Patent Description:
During manufacturing of aircraft, loose debris within an aircraft structure is undesirable. Currently airplane structures are taken apart and burrs or drilling debris are removed from gaps between components after drilling. Cleaning and repositioning the components adds significant flow time and labor to the airplane build process.

Therefore, it would be desirable to have a method and apparatus that takes into account at least some of the issues discussed above, as well as other possible issues. For example, it would be desirable to have an alternative to taking apart structures and removing loose debris between the structures. <CIT> discloses an applicator for applying a fluid substance to a drilled hole as part of an automatic fastening machine. The fastener machine drills the hole in the workpiece, such as an aircraft wing panel, and then the substance applicator applies the substance to the hole, prior to subsequent installation of the fastener within the hole.

An embodiment of the present disclosure provides a method of performing one-up assembly of a structure. An injection hole is drilled through the first component and second component. Drilling debris generated between the first component and the second component during drilling of the injection hole are encapsulated by injecting a structural gap filler through the injection hole and between the first component and the second component. A hole is drilled through the injection hole and through the first component, the structural gap filler, and the second component. Clamp-up of the first component and the second component is maintained between drilling the injection hole and drilling the hole.

An embodiment of the present disclosure provides a method of performing one-up assembly of a structure. An injection hole is drilled through a first component and a second component. Drilling debris generated between the first component and the second component during drilling of the injection hole is encapsulated by injecting a structural gap filler through the injection hole and between the first component and the second component. A hole is drilled through the first component, the structural gap filler, and the second component, the hole offset from the injection hole. Clamp-up of the first component and the second component is maintained between drilling the injection hole and drilling the hole.

Yet another embodiment of the present disclosure provides a method of performing one-up assembly of a structure. An injection hole is drilled through the first component and second component. A structural gap filler is injected through the injection hole and between the first component and the second component to fill a gap between the first component and the second component. Clamp-up of the first component and the second component is maintained between drilling the injection hole and injecting the structural gap filler.

A further embodiment of the present disclosure provides a method of performing one-up assembly. A first component is positioned relative to a second component. The first component and the second component are pulled up to reduce space between the first component and the second component. An injection hole is drilled through the first component and the second component. Drilling debris generated between the first component and the second component during drilling of the injection hole are encapsulated by injecting a structural gap filler through the injection hole and between the first component and the second component. A hole is drilled through the injection hole and through the first component, the structural gap filler, and the second component. Drilling the hole through the structural gap filler reduces burr production during drilling of the hole. Clamp-up of the first component and the second component is maintained between drilling the injection hole and drilling the hole.

The illustrative examples recognize and take into account one or more different considerations. The illustrative examples recognize and take into account that currently it is desirable for two drilled surfaces in aircraft manufacturing to be pulled together less than <NUM>". The illustrative examples recognize and take into account that it is desirable to reduce the manufacturing time of components. The illustrative examples recognize and take into account that reducing manufacturing steps can also reