear, stability and control devices, auxiliary fuel tanks, etc. to the aircraft or wing assembly. For example, referring to FIGS. 1A and 1B, the second part 110A can assist in fixing the engine 105 to the wing 101 at location 107. Typically, the external components are fixed using larger diameter shear pins. These shear pins are offset from the monocoque structure of the wing box. Therefore, for static equilibrium, a reaction force is required in addition to the reaction moment. Essentially, the shear reaction force is parallel to the middle plane of the monocoque outer panel or spar and translates directly into the middle plane of the monocoque outer panel or spar. The middle plane of the monocoque outer panel or spar has sufficient capacity to react to and dissipate the shear. Typically, the reaction moment appears as a reaction force having vector components that can be described as parallel (shear) and perpendicular (tension / compression) to the coordinate system of the local monocoque middle plane.

[0031] Furthermore, in the illustrated embodiment, the second component 110B is an internal rib 111 of the main wing 101 that is attached to the inner surfaces of the upper and lower outer panel 103 of the main wing 101 and the inner surfaces of the front spar and rear spar (not shown) of the main wing 101. The internal rib 111 extends in the chord direction across the main wing, stabilizes a closed-cell torque box, reacts to external and internal pressure loads, and helps to couple together spaced stringers that extend in the span direction along the main wing. Further, the vertical vector component from the second component 110A passes through the outer panel and is reacted by the second component 110B. The vertical vector component reacted by the internal rib 111 is transmitted to the spar via the internal rib 111. Although illustrated as external attachments 113 and internal ribs 111 of the main wing 101 or the main wing assembly, in other embodiments, the second component 110A and the second component 110B are attached to other parts of the aircraft such as a stabilizer or a fuselage. Further, although the second component 110A and the second component 110B are depicted as external attachments 113 and internal ribs 111 respectively, in other embodiments, the second component 110A and the second component 110B are any of a variety of other parts, and are attached to any of the other parts of the aircraft configured to transmit loads to the aircraft.

[0032] As shown in FIG. 2, the second component 110A includes a non-joint surface 112 and a plurality of bosses 116 protruding from the non-joint surface 112. The bosses 116 (e.g., pad-up) are spaced from each other around the non-joint surface. The distance between at least some of the bosses 116 is the same in some embodiments and different in some embodiments. In certain embodiments, the quantity of the bosses 116 and the spacing of the bosses 116 relative to each other are based on the predicted distribution of the transmitted load on the second component 110A. For example, to accommodate a non-uniform distribution of the transmitted load, the second component 110A may have more bosses 116 per unit area at locations on the second component 110A that are predicted to receive a greater transmitted load than other locations.

[0033] Each boss 116 includes a mating surface 118 defined as the maximum distal surface of the boss 116 away from the non-mating surface 112. In other words, the mating surface 118 of each boss 116 is offset from the non-mating surface 112 by a distance equal to the height (H) of the boss 116 (see, e.g., FIG. 5A). Further, the boss 116 defines a space between the non-mating surface 112 of the second component 110A and the base surface 120 of the first component 102. The mating surface 118 of each boss 116 is configured to directly engage (e.g., contact) the base surface of the first component 102. Thus, as used herein, a mating surface is a surface configured to directly engage the base surface of an engaging component, and a non-mating surface is a surface configured to be spaced from or not directly engage the surface of an engaging component. The profile of the mating surface 118 of each boss 116 corresponds to the profile of the base surface of the engaging component with which the mating surface 118 is configured to directly engage. Thus, the mating surface 118 is flat when the base surface of the engaging component is flat, and the mating surface 118 has undulations that match the undulations of the base surface when the base surface has undulations.

[0034] The outer periphery of the boss 116 defines the shape of the boss 116. In FIG. 2, the boss 116 has a circular shape. However, in other embodiments, the boss 116 has a non-circular shape such as a rectangular shape, a square shape, a triangular shape, or other polygonal shape. In the illustrated embodiment, the shape of the boss 116 is constant along the height of the boss 116. In other words, according to some embodiments, the outer peripheral wall that defines the shape of the boss 116 is perpendicular to the portion of the non-mating surface 112 of the second component 110A from which the boss 116 projects.

[0035] The second component 110A also includes a plurality of through-holes 114. Each of the through-holes 114 is formed within a corresponding mating surface 118 of the boss 116 and extends completely through the corresponding boss 116 and the non-mating surface from which the boss 116 projects. In other words, each through-hole 114 passes through a corresponding one of the bosses 116 and the portion of the second component 110A on which the corresponding boss 116 lies.

[0036] Similar to the second component 110A, the second component 110B includes a plurality of bosses 116 and a plurality of through-holes 114, as shown in FIGS. 3 and 4. The bosses 116 and through-holes 114 of the second component 110B are configured in the same manner as the bosses 116 and through-holes 114 of the second component 110A. Therefore, the description of the bosses 116 and through-holes 114 regarding the second component 110A is equally applicable to the bosses 116 and through-holes 114 of the second component 110B. However, instead of having a single continuous non-joint surface 112 like the second component 110A, the second component 110B includes a plurality of discontinuous or spaced non-joint surfaces 112. Each of the non-joint surfaces 112 or segments of the non-joint surfaces includes at least two bosses 116 protruding therefrom, and at least two through-holes 114 each passing through each of the two bosses 116.

[0037] Referring to FIG. 5A, an embodiment of the joining assembly 100 is shown. The joining assembly 100 is similar to the joining assembly 100 of FIG. 1B having similar numbers referring to similar features. For example, the joining assembly 100 of FIG. 5A includes a first component 102 and a second component 110 attached to the first component. The second component 110 includes features similar to those of the second component 110A and the second component 110B. Therefore, the features and related descriptions of the second component 110A and the second component 110B are equally applicable to the second component 110. In some embodiments, the second component 110 of FIG. 5A represents one of the second component 110A or the second component 110B.

[0038] As shown in FIG. 5A, the first component 102 of the joining assembly 100 includes a base surface 120 and a plurality of through-holes 132 formed within the base surface 120. The through-holes 132 extend completely through the first component 102 from the base surface 120 to the non-opposing surface 121 of the first component 102 on the side opposite to the base surface 120. As used herein, the non-opposing surface 121 is the surface of the first component 102 facing away from the second component 110.

[0039] The through-hole 132 of the first component 102, which can be considered as the first through-hole 132, can be aligned with the through-hole 114 of the second component 110, which can be considered as the second through-hole 114. More specifically, the central axis 142 of each first through-hole 132 can be coaxially aligned with the corresponding one of the central axes 142 of the second through-holes 114. The second through-hole 114 extends completely through the second component 110 from the non-joint surface 118 of the boss 116 to the non-opposing surface 130 of the second component 110. As used herein, the non-opposing surface 130 is the surface of the second component 110 facing away from the first component 102. The first component 102 and the second component 110 are fixed 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 the bolt 123, although other fastening configurations may also 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 joining assembly 100. Thus, each of the plurality of bolts 123 passes through a corresponding one of the plurality of coaxially aligned pairs of the first through-hole 132 and the second through-hole 114. The first through-hole 132 and the second through-hole 114 are sized to hold the bolts 123 in a nested manner. Thereby, when the bolts 123 are received within the through-holes, they remain coaxially aligned with the central axes 142 of the first through-hole 132 and the second through-hole 114.

[0040] The bolt 123 includes a head 124 and a shank 126 extending from the head 124. In some embodiments, a first through hole 132 includes a counterbore portion 134 formed in a non-opposing surface 121 of a first component 102 configured to receive the corresponding one of the bolts 123 (a countersunk head in FIG. 5A) in a nested manner. The nested engagement between the head 124 of the bolt 123 and the counterbore portion 134 of the first through hole 132 allows the head 124 to be flush with or below the non-opposing surface 121 and prevents the head 124 and thus the bolt 123 from moving in a direction toward the second component 110 along the central axis 142 of the through hole. The movement of the bolt 123 in a direction toward the first component 102 along the central axis 142 of the through hole is prevented by the engagement of a nut 128 fixed to the shank 126 of the bolt 123 with the non-opposing surface 130 of the second component 110. In some embodiments, the shank 126 has external threads and an internally threaded nut 128 is threaded onto the shank 126 to secure the nut 128 to the shank 126. Although the counterbore portion 134 is shown as part of the first through hole 132 of the first component 102 and the nut 128 is shown as engaging the non-opposing surface 130 of the second component 110, in other embodiments, the counterbore portion 134 forms part of the second through hole 114 of the second component 110 and the nut 128 engages the non-opposing surface 121 of the first component 102.

[0041] Moreover, in some embodiments, as shown in FIG. 5C, the head 124 of the bolt 123 is not a countersunk head, but rather a non-countersunk head such as a domed head, button head, or pan head. In the embodiment of FIG. 5C, the first through hole 132 is not countersunk. Thereby, the head 124 of the bolt 123 is disposed on the non-countersunk portion of the non-opposing surface 121 of the first component 102. Thus, in some embodiments, 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 corresponding non-opposing surface of one of the first component 102 or the second component 110.

[0042] The first through hole 132 is coaxially aligned with the corresponding second through hole 114, and with the bolt 123 passing through the corresponding pair of coaxially aligned first through hole 132 and second through hole 114, the nut 128 is fixed to the shank 126 of the corresponding bolt 123 and the nut 128 is tightened against the shank 126, which tightens the joint surface 118 of the boss 116 of the second component 110 against the base surface 120 of the first component 102 to form the joint assembly 100. When the joint assembly 100 is formed, the portion of the non-joint surface 112 of the base surface 120 does not contact the base surface 120 of the first component 102. In fact, in some embodiments, the non-joint surface 112 is offset from the base surface 120 by at least the height (H) of the boss 116. In some embodiments, the height (H) of the boss 116 is included between 0.025 inches and 0.035 inches. In a more specific embodiment, the maximum distance between the base surface 120 and the non-joint surface 112 is equal to the height (H) of the boss 116. Thus, in the state where the joint assembly 100 is formed, only the surface of the second component 110 that is in contact with the first component 102 is the respective joint surface 118 of the boss 116.

[0043] To show that alternative embodiments of the joining assembly 100 are possible, FIG. 5E shows an alternative embodiment of the joining assembly 100. Like the joining assembly 100 of FIG. 5A, the joining assembly 100 of FIG. 5E includes a first part 102 and a second part 110, and the second part 110 includes a boss 116. However, unlike the joining assembly 100 of FIG. 5A, the joining assembly 100 of FIG. 5E includes a further second part 110 having a boss 116 attached to the opposite side of the first part 102. In other words, the joining assembly 100 of FIG. 5E includes two second parts 110 attached to the first part 102 on both sides of the first part 102. Thus, the first part 102 is sandwiched between the two second parts 110. The fastener 122 is configured to fix both second parts 110 to the first part 102.

[0044] In certain embodiments, the total surface area of the joining surface 118 of the boss 116 is less than the total surface area of the non-joining surface(s) 112 (one or more). According to one embodiment, with particular reference to the second part 110A of FIG. 2, the joining surface 118 of the boss 116 and the non-joining surface(s) 112 (one or more) respectively account for approximately 6% and approximately 94% of the total surface area of the second part 110 facing the first part 102. Thus, in this embodiment, the total surface area of the joining surface 118 is 7% or less of the total surface area of the non-joining surface(s) 112 of the second part 110. In another embodiment, with particular reference to the second part 110B of FIGS. 3 and 4, the joining surface 118 of the boss 116 and the non-joining surface(s) 112 (one or more) respectively account for 15% and 85% of the total surface area of the second part 110 facing the first part 102. Thus, in this further embodiment, the total surface area of the joining surface 118 is 18% or less of the total surface area of the non-joining surface(s) 112 of the second part 110.

[0045] The percentage of the surface of the second component 110 that faces and directly engages the first component 102 is significantly lower (e.g., up to 94% lower) than that of conventional assemblies, particularly those used in aerospace applications. However, the smaller surface area that directly engages the first component 102, compared to conventional assemblies, does not adversely affect the ability of the joining assembly 100 to handle the transfer of loads (e.g., clamp-up compression bearing load) through the joining assembly 100, and in particular the second component 110 of the joining assembly 100. As described in more detail with reference to FIG. 5A, the load transfer between two components attached together by fasteners occurs primarily through the fasteners and the immediate surrounding structure that supports the fasteners. Thus, positioning the bosses 116 and corresponding mating surfaces 118 in the second through holes 114 enables the second component 110 to properly transfer loads (e.g., represented by arrow 191 in FIG. 5A) through the joining assembly 100 with such a large percentage (one or more) of the non-mating surfaces 112 facing the first component 102.

[0046] Referring to FIG. 5A, the volume of residence of the clamp-up compression support surface load (e.g., represented by arrow 191) between the first component 102 and the second component 110 is shown by dashed line 162 and dashed line 160. In other words, the integration of the clamp-up compression support surface load, which appears as the compression support surface between the joint surface 118 and the base surface 120, balances equally and oppositely with the pre-applied fastener tensile load. The pre-applied fastener tensile load results from the elongation of the bolt due to the torque applied to the nut. The pre-applied fastener tensile load is defined with the goal of zero gapping under specific load conditions, e.g., no gapping below the design limit load. The resulting retained clamp-up compression support surface contact load from the pre-applied fastener tensile load resulting from the torque applied to the nut on the assembled structure at the fastener location must be overcome by the load that appears to pull away from the assembled structure before the compression support surface contact between the joint surfaces disappears and the joint separates (a gap forms). All relevant assembly build load vectors from the first component 102 to the second component 110 are positioned within the frustum-shaped region 190 defined by dashed line 160 (see, e.g., FIG. 5B), and the clamp-up compression load vector from the second component 110 to the first component 102 is positioned within a frustum-shaped region (similar to frustum-shaped region 190) defined by dashed line 162. The frustum-shaped regions are coaxial or concentric with the central axis 142. Thereby, dashed line 160 and dashed line 162 extend 360 degrees around the central axis 142 of the first through-hole 132 and the second through-hole 114, respectively, defining frustum-shaped maximum transfer loads corresponding to regions of the same shape.

[0047] The transfer load from the first component 102 to the second component 110 starts at the interface between the head 124 of the bolt 123 and the first through-hole 132. Thus, the dashed line 160 extends from the outer periphery of the head 124 at an angle θ with respect to the central axis 142 of the first through-hole 132. Similarly, the transfer load from the second component 110 to the first component 102 starts at the interface between the nut 128 and the non-opposing surface 130 of the second component 110. Thus, the dashed line 162 extends from the outer periphery of the nut 128 at the non-opposing surface 130 at an angle θ with respect to the central axis 142 of the first through-hole 132. In this way, the frustum-shaped maximum transfer load region between the first component 102 and the second component 110 has a maximum span that is twice the angle θ. In one embodiment, the angle θ is at most 25 degrees. According to another embodiment, the angle θ is at most 17 degrees. According to yet another embodiment, the angle θ is at most 15 degrees.

[0048] To provide a structure sufficient to accept the range of transfer loads between the first component 102 and the second component 110 in a given fastener 122, the width (W) of the corresponding boss 116 must be at least as wide as the maximum transfer load range along the height of the boss 116. Thus, as shown in FIG. 5A, the width (W) of the boss 116 is such that all transfer loads within the maximum transfer load range (e.g., between the dashed lines 160 and between the dashed lines 162) are sufficient to pass through the boss 116. Since the maximum transfer load range can be parallel to and symmetric across the plane passing through and along the central axes 142 of the first through-hole 132 and the second through-hole 114, in some embodiments, each boss 116 is symmetric across that same plane. Further, in certain embodiments, the central axes 142 of the first through-hole 132 and the second through-hole 114 pass through the geometric center of the boss 116 corresponding to the first through-hole 132 and the second through-hole 114. Thus, in some embodiments, the boss 116 is concentric with the second through-hole 114 extending through the boss 116.

[0049] For any type of fastener 122, in some embodiments, the width (W) of each of the plurality of bosses 116 is 2(r + Ttanθ) or more. This formula is derived from the cross-sectional shape of the maximum transmission load range which is frustum-shaped as described above. In this formula, r is the maximum radius dimension of the outermost peripheral portion of the fastener 122, the fastener 122 penetrates through the corresponding second through-hole 114, the outermost peripheral portion contacts the first component 102 or the second component 110, T (for example, T1 or T2 in FIG. 5A) is the distance from the contact point between the outermost peripheral portion of the fastener 122 and the first component 102 or the second component 110 to the joint surface 118 of the corresponding boss 116, and θ is the angle between the central axis 142 of the corresponding second through-hole 114 and the outermost load vector starting at the contact point between the outermost peripheral portion of the fastener 122 and the first component 102 or the second component 110. The outermost peripheral portion of the fastener 122 that contacts the first component 102 or the second component 110 has the maximum radius dimension regardless of the cross-sectional shape of the outermost peripheral portion of the fastener 122. In other words, the term "radius dimension" does not mean or require a circular cross-section. Instead, as used herein, the radius dimension is a dimension that extends perpendicularly away from the central axis of the fastener 122.

[0050] According to a specific embodiment in which the fastener 122 includes a bolt 123 and a nut 128, the width (W) of each boss 116 is equal to or greater than the minimum of 2(r1 + T1tanθ) or 2(r2 + T2tanθ). As shown in FIG. 5A, the variable r1 is the maximum radius dimension of the head 124 of the bolt 123 of the fastener 122 that is in contact with the first component 102. As shown in FIG. 5A, the variable r2 is the maximum radius dimension of the nut 128 of the fastener 122 that is in contact with the second component 110. Thus, in a specific embodiment, the width (W) of each boss 116 is equal to or greater than 2(r + Ttanθ). Here, r is equal to the smaller of the maximum radius dimension of the outermost periphery of the head 124 that is in contact with the first component 102 or the second component 110, or the maximum radius dimension of the outermost periphery of the nut 128 that is in contact with the first component 102 or the second component 110. When the head 124 or the nut 128 has a circular cross-section, the maximum radius dimension r1 of the head 124 is the radius of the head 124 that is in contact with the first component 102, and the maximum radius dimension r2 of the nut 128 is the radius of the nut 128. In an embodiment in which one or both of the head 124 and the nut 128 have a non-circular cross-section (such as hexagonal), the maximum radius dimension r1 of the head 124 is half of the head 124 at the maximum width of the head 124, and the maximum radius dimension r2 of the nut 128 is half of the nut 128 at the maximum width of the nut 128. By applying the above formula, the corresponding width (W) of the boss 116 is large enough to capture the transmission load vectors from both the head 124 and the nut 128.

[0051] As depicted in FIG. 5A, the distance T1 is the thickness of the first component 102, and the distance T2 is the total thickness of the second component 110. The total thickness includes the distance between the non-joint surface 112 and the non-opposing surface 130 and the height H of the boss 116.

[0052] The variable 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 peripheral portion of the fastener 122 and the first component 102 or the second component 110. Thus, as shown in FIG. 5A, the variable θ is the angle θ between the central axis 142 and the corresponding one of the dashed line 160 or the dashed line 162.

[0053] Since the joint surface 118 of the joining assembly 100 is reduced as compared to a conventional assembly, the possibility of a gap requiring shimming is reduced (to zero in some cases). However, referring to FIG. 6, according to some embodiments, after the second component 110 is attached to the first component 102 as described above, a gap requiring shimming may exist between the base surface 120 of the first component 102 and the joint surface 118 of the boss 116. Such a gap is not intentionally implemented in the design of the joining assembly 100. However, due to manufacturing tolerances and other manufacturing limitations, a gap may be formed between the base surface 120 and the joint surface 118 after the joining assembly 100 is first formed. In some industries such as the automotive and aerospace industries, the gap between the joint surfaces of two components can be regulated. In such industries, the gap between the joint surfaces must not be above some predetermined maximum threshold. In the aircraft industry, the predetermined maximum threshold may be 0.005 inches. If the gap between two joint surfaces exceeds the predetermined maximum threshold, the gap needs to be closed to below the predetermined maximum threshold for implementation in an operating structure such as a transporter or an aircraft.

[0054] One way to close the gap to comply with the gap regulation is to shim the gap. Shim insertion involves placing one or more shims (e.g., thin strips of material) within the gap to effectively close the gap. Only those gaps that do not meet a predetermined maximum threshold require shimming, so the gaps are typically measured to determine whether they comply with the predetermined maximum threshold. As the number of joint surfaces to be measured increases, the time, labor, and cost for complying with the gap regulation increase. Therefore, measuring the gaps of the second component 110 for gap compliance due to a relatively low ratio of the joint surface 118 to the non-joint surface 112 of the second component 110 is less time-consuming, less labor-intensive, and less costly than conventional assemblies with a higher ratio of joint surfaces to non-joint surfaces.

[0055] As shown in FIG. 6, according to one embodiment, after the first component 102 is attached to the second component 110, there is a gap G1 between the joint surface 118 of one boss 116 and the base surface 120 of the first component 102, and a gap G2 between the joint surface 118 of another boss 116 and the base surface 120 of the first component 102. Gap G1 may be the same size as or different from gap G2. Referring to FIG. 8, after gaps G1 and G2 are detected and measured, if the gaps are greater than a predetermined maximum threshold, one or more shims 140 are placed within gap G1 and one or more shims 140 are placed within gap G2. In some embodiments, the thickness of a single shim 140 or combination of shims 140 placed within gap G1 is substantially equal to the size of gap G1. Similarly, in certain embodiments, the thickness of a single shim 140 or combination of shims 140 placed within gap G2 is substantially equal to the size of gap G2. However, it should be noted that in some embodiments, the thickness of the shim 140 or combination of shims 140 is such that any gap remaining within gap G1 or gap G2 after the shim 140 is positioned therein does not exceed the predetermined maximum threshold. In embodiments where multiple shims 140 are positioned within gap G1 or G2, the thicknesses of the shims 140 may be the same or different. As used herein, the term "substantially" means a deviation of 5% or less.

[0056] According to a particular embodiment, as shown in FIG. 7, each shim 140 is positioned only within the gap between the mating surface 118 of the boss 116 and the base surface 120 of the first component 102. In other words, in such an embodiment, no shim is disposed between the base surface 120 of the first component 102 and the non-mating surface 112 of the second component 110. This configuration helps to save the cost associated with shimming the material. However, in some embodiments, as shown in FIG. 8, a single shim 140 extends from the mating surface 118 of one boss 116 to another mating surface 118. Thus, a single shim 140 can fill the gap between two bosses 116 and the base surface 120 of the first component 102. As shown in FIG. 8, the fact that a single shim 140 extends over at least two bosses 116 also serves to hold the shim 140 in place and prevent rotation of the shim 140.

[0057] The first component 102 is made from any of a variety of materials. In a particular embodiment, the first component 102 is made from a fiber-reinforced polymer material. Here, the fibers are, for example, carbon-based fibers. In a particular embodiment, the second component 110 is made from a metallic material. This allows the bosses 116 to be formed using machining techniques. According to some embodiments, the first component 102 is made from a fiber-reinforced polymer material and the second component 110 is made from a metallic material. The shims 140 are made from any of a variety of materials. In one embodiment, the shims 140 are made from a fiber-reinforced polymer material which can be a carbon fiber-reinforced polymer material.

[0058] Referring to FIG. 9, according to some embodiments, a method 200 of fabricating the above-described joining assembly 100 includes indexing a second component 110 to a first component 102 (block 202). After the second component 110 is indexed to the first component 102 at block 202, the method 200 includes measuring a gap such as a gap G1 and / or a gap G2 between at least one joining surface 118 of the base surface 120 and the boss 116 (block 204). If the gap G1 or the gap G2 is determined to be greater than a predetermined threshold such as a predetermined maximum threshold (at block 206), the method 200 places at least one shim 140 within the gap G1 or the gap G2 between at least one joining surface 118 of the base surface 120 and the boss 116, and fastens the first component 102 to the second component 110 with at least one shim 140 within the gap G1 or the gap G2 between at least one joining surface 118 of the base surface 120 and the boss 116 (block 208). However, if the gap G1 or the gap G2 is determined to not be greater than the predetermined threshold (e.g., is less than or equal to the predetermined threshold) (at block 206), the method 200 includes maintaining a shimless engagement between the base surface 120 and at least one joining surface 118 of the plurality of bosses 116 (block 210).

[0059] In some embodiments, the method 200 further includes measuring only the gap between at least one joining surface 118 of the base surface 120 and the boss. This means that the second gap between the base surface 120 and the non-joining surface 112 is not measured. Thus, before fastening the first component 102 to the second component 110, the second gap is not measured with the shim 140 within the gap and the shim not within the second gap between the base surface 120 and the non-joining surface 112 at block 210. Omitting the measurement of the second gap is acceptable because it is unnecessary to shim the non-joining surface, saving the time, labor, and cost associated with shimming the joining assembly 100.

[0060] In certain embodiments, method 200 further includes additional steps after performing the steps associated with block 208 to block 210. In one embodiment, 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 components (e.g., first component 102 and second component 110), inserting fastener 122, applying torque (e.g., tightening) to fastener 122, pausing for a predetermined time, and reapplying torque to fastener 122.

[0061] In the above description, certain terms such as "upper", "lower", "upper part", "lower part", "horizontal", "vertical", "left", "right", "above", "below", etc. may be used. These terms are used, if necessary, to provide some clarity in the description when dealing with correlations. However, these terms are not intended to imply absolute relationships, positions, and / or orientations. For example, with respect to an object, simply reversing the up and down of this object can make the "upper" surface become the "lower" surface. Nevertheless, it is still the same object. Further, terms such as "including", "comprising", "having", and variations thereof mean "including but not limited to" unless otherwise explicitly stated. The listed items do not imply that any or all of those items exclude each other and / or include each other unless otherwise explicitly stated. Terms such as "a", "an", and "the" also represent the meaning of "one or more" unless otherwise explicitly stated. Further, the term "plurality" may be defined as "at least two".

[0062] Furthermore, as used herein, one element being "connected to" another element may include direct connection and indirect connection. Direct connection may be defined as one element being coupled to another element and having some contact with the other element. Indirect connection may be defined as a connection between two elements that are not in direct contact with each other and have one or more additional elements between the connected elements. Furthermore, fixing one element to another element may include direct fixing and indirect fixing as used herein. Furthermore, "adjacent" as used herein does not necessarily mean contact. For example, one element may be adjacent to another element without contacting it.

[0063] As used herein, the phrase "at least one of" when used with a listed item means that various combinations of one or more of the listed items may be used, or only one of each of the listed items may be required. An item may be a particular object, article, or category. That is, "at least one of" means that any combination of items or some of the items listed may be used, but not all of the listed items may be required. For example, "at least one of item A, item B, and item C" may mean, for example, "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 item A, item B, and item C" may mean, for example, but not by way of limitation, "2 item As and 1 item B and 10 item Cs", "4 item Bs and 7 item Cs", or other suitable combinations.

[0064] Unless otherwise indicated, terms such as "first," "second," etc. are used in this specification merely as labels, and are not intended to impose any sequential, positional, or ordinal requirements on the items they represent. Further, for example, when a "second" item is referred to, there is no requirement for, or exclusion of, a "first" or smaller-numbered item and / or a "third" or larger-numbered item.

[0065] As used herein, a system, apparatus, structure, article, element, component, or hardware "configured to" perform a particular function is not necessarily one that can perform the particular function without any change and is only likely to perform the particular function after further modification. In other words, a system, apparatus, structure, article, element, component, or hardware "configured to" perform a particular function is specifically selected, created, implemented, utilized, programmed, and / or designed for the purpose of performing that particular function. As used herein, the phrase "configured to" means the existing characteristics of a system, apparatus, structure, article, element, component, or hardware that enable it to perform a particular function without further modification. In this disclosure, a system, apparatus, structure, article, element, component, or hardware described as "configured to" perform a particular function may additionally or alternatively be described as "adapted to" and / or "operative to" perform that function.

[0066] The schematic flowcharts included in this specification are generally described as logical flowcharts. Accordingly, the order of description and the named steps represent one example of the presented method. Other steps and methods that are equivalent in function, logic, or effect to one or more steps or portions thereof of the presented method may be envisioned. Further, the forms and symbols used are provided to explain the logical steps of the method and are not to be construed as limiting the scope of the method. Although various types of arrows and lines may be used in the flowchart, it is understood that they do not limit the scope of the corresponding method. In fact, some arrows or other connectors may be used only to indicate the logical flow of the method. For example, an arrow may indicate a waiting time or a monitoring time of unspecified length between the enumerated steps of the described method. Further, the order in which the specific method occurs may or may not strictly follow the order of the corresponding steps shown.

