Aerospace Adhesive Joints With Reinforcing Protrusions Against Bond Failure

Solution Overview

Problem

Aerospace component joints using adhesive bonds are prone to failure due to excessive stresses, which can be partial or complete, requiring maintenance and complicating failure detection, and traditional rivets are difficult to install and maintain, especially in confined spaces.

Innovation Solution

Aerospace component joints with bond-enhancing features such as reinforcing protrusions or adhesive-receiving recesses that integrate with the component members, enhancing the adhesive bond's strength and durability, and reducing the likelihood of failure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If rivets are installed along the edges of an aerospace adhesive bond to limit the load applied to the adhesive bond, then the joint can withstand operable stresses after adhesive bond failure, but the rivets complicate bond failure detection and are difficult to install and maintain, particularly when the adhesive bond is within a confined space

Engineering Contradiction:

Improvejoint strength after adhesive bond failureVSAvoidcomplexity of bond failure detection

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent removes rivets from the joint configuration and replaces them entirely with bond-enhancing features (recesses and protrusions) that are integrated into the adhesive bond itself. This extraction of the rivet system eliminates the complexity of detecting whether rivets are properly installed while maintaining joint strength through the adhesive-reinforced bond.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent merges the load-bearing function previously performed by separate rivets into the adhesive bond itself by integrating bond-enhancing features directly into the adhesive layer and bonding faces. The recesses and protrusions become part of the adhesive system, combining the fastening and bonding functions into a single integrated solution.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If rivets are installed along the edges of an aerospace adhesive bond to limit the load applied to the adhesive bond, then the joint can withstand operable stresses after adhesive bond failure, but the rivets are difficult to install and maintain, particularly when the adhesive bond is within a confined space

Engineering Contradiction:

Improvejoint strength after adhesive bond failureVSAvoidease of installation and maintenance

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent removes rivets from the joint configuration and replaces them entirely with bond-enhancing features (recesses and protrusions) that are integrated into the adhesive bond itself. This extraction of the rivet system eliminates the complexity of detecting whether rivets are properly installed while maintaining joint strength through the adhesive-reinforced bond.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent merges the load-bearing function previously performed by separate rivets into the adhesive bond itself by integrating bond-enhancing features directly into the adhesive layer and bonding faces. The recesses and protrusions become part of the adhesive system, combining the fastening and bonding functions into a single integrated solution.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If traditional adhesive bonds are used between aerospace parts, then the parts are held in mechanical connection, but the adhesive bond is prone to failure due to excessive stresses requiring maintenance

Engineering Contradiction:

Improvesimplicity of adhesive bondingVSAvoidadhesive bond durability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies local quality by creating specific regions within the adhesive bond (recesses in the bonding faces and corresponding protrusions in the adhesive layer) that have enhanced load-bearing capabilities. These localized features concentrate reinforcement where stresses are highest, improving overall bond durability while maintaining the simplicity of adhesive bonding elsewhere.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent creates a composite adhesive bond structure by combining the adhesive material with integrated recesses and protrusions that form a mechanically interlocked system. This composite structure combines the bonding properties of the adhesive with the mechanical strength of the geometric features, resulting in a more durable joint.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS12552515B2Aerospace component joints for aircraft and related methods

Publication Date: 2026.02.17 AURORA FLIGHT SCIENCES CORP

AI summary

The aerospace component joints comprise a first component member comprising a first bonding face, a second component member comprising a second bonding face, one or more bond-enhancing features, and an adhesive layer forming a bond between the first and second bonding faces. The one or more bond-enhancing features comprises a plurality of reinforcing protrusions integral with the first component member, projecting from the first bonding face through the adhesive layer, and into the component member and/or one or more adhesive-receiving recesses defined in the first or second bonding faces and filled by the adhesive layer. The methods of preparing a component member for an aerospace component joint comprise integrating one or more bond-enhancing features into the component member. The methods of forming the aerospace component joint comprise positioning and adhesive-bonding the first bonding face to the second bonding face, and integrating the bond-enhancing feature(s) into the aerospace component joint.