Multilayer Riblet Applique Bonding via Partial Curing
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Solution Overview
Problem
Multilayered riblets on aircraft surfaces face challenges with reliable and consistent bonding between layers, leading to potential delamination and separation under high flight loads, which affects drag reduction and durability.
Innovation Solution
The method involves partially curing a high elongation polymer, such as fluorosilicone, before applying another high elongation material, and using a support layer with a metal sub-layer, adhesive sub-layer, and thermoplastic sub-layer to enhance interlayer bonding and robustness, employing multiple curing processes to ensure effective assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multilayered riblets are adhered to aircraft surfaces using adhesive, then the riblets can provide drag reduction and aesthetic functions, but the bonding between layers may be unreliable and inconsistent under high flight loads
Solution Approach 1:
The patent applies preliminary action by partially curing the first high elongation polymer material before applying the second polymer material. This preliminary curing creates a stable base layer that improves subsequent bonding, preventing delamination under flight loads while maintaining the multilayered construction's drag reduction capabilities
Solution Approach 2:
The patent changes the curing parameter by implementing a multi-stage curing process where the first polymer is partially cured at specific temperature and time conditions before the second polymer is applied. This parameter control ensures optimal interlayer bonding without compromising the elastomeric properties needed for drag reduction
2Reliability
If multiple high elongation polymer layers are used for multilayered riblet construction, then the drag reduction and aesthetic functions are improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent merges multiple functions into a single integrated manufacturing process. The support layer with metal sub-layer, adhesive sub-layer, and thermoplastic sub-layer combines structural support, bonding, and protective functions, simplifying the overall construction while maintaining bonding consistency across multiple polymer layers
Solution Approach 2:
The patent uses composite materials by combining different polymer layers with distinct properties. The first and second high elongation polymer materials provide drag reduction, while the support layer composite provides structural stability and bonding, creating a multi-functional structure that manages complexity through material differentiation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in robust interlayer bonding, preventing delamination and separation, thereby improving the durability and aerodynamic performance of multilayer riblet constructions, reducing drag and fuel consumption.
Implementation Method 1
heating, via a first heating process, the first high elongation polymer material wherein the first heating process includes a first oven through which the web tool moves
Implementation Method 2
heating, via a first heating process, the first high elongation polymer material
Implementation Method 3
heating, via a second heating process, the second high elongation polymer material wherein the second heating process includes a second oven through which the web tool moves
Implementation Method 4
heating, via a second heating process, the second high elongation polymer material
Implementation Method 5
a support layer proximate the fluorosilicone layer, the support layer including a metal sub-layer adjacent the fluorosilicone layer, an adhesive sub-layer, and at least one thermoplastic sub-layer
Data Source
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AI summary
Multilayer riblet applique and methods of producing the same are described herein. One disclosed example method includes applying a first high elongation polymer material to a web tool, where the web tool is to be provided from a first roll, and heating, via a first heating process, the first high elongation polymer material. The disclosed example method also includes applying a second high elongation polymer material to the first high elongation polymer material, and heating, via a second heating process, the second high elongation polymer material. The disclosed example method also includes applying, via a laminating roller, a support layer to the second high elongation polymer material.