[0067] Furthermore, the present disclosure includes embodiments according to the following clauses. Clause 1. A first component, comprising a base surface and a plurality of first through holes formed in the base surface and extending through the first component. A second component directly attached to the base surface of the first component, a non-bonding surface facing the base surface, a plurality of bosses spaced apart from each other, each boss protruding from the non-bonding surface and defining a bonding surface that engages a corresponding portion of the base surface of the first component, and a plurality of second through holes, each formed in the bonding surface of a corresponding one of the plurality of bosses and each coaxially aligned with a corresponding one of the plurality of first through holes, the second component comprising the plurality of second through holes, and A plurality of fasteners, each fastener penetrating through a corresponding one of the plurality of first through-holes and a corresponding one of the plurality of second through-holes that is coaxially aligned with the corresponding one of the plurality of first through-holes, comprising a plurality of fasteners, For each of the plurality of bosses, a width (W) thereof is 2(r + Ttanθ) or more, where r is a maximum radius dimension of the outermost peripheral portion of the fastener, the fastener penetrates through the corresponding one of the plurality of second through-holes, the outermost peripheral portion contacts the first component or the second component, T is a distance from a contact point between the outermost peripheral portion of the fastener and the first component or the second component to the joint surface of the corresponding one of the plurality of bosses, and θ is an angle between a central axis of the corresponding second through-hole and an outermost load vector starting at the contact point between the outermost peripheral portion of the fastener and the first component or the second component, an assembly. Clause 2. The assembly according to clause 1, wherein a total surface area of the joint surfaces of the plurality of bosses is 18% or less of a total surface area of the non-joint surfaces. Clause 3. The assembly according to clause 1 or 2, wherein a total surface area of the joint surfaces of the plurality of bosses is 7% or less of a total surface area of the non-joint surfaces. Clause 4. The assembly according to any one of clauses 1 to 3, wherein a height (H) of each of the plurality of bosses is included between 0.025 inches and 0.035 inches. Clause 5. The assembly according to clause 4, wherein a maximum distance between the base surface of the first component and the non-joint surface of the second component is equal to the height (H) of each of the plurality of bosses. Clause 6. Each of the plurality of fasteners comprises a bolt and a nut, The bolt comprises a head and a shank extending from the head, The nut engages with the shank of the bolt to fix the first component and the second component together between the head of the bolt and the nut, The assembly according to any one of clauses 1 to 5, wherein r is equal to the smaller of the maximum radius dimension of the outermost peripheral portion of the head that contacts the first component or the second component and the maximum radius dimension of the outermost peripheral portion of the nut that contacts the first component or the second component. Clause 7. The assembly according to any one of clauses 1 to 6, wherein θ is at most 25 degrees. Clause 8. The assembly according to clause 7, wherein θ is at most 17 degrees. Clause 9. The assembly according to any one of clauses 1 to 8, further comprising at least one shim disposed between the base surface and at least one of the joint surfaces of the plurality of bosses. Clause 10. The gap (G1) between the base surface and at least one of the joint surfaces of the plurality of bosses is greater than 0.005 inches. The assembly according to clause 9, wherein the thickness of the at least one shim is substantially equal to the gap (G1). Clause 11. The assembly according to clause 9 or 10, wherein at least one shim is disposed between the base surface and two or more of the joint surfaces of the plurality of bosses. Clause 12. The assembly according to any one of clauses 9 to 11, wherein no shim is disposed between the base surface of the first component and the non-joint surface of the second component. Clause 13. The assembly according 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 bosses. Clause 14. The assembly further comprises at least one shim disposed between the base surface and at least one of the joint surfaces of the plurality of bosses. The first component is made of a fiber-reinforced polymer material. The second component is made of a metallic material. The assembly according to any one of clauses 1 to 13. Clause 15. The assembly according to Clause 14, wherein the width (W) of each of the plurality of bosses is equal to 2(r + Ttanθ). Clause 16. An aircraft comprising the assembly according to any one of Clauses 1 to 15. Clause 17. The aircraft comprises a main wing, the first component comprises an outer panel of the main wing, The aircraft according to Clause 16, wherein the second component comprises an internal rib of the main wing. Clause 18. The aircraft comprises a main wing, the first component comprises an outer panel of the main wing, The aircraft according to Clause 16, wherein the second component comprises an external attachment of the main wing. Clause 19. A method of manufacturing an assembly, comprising: aligning a second component with a first component, the second component comprising a non-joint surface and a plurality of bosses, each boss defining a joint surface that directly engages a base surface of the first component; after the second component is aligned with the first component, measuring a gap (G1) between the base surface and the joint surface of at least one of the plurality of bosses; if the gap (G1) is greater than a predetermined threshold, disposing at least one shim within the gap (G1) between the base surface and the joint surface of at least one of the plurality of bosses, and fastening the first component to the second component with the at least one shim disposed between the base surface and the joint surface of at least one of the plurality of bosses; and if the gap (G1) is less than or equal to the predetermined threshold, maintaining a shimless engagement between the base surface and the joint surface of at least one of the plurality of bosses. Clause 20. The width (W) of each of the plurality of bosses is 2(r + Ttanθ) or more, where r is the maximum radius dimension of the outermost peripheral portion of the fastener, the fastener penetrates a corresponding one of the plurality of second through-holes of the second component, the outermost peripheral portion contacts the first component or the second component, T is the distance from the contact point between the outermost peripheral portion of the fastener and the first component or the second component to the joint surface of a corresponding one of the plurality of bosses, 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 starting at the contact point between the outermost peripheral portion of the fastener and the first component or the second component. The method according to clause 19, further comprising not measuring a second gap between the base surface and a non-contact surface of the second component.

