Multilayer riblet applique and methods of producing the same

Patent metadata

Field	Value
Publication number	US-10946559-B2
Application number	US-201816148760-A
Country	US
Kind code	B2
Filing date	Oct 1, 2018
Priority date	Jul 8, 2016
Publication date	Mar 16, 2021
Grant date	Mar 16, 2021

Abstract

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.

First claim

What is claimed is:

1. A multilayer riblet applique comprising:
a fluorosilicone riblet structure including riblet ridges and a base from which the riblet ridges extend;
a fluorosilicone layer adjacent the base on a first side of the fluorosilicone layer; and
a support layer adjacent the fluorosilicone layer on a second side of the fluorosilicone layer opposite the first side, the support layer including:
a metal sub-layer adjacent the fluorosilicone layer,
an adhesive sub-layer, and
a first thermoplastic sub-layer and a second thermoplastic sub-layer between the metal sub-layer and the adhesive sub-layer, wherein the first thermoplastic sub-layer and the second thermoplastic sub-layer are different materials.

2. The multilayer riblet applique as defined in claim 1 , further including a masking adjacent the fluorosilicone riblet structure.

3. The multilayer riblet applique as defined in claim 2 , further including a polymer coating between the masking and the fluorosilicone riblet structure.

4. The multilayer riblet applique as defined in claim 1 , wherein the fluorosilicone layer includes a color layer.

5. The multilayer riblet applique as defined in claim 1 , wherein the fluorosilicone riblet structure includes a repeating pattern of ridges and valleys.

6. An aircraft component including the multilayer riblet applique as defined in claim 1 applied thereto.

7. An aircraft having a plurality of surfaces with the multilayer riblet applique as defined in claim 1 applied thereto.

8. The multilayer riblet applique as defined in claim 1 , wherein at least one of the first thermoplastic sub-layer or the second thermoplastic sub-layer includes at least one of polyether ether ketone (PEEK), polyether ketone ketone (PEKK), or polyether amide (PEI).

9. The multilayer riblet applique as defined in claim 1 , wherein the fluorosilicone layer and the fluorosilicone riblet structure include different materials from one another.

10. The multilayer riblet applique as defined in claim 1 , wherein the riblet ridges are spaced apart at distances in a range from 10 microns to 200 microns.

11. The multilayer riblet applique as defined in claim 1 , wherein the riblet ridges include a triangular cross-sectional profile.

12. The multilayer riblet applique as defined in claim 1 , wherein riblet ridges are transparent.

13. The multilayer riblet applique as defined in claim 1 , further including a removable liner coupled to the adhesive sub-layer.

14. An apparatus to produce a multilayered riblet applique comprising:
a first dispenser to apply a first fluorosilicone material to a web tool that is unrolled from a first roll, the first fluorosilicone material including riblet ridges and a base from which the riblet ridges extend;
a second dispenser to apply a second fluorosilicone material to the first fluorosilicone material so that a first side of the second fluorosilicone material is adjacent to the first fluorosilicone material; and
a laminating roller to couple a support layer to the second fluorosilicone material adjacent a second side of the second fluorosilicone material opposite of the first side, the support layer including a metal sub-layer adjacent the fluorosilicone layer, an adhesive sub-layer, and first and second thermoplastic sub-layers between the metal sub-layer and the adhesive sub-layer, wherein the first thermoplastic sub-layer and the second thermoplastic sub-layer are different materials.

15. The apparatus as defined in claim 14 , further including:
a first inline oven to cure the first fluorosilicone material onto the web tool via a first heating process; and
a second inline oven to cure the second fluorosilicone material onto the first fluorosilicone material via a second heating process.

16. The apparatus as defined in claim 15 , wherein at least one of the first and second ovens includes a conveyor moving therethrough to transport the multilayered riblet applique.

17. A method of producing a multilayered riblet applique, the method comprising:
coupling a fluorosilicone riblet structure to a fluorosilicone layer on a first side of the fluorosilicone layer, the fluorosilicone riblet structure including riblet ridges and a base from which the riblet ridges extend; and
coupling a support layer to the fluorosilicone layer on a second side of the fluorosilicone layer opposite the first side, the support layer including:
a metal sub-layer adjacent the fluorosilicone layer,
an adhesive sub-layer, and
first and second thermoplastic sub-layers between the metal sub-layer and the adhesive sub-layer, wherein the first thermoplastic sub-layer and the second thermoplastic sub-layer are different materials.

18. The method as defined in claim 17 , further including:
curing, via a first inline oven, the fluorosilicone riblet structure; and
curing, via a second inline oven, the fluorosilicone layer.

19. The method as defined in claim 17 , further including moving, via a conveyor, the fluorosilicone riblet structure and the fluorosilicone layer.

20. The method as defined in claim 17 , further including applying a masking to the multilayered riblet applique.

Assignees

• Boeing Co

Inventors

• Rawlings Diane C
• Keough Bruce K
• Olli Larry K
• Burg Alan G
• Kestner James M
• Granger George Michael
• Mcgarvey James Charles

Classifications

• Y02T50/10

  Drag reduction · CPC title

• B32B3/30

  characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)} · CPC title

• B32B27/285

  comprising polyethers · CPC title

• B29C41/30

  incorporating preformed parts or layers, e.g. moulding around inserts or for coating articles · CPC title

• B64C21/10

  using other surface properties, e.g. roughness · CPC title