Patent Description:
The present invention concerns a chamfered bracket component for reinforcing a damaged structural element made from a composite material. The present invention also concerns a method of repairing a damaged structural element via a chamfered bracket. More specifically, the present invention concerns a method of repairing a damaged structural element in an aircraft using a chamfered, metal bracket.

In the prior art, as exemplified by <CIT>, when repairing a damaged structural element made from a composite material, it is customary to attach a metal brace or bracket to the structural element.

It is also customary to apply sealant to fill any gaps created between the metal bracket and the damaged structural element.

It is understood that, when applying sealant to fill any gaps between the metal bracket and the structural element, the sealant should be applied to minimize the creation of air bubbles.

As should be apparent to those skilled in the art, if the sealant is exposed to a high voltage, such as might be experienced as a result of a lighting strike, any gases trapped in an air bubble in the sealant might become heated to a sufficiently high temperature to cause the bubble to burst. This may result in damage to the sealant and associated components.

Where bubbles are present in sealant in an aircraft fuel tank, there is an increased risk that the bubbles might burst, damaging the fuel-tight sealing of the fuel tank or creating an unwanted ignition risk.

Other potential difficulties associated with prior art repairs also should be apparent to those skilled in the art.

Accordingly, an improved repair for improving sealing of a damaged structural element made from composite material is desired.

<CIT> describes assembly of a composite drive shaft to an annular member, via a flange. Adhesive is injected into a void defined between the annular member and the shaft and the drive shaft and annular member are bolted together.

<CIT> describes repair laminates and methods of repairing or forming various structures utilizing the repair laminates. A method of repairing a substrate comprises providing a repair laminate with a layer of pressure sensitive adhesive and a polymeric support backing. The layer of pressure sensitive adhesive is applied to the substrate to be repaired.

<CIT> describes a bracket for use in the steel frame construction.

The present invention addresses one or more of the deficiencies with respect to the prior art. Aspects of the invention are in accordance with claims <NUM> and <NUM>. Selected further features are recited in the dependent claims.

In particular, the present invention provides for a repair for a structural element made from a composite material. The repair includes a bracket defining a first surface and a second surface. The first surface is adapted for facing the structural element. A chamfer is located on a first end of the bracket. An angle is defined between a plane of the chamfer and a plane of the first surface, the first surface of the bracket being adapted to be disposed adjacent to a side of the structural element. The repair also includes a sealant material between the bracket and the structural element. The sealant material occupies a space established between the chamfer and the structural element. The sealant material forms a sealant bead adjacent to a top of the chamfer. The sealant material within the sealant bead is sufficient to fill gaps established between the chamfer and the structural element if a top portion of the bead is eroded.

It is contemplated that the bracket may define a first side, a second side, and a third side, the second side extending between the first side and the third side. If so, the chamfer is contemplated to extend between a first position on the first side and a second position on the second side.

In one contemplated embodiment, the chamfer defines a chamfer thickness as a distance measured from the first position to the second position along a line normal to the plane of the first surface. A bracket thickness is defined as a distance measured from the first side to the third side along the line normal to the plane of the first surface. The chamfer thickness is less than the bracket thickness.

Alternatively, it is contemplated that the chamfer is a first chamfer, the bracket including a second chamfer located on a second end of the bracket.

In another contemplated embodiment, a polyimide film is disposed between the bracket and the structural element.

It is contemplated that the polyimide film may be positioned between two layers of sealant material.

The bracket may be made from at least one of titanium, alloys of titanium, aluminum, alloys of aluminum, iron, alloys of iron, steel, plastics, composite materials, and ceramics.

The angle of the chamfer is contemplated to lie between about <NUM>° - <NUM>°.

The chamfer thickness is contemplated to be at least one of greater than about <NUM> inches (<NUM>), greater than about <NUM> inches (<NUM>), greater than about <NUM> inches (<NUM>), greater than about <NUM> inches (<NUM>), and greater than about <NUM> inches (<NUM>).

The ratio of the chamfer thickness to the bracket thickness is contemplated to be at least one of about <NUM>, about <NUM>-<NUM>, about <NUM>-<NUM>, or about <NUM>-<NUM>.

In another contemplated embodiment of the repair of the present invention, the repair also may include a second bracket with a construction identical to the first bracket, the second bracket being adapted to be disposed adjacent to a second side of the structural member made from the composite material.

Still further, it is contemplated that the repair may include at least one fastener adapted to connect the bracket to the structural member.

Also disclosed but not claimed is a chamfered bracket suitable for being connected to a structural element made from a composite material. The chamfered bracket is contemplated to include a first surface and a second surface, the first surface being adapted for facing the structural element and a chamfer located on a first end of the bracket. An angle is contemplated to be defined between a plane of the chamfer and a plane of the first surface, the first surface of the bracket being adapted to be disposed adjacent to a side of the structural element. The chamfer is contemplated to define a chamfer thickness as a distance measured from a first position where the chamfer intersects the first surface to a second position where the chamfer intersects an end surface along a line normal to the plane defined by the first surface. A bracket thickness is defined as a distance measured from the first surface to the second surface along the line normal to the plane defined by the first surface. The chamfer thickness is contemplated to be less than the bracket thickness.

As with the repair, the chamfered bracket is contemplated to include a second chamfer located on a second end of the bracket.

Concerning the chamfered bracket, it is contemplated that at least one layer of sealant material may be applied to the first surface, such that the sealant material occupies a space established between the chamfer and the structural element when installed.

Also concerning the chamfered bracket, a polyimide film may be positioned between two layers of the sealant material.

For the chamfered bracket, the at least one layer of sealant material may be an interfay sealant.

It is contemplated that the chamfered bracket may be made from at least one of titanium, alloys of titanium, aluminum, alloys of aluminum, iron, alloys of iron, steel, plastics, composite materials, and ceramics.

The angle of the chamfer(s) on the chamfered bracket is contemplated to lie between about <NUM>° - <NUM>°.

The chamfer thickness for the chamfered bracket is contemplated to be at least one of greater than about <NUM> inches (<NUM>), greater than about <NUM> inches (<NUM>), greater than about <NUM> inches (<NUM>), greater than about <NUM> inches (<NUM>), and greater than about <NUM> inches (<NUM>).

For the chamfered bracket, the ratio of the chamfer thickness to the bracket thickness may be at least one of about <NUM>, about <NUM>-<NUM>, about <NUM>-<NUM>, or about <NUM>-<NUM>.

The present invention also provides for a method for repairing a damaged structural element made from a composite material. The method includes providing a bracket defining a first surface and a second surface, the first surface being adapted for facing the structural element, and a chamfer located at a first end of the bracket, where an angle is defined between a plane of the chamfer and a plane of the first surface. The method includes applying a sealant material to one of the first surface of the bracket and a side surface of the structural element, and placing the bracket adjacent the side surface of the structural element such that the sealant material occupies a space established between the chamfer and the structural element, and connecting the bracket to the structural element via a mechanical fastener. The method includes forming a sealant bead adjacent to a top of the chamfer with sufficient sealant to fill gaps established between the chamfer and the structural element if a top portion of the bead is eroded and connecting the bracket to the structural element via a mechanical fastener.

It is contemplated, for the method, that the method also may include applying a film to the sealant material.

The invention may also be understood from the paragraphs that follow.

The present invention will now be described in connection with the drawings appended hereto, in which:.

The present invention will now be described in connection with one or more embodiments thereof. The discussion of the embodiments is not intended to be limiting of the present invention. To the contrary, any discussion of embodiments is intended to exemplify the breadth and scope of the present invention. As should be apparent to those skilled in the art, variations and equivalents of the embodiment(s) described herein may be employed without departing from the scope of the present invention. Those variations and equivalents are intended to be encompassed by the scope of the present patent application that is defined by the claims.

<FIG> is a graphical, side view of the construction of a traditional repair <NUM> for a structural element <NUM> made from a composite material. In the non-limiting example where the structural element <NUM> is an aircraft component, the structural element <NUM> may be a damaged stringer, frame member, spar, or other element, as should be appreciated by those skilled in the art. The structural element <NUM> may be connected to a substrate <NUM>, such as an aircraft skin for example, as illustrated in <FIG>.

In order to reinforce the damaged structural element <NUM>, the repair <NUM> includes a bracket <NUM>. In the illustrated prior art embodiment, the bracket <NUM> is made from metal and is L-shaped. As such, the bracket <NUM> includes a vertical segment <NUM> and a horizontal segment <NUM>. In the illustrated example, the bracket <NUM> is connected to the structural element <NUM> via a nut <NUM> and bolt <NUM>.

As also illustrated in <FIG>, a gap <NUM> exists between the bracket <NUM> and the structural element <NUM>. Air pockets may get trapped within the gap <NUM> between the bracket <NUM> and the structural element <NUM>. These air pockets can be dangerous during a lightning strike, since current conduction across the interface between the two parts may cause the air pockets to become super-heated and burst, which could possibly present an unwanted ignition risk within an aircraft fuel tank.

To seal the gap <NUM>, sealant <NUM> is applied. The sealant <NUM> bridges the gap <NUM> and forms a bead that extends from the top end <NUM> of the bracket <NUM> to the top end <NUM> of the structural element <NUM>.

However, due to constant sloshing of fuel within the fuel tank, the bead of sealant <NUM> can suffer from erosion and get worn down over time. As the bead of sealant <NUM> wears down, there is a risk that air pockets can form within the gap between the bracket <NUM> and the structural element <NUM>. More particularly, continued exposure to the flow of fuel within the tank across outer faces <NUM> and <NUM> of the repair and structural element will also tend to erode the sealant <NUM> applied to this interface, resulting in reduced protection of the interface with continued time in service.

To avoid this possible outcome, among others, <FIG> illustrates one aspect of the present invention. <FIG> provides an enlarged, graphical illustration of a portion of a repair <NUM> according to the present invention.

As discussed in connection with <FIG> and <FIG>, the repair <NUM> of the present invention relies upon an L-shaped bracket <NUM> with a chamfer <NUM> incorporated at the end <NUM> of the vertical segment <NUM> and a chamfer <NUM> incorporated at the end <NUM> of the horizontal segment <NUM>. In connection with the discussion of the present invention, it is noted that the terms "vertical" and "horizontal" are employed with reference to the orientation in the figures. The terms "vertical" and "horizontal" should not be understood to be limiting of the present invention.

As illustrated in <FIG>, the chamfer <NUM> extends from a first position <NUM> on a first side <NUM> of the bracket <NUM> to a second position <NUM> on a second side <NUM> of the bracket <NUM>. The second side <NUM> of the bracket <NUM> is located at the top end <NUM> of the bracket <NUM> and is, therefore, the top side of the bracket <NUM> in this embodiment. It is noted that the first side <NUM> of the bracket <NUM> is the side facing toward the structural element <NUM>. For clarity, the third side <NUM> of the bracket <NUM> is the side facing away from the structural element <NUM>.

The thickness <NUM> of the chamfer <NUM> (also referred to as the chamfer thickness <NUM>) is the distance from the first position <NUM> to the second position <NUM>, as measured along a line that is perpendicular (normal) to a plane defined by the first side <NUM>. It is noted that, for the illustrated embodiment, the first side <NUM> is contemplated to be parallel to the third side <NUM>. The second side <NUM> is contemplated to be perpendicular both to the first side <NUM> and to the third side <NUM>. It is noted that the orientations of the first side <NUM>, the second side <NUM>, and the third side <NUM> may differ from the construction illustrated without departing from the scope of the present invention.

As illustrated in <FIG>, the thickness <NUM> of the chamfer <NUM> is less than the thickness <NUM> of the bracket <NUM> (also referred to as the bracket thickness <NUM>). The bracket thickness <NUM> is measured between the first side <NUM> and the third side <NUM> also along a line perpendicular (normal) to a plane defined by the first side <NUM>. With this construction, the second position <NUM> lies on the second side <NUM>, between the first side <NUM> and the third side <NUM>. It should however be appreciated that in an alternative embodiment, the chamfer <NUM> may extend between the first side <NUM> and the third side <NUM>, such that the top end <NUM> is defined entirely by the chamfer <NUM>.

With the construction of the chamfer <NUM> described, it is contemplated that the angle <NUM> of the chamfer <NUM> will be about <NUM>°. The angle <NUM> is measured as the angle defined between a plane defined by the chamfer <NUM> and a plane defined by the first surface <NUM>. In the alternative, it is contemplated that the angle <NUM> may lie in a range between about <NUM>° ± <NUM>°, about <NUM>° ± <NUM>°, about <NUM>° ± <NUM>°, or about <NUM>° ± <NUM>° without departing from the scope of the present invention. In a further alternative, it is contemplated that the angle <NUM> may lie anywhere in a range of between <NUM>° and <NUM>° without departing from the scope of the present invention.

The thickness <NUM> is contemplated to be greater than about <NUM> inches (<NUM>). Alternatively, the thickness may be greater than about <NUM> inches (<NUM>), greater than about <NUM> inches (<NUM>), greater than about <NUM> inches (<NUM>), or greater than about <NUM> inches (<NUM>) without departing from the scope of the present invention.

The ratio of the chamfer thickness <NUM> to the bracket thickness <NUM> is contemplated to be about <NUM>. In alternative embodiments, the ratio may be between about <NUM>-<NUM>, about <NUM>-<NUM>, or about <NUM>-<NUM> without departing from the scope of the present invention. By relying on a ratio, the present invention is considered to be scalable to any thickness of the bracket <NUM> without departing from the scope of the present invention.

It is noted that the construction and dimensioning of the chamfer <NUM> at the end <NUM> is contemplated to be the same as the chamfer <NUM>. However, the angle of the chamfer <NUM> is measured as the angle defined between a plane defined by the chamfer <NUM> and a plane defined by a bottom surface of the horizontal segment <NUM>. The construction and dimensioning of the chamfers <NUM>, <NUM> may differ from one another without departing from the scope of the present invention. It is also noted that the chamfer <NUM>, like the chamfer <NUM>, also faces the structural element <NUM> or the substrate <NUM> to which the bracket <NUM> is attached, as discussed in greater detail with respect to <FIG> and <FIG>.

Reference is now made to <FIG>, which illustrates a repair <NUM> contemplated to fall within the scope of the present invention. <FIG> illustrates a repair <NUM> that includes a first bracket <NUM> and a second bracket <NUM>. The first bracket <NUM> and the second bracket <NUM> are contemplated to have the same construction as described in connection with the bracket <NUM>. Here, the first bracket <NUM> and the second bracket <NUM> are contemplated to have identical structures. However, to practice the present invention, the first bracket <NUM> and the second bracket <NUM> do not need to be identical in construction.

As illustrated, the first bracket <NUM> connects to a first side <NUM> of a structural element <NUM>. The second bracket attaches to a second side <NUM> of the structural element <NUM>. To facilitate discussion of the present invention, the construction of the repair <NUM> associated with the second bracket <NUM> is provided in exploded detail. The construction of the repair associated with the first bracket <NUM>, in contrast, is shown in the assembled condition as might appear on an aircraft.

The first and second brackets <NUM>, <NUM> are contemplated to be made from metal. Suitable metals include, but are not limited to titanium, alloys of titanium, aluminum, alloys of aluminum, iron, alloys of iron, steel, plastics, composite materials, and ceramics. In the illustrated embodiment, the first and second brackets <NUM>, <NUM> are made from titanium, which offers light weight and high strength for the repair <NUM>. The first and second brackets <NUM>, <NUM> do not need to be made from the same material to practice the present invention.

The first and second brackets <NUM>, <NUM> are L-shaped in this embodiment. While the first and second brackets <NUM>, <NUM> are illustrated as being L-shaped, the first and second brackets <NUM>, <NUM> may have any alternative shape without departing from the scope of the present invention.

There are three layers between the first and second brackets <NUM>, <NUM> and the structural element <NUM>. The first layer <NUM> comprises a first sealant, such as an interfay sealant. The second layer <NUM> is an interlayer comprising a polyimide. The third layer <NUM> comprises a second sealant, such as an interfay sealant. In the illustrated embodiment, the first and second sealants are contemplated to be the same, but this is not required to practice the present invention.

The layers of interfay sealant <NUM>, <NUM> may be any suitable sealant that helps to insulate against electricity transfer. More particularly, the layers of sealant <NUM>, <NUM> provide the dual function of preventing lightning strike from transferring into the skin of the aircraft as well as to reduce the air pockets between the brackets <NUM>, <NUM> and the structural element <NUM>. In addition, the layer of polyimide <NUM>, is included between the composite structural element <NUM> and the metallic brackets <NUM>, <NUM> in order to isolate the metal from the carbon in order to avoid corrosion. The layers of material <NUM>, <NUM>, <NUM> may be any suitable materials known in the art for at least partially achieving these functions.

While the present invention is described in connection with the first layer <NUM>, the second layer <NUM>, and the third layer <NUM>, the present invention should not be considered to be limited solely to a three layer construction. At a minimum, it is contemplated that the present invention will incorporate at least the first layer <NUM>. Alternatively, the present invention may incorporate more than three layers, as required or as desired.

The brackets <NUM>, <NUM> may be pre-fabricated to incorporate all three layers <NUM>, <NUM>, <NUM>. In this contemplated embodiment, the brackets <NUM>, <NUM> and the layers <NUM>, <NUM>, <NUM> are presented as chamfered bracket components <NUM>, a typical example of which is illustrated graphically in <FIG> in exploded detail. To effectuate the repair <NUM>, therefore, all that is necessary is for the chamfered bracket components <NUM> to be placed against the damaged structural element <NUM> to reinforce the damaged structural element <NUM>.

To construct a chamfered bracket component <NUM>, the first layer <NUM> is applied to the bracket <NUM>, <NUM>. The second layer <NUM> is then applied to the first layer <NUM>. The third layer <NUM> is then applied to the second layer <NUM>. The chamfered bracket component <NUM> may then be positioned adjacent to the damaged structural element <NUM>, as an integral component, to effectuate the repair <NUM>, for example.

Alternatively, the repair <NUM> may be assembled in situ on the aircraft by constructing the repair <NUM> directly onto the structural element <NUM>. Here, it is contemplated that the third layer <NUM> of interfay sealant will first be applied to the damaged structural element <NUM>. As noted above, the damaged structural element is contemplated to be a stringer, brace, spar, or other element made from a composite material. After the third layer <NUM> of sealant is deposited, the second layer <NUM> is placed thereon. After placement of the second layer <NUM>, the first layer <NUM> is deposited over the second layer <NUM>. The bracket <NUM>, <NUM> is then fitted onto the first layer <NUM>, in contact with the first layer <NUM>.

As necessary, the repair <NUM> may be cured by any methodology understood by those skilled in the art. In the alternative, it is contemplated that the repair <NUM> may be effectuated without curing. If curing is required, it is contemplated that the curing may require application of heat and/or a vacuum to the repair <NUM>. Where a vacuum is required, it may be necessary to position a vacuum bag over the repair <NUM>, as should be appreciated by those skilled in the art.

In the illustrated examples, the first layer <NUM> may be applied as a liquid, as a solid, as a powder, or as a film. It is contemplated that the first layer <NUM> will be applied as a liquid or as a film, but the present invention should not be considered to be limited solely to these contemplated constructions.

The second layer <NUM> is contemplated to be applied as two sheets of polyimide film, which are designated as a first film <NUM> and a second film <NUM>. As should be apparent to those skilled in the art, however, the second layer <NUM> may be applied as an integral, single layer without departing from the scope of the present invention. In addition, while the second layer <NUM> is contemplated to be a polyimide, other materials may be substituted therefor without departing from the scope of the present invention.

Like the first layer <NUM>, the third layer <NUM> may be applied as a liquid, as a solid, as a powder, or as a film, as should be apparent to those skilled in the art. It is contemplated that the third layer <NUM> will be applied as a liquid or as a film, but the present invention should not be considered to be limited solely to the contemplated constructions.

The third layer <NUM> is contemplated to differ from the first layer <NUM> in that additional sealant beads <NUM>, <NUM>, <NUM> are provided on the first layer <NUM>. The first additional sealant bead <NUM> is provided at the top end of the first layer <NUM>, adjacent to the top chamfer <NUM>. The second additional sealant bead <NUM> is provided at the corner of the structural element <NUM> where the structural element forms a T-junction (or where the structural element <NUM> and the substrate <NUM> form a T-junction). The third additional sealant bead <NUM> is provided at the bottom end of the first layer <NUM>, adjacent to the bottom chamfer <NUM>. The additional sealant beads <NUM>, <NUM> provide additional sealant material to fill the gaps established by the chamfers <NUM>, <NUM>. As should be apparent, the additional sealant bead <NUM> provides additional sealant material to fill the corners established between the vertical segment <NUM> and the horizontal segments <NUM> of the structural element <NUM>.

While not limiting of the present invention, it is contemplated that the sealant beads <NUM>, <NUM> cooperate with the chamfers <NUM>, <NUM> to establish a durable seal between the brackets <NUM>, <NUM> and the structural element <NUM>. Since the beads <NUM>, <NUM> are positioned between the chamfers <NUM>, <NUM> and the structural element, they are protected from sloshing within the fuel tank such that even if erosion of a top portion of the beads <NUM>, <NUM> should erode, there is still sufficient sealant within the chamfer to prevent air pockets from forming between the brackets <NUM>, <NUM> and the structural element <NUM>. In particular, the chamfers <NUM>, <NUM> establish spaces with gradient openings that accommodate the sealant beads <NUM>, <NUM>, providing a larger area of attachment between the brackets <NUM>, <NUM> and the structural element <NUM> and/or substrate <NUM>, and less risk of air pockets forming. As a result, there is a smaller likelihood of damage if the repair <NUM> is exposed to high voltage. Finally, the chamfers <NUM>, <NUM> establish locations where greater thicknesses of sealant are deposited by comparison with the repair <NUM>. In particular, the sealant accumulates in the spaces created by the chamfers <NUM>, <NUM>, which does not occur in the prior art repair <NUM>. As a result, there is a smaller likelihood that the sealant <NUM>, <NUM> might be removed inadvertently from the repair <NUM>, as might occur in the prior art construction. (With renewed reference to <FIG>, it is noted that the sealant <NUM> might be inadvertently removed if, for example, a maintenance person were to strike the sealant <NUM> with a tool. ) In summary, the chamfers <NUM>, <NUM> offer a number of advantages over the prior art.

In an alternative, contemplated embodiment, it is contemplated that one or more of the additional sealant beads <NUM>, <NUM>, <NUM> may be provided in connection with the third layer <NUM> without departing from the present invention.

<FIG> is a graphical side view of a second embodiment of a repair <NUM> according to the present invention. This embodiment is contemplated to be the same as the first embodiment illustrated in <FIG>. However, in this illustration, two fasteners <NUM>, <NUM> are added.

In the embodiment illustrated in <FIG>, the first fastener <NUM> comprises a first threaded member <NUM> and a first nut <NUM> that connect the vertical segments <NUM> of the brackets <NUM>, <NUM> to the vertical segment <NUM> of the structural element <NUM>. The second fastener <NUM> comprises a second threaded member <NUM> and a second nut <NUM> that connects the horizontal segment <NUM> of the bracket <NUM> to one of the horizontal segments <NUM> of the structural element <NUM> and also to the substrate <NUM>.

As should be apparent to those skilled in the art, the horizontal segment <NUM> of the second bracket <NUM> also may be bolted to the other one of the horizontal segments <NUM> of the structural element <NUM> and the substrate <NUM> without departing from the scope of the present invention.

As illustrated in <FIG>, the first threaded member <NUM> may be a bolt. The second threaded member <NUM> may be a flat-headed screw. The exact construction of the threaded member <NUM>, <NUM> is not critical to the present invention. Different threaded members <NUM>, <NUM> may be selected based on the positioning of the threaded member <NUM>, <NUM> and other variables that should be apparent to those skilled in the art. Separately, it is contemplated that any suitable fastener may be substituted for the fasteners <NUM>, <NUM> without departing from the scope of the present invention.

As also illustrated in <FIG>, it is contemplated that selected, exposed ends of the threaded members <NUM>, <NUM> may be encased in sealant <NUM>, <NUM>, <NUM>. The sealant encapsulations <NUM>, <NUM>, <NUM> are contemplated to electrically isolate the ends of the threaded members <NUM>, <NUM> from the adjacent structures, particularly the metal brackets <NUM>, <NUM>.

As discussed above, <FIG> graphically illustrates a chamfered bracket component <NUM>. While the bracket <NUM>, the first layer <NUM>, the second layer <NUM>, and the third layer <NUM> are shown as being separated from one another, elements <NUM>, <NUM>, <NUM>, <NUM> are contemplated to be adhered to one another in a pre-cured state. As may be apparent, during curing, the sealant from the layers <NUM>, <NUM> and the sealant beads <NUM>, <NUM>, <NUM> will migrate to fill any voids adjacent thereto, thereby assuring, among other things, a uniform, bubble-free connection.

Claim 1:
A repair for a structural element (<NUM>) made from a composite material, comprising:
a bracket (<NUM>) defining a first surface (<NUM>) and a second surface (<NUM>), the first surface (<NUM>) adapted for facing the structural element (<NUM>), and a chamfer (<NUM>) located on a first end (<NUM>) of the bracket (<NUM>), wherein an angle is defined between a plane of the chamfer (<NUM>) and a plane of the first surface (<NUM>) , the first surface (<NUM>) of the bracket (<NUM>) being adapted to be disposed adjacent to a side of the structural element (<NUM>); and
a sealant material between the bracket (<NUM>) and the structural element (<NUM>) , wherein the sealant material occupies a space established between the chamfer (<NUM>) and the structural element (<NUM>);
wherein the sealant material forms a sealant bead (<NUM>) adjacent to a top of the chamfer (<NUM>); and
wherein the sealant material within the sealant bead (<NUM>) is sufficient to fill gaps established between the chamfer (<NUM>) and the structural element (<NUM>) if a top portion of the bead is eroded.