[0068] The present subject matter can be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments should be construed in all respects as illustrative only and not restrictive. All modifications and changes that come within the purpose and scope of the claims and their equivalents are within the scope of the present invention.

Claims

1. A first component (102) comprising a base surface (120) and a plurality of first through-holes (132) formed in the base surface (120) and extending through the first component (102). A second component (110) directly attached to the base surface (120) of the first component (102), A non-bonding surface (112) facing the base surface (120), A plurality of bosses (116) spaced apart from each other, each boss protruding from the non-bonding surface (112), and each boss defining a bonding surface (118) that engages a corresponding portion of the base surface (120) of the first component (102), and A plurality of second through-holes (114), each formed in a corresponding one of the bonding surfaces (118) of the plurality of bosses (116) and each coaxial and aligned with a corresponding one of the plurality of first through-holes (132). A second component (110) comprising a plurality of second through-holes (114), 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) coaxial and aligned with the corresponding one of the plurality of first through-holes (132). Comprising a plurality of fasteners (122), The width (W) of each of the plurality of bosses (116) is 2(r + Ttanθ) or more, where r is the maximum radius dimension of the outermost peripheral portion of the fastener (122), the fastener (122) passes through a corresponding one of the plurality of second through-holes (114), the outermost peripheral portion contacts the first component (102) or the second component (110), T is from the contact point of the outermost peripheral portion of the fastener (122) with the first component (102) or the second component (110) to the bonding surface (118) of the corresponding one of the plurality of bosses (116). The distance, and θ is the angle between the central axis (142) of the corresponding second through-hole (114) and the outermost load vector starting at the contact point of the outermost peripheral portion of the fastener (122) with the first component (102) or the second component (110). An assembly (100) in which the total surface area of the bonding surfaces (118) of the plurality of bosses (116) is 18% or less of the total surface area of the non-bonding surface (112).

2. The assembly (100) according to claim 1, wherein the height (H) of each of the plurality of bosses (116) is included between 0.0635 centimeters and 0.0889 centimeters.

3. Each of the plurality of fasteners (122) comprises a bolt (123) and a nut (128), The bolt (123) comprises a head (124) and a shank (126) extending from the head (124), The nut (128) engages with the shank (126) of the bolt (123) to fix the first part (102) and the second part (110) together between the head (124) of the bolt (123) and the nut (128), The assembly (100) according to claim 1 or 2, wherein r is equal to the smaller of the maximum radius dimension of the outermost peripheral portion of the head (124) contacting the first part (102) or the second part (110) and the maximum radius dimension of the outermost peripheral portion of the nut (128) contacting the first part (102) or the second part (110).

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

5. The assembly (100) according to any one of claims 1 to 4, further comprising at least one shim (140) disposed between the base surface (120) and at least one of the joint surfaces (118) of the plurality of bosses (116).

6. The assembly (100) further comprises at least one shim (140) disposed between the base surface (120) and at least one of the joint surfaces (118) of the plurality of bosses (116), The first part (102) is made of a fiber-reinforced polymer material, The second part (110) is made of a metal material, and the assembly (100) according to any one of claims 1 to 5.

7. An aircraft (117) comprising the assembly (100) according to any one of claims 1 to 6.

8. A method (200) of manufacturing an assembly (100), Aligning a second component (110) with a first component (102), wherein the second component (110) comprises a non-joint surface (112) and a plurality of bosses (116), and each boss (116) defines a joint surface (118) that directly engages with the base surface (120) of the first component (102), aligning the second component (110) with the first component (102). After the second component (110) is aligned with the first component (102), measuring a gap (G1) between the base surface (120) and at least one of the joint surfaces (118) of the plurality of bosses (116). When the gap (G1) is greater than a predetermined threshold value, disposing at least one shim (140) within the gap (G1) between the base surface (120) and at least one of the joint surfaces (118) of the plurality of bosses (116), and fastening the first component (102) to the second component (110) with the at least one shim (140) disposed between the base surface (120) and at least one of the joint surfaces (118) of the plurality of bosses (116), and When the gap (G1) is less than or equal to the predetermined threshold value, maintaining a shimless engagement between the base surface (120) and at least one of the joint surfaces (118) of the plurality of bosses (116), a method (200).

9. The width (W) of each of the plurality of bosses (116) is 2(r + Ttanθ) or more, where r is the maximum radius dimension of the outermost periphery of the fastener (122), the fastener (122) passes through a corresponding one of the plurality of second through holes (114) of the second component (110), the outermost periphery contacts the first component (102) or the second component (110), T is the distance from the contact point between the outermost periphery of the fastener (122) and the first component (102) or the second component (110) to the corresponding one of the joint surfaces (118) of the plurality of bosses (116), and θ is the angle between the central axis (142) of the corresponding one of the plurality of second through holes (114) and the outermost load vector starting at the contact point between the outermost periphery of the fastener (122) and the first component (102) or the second component (110). The method (200) according to claim 8, further comprising not measuring a second gap between the base surface (120) and a non-contact surface (112) of the second component (110).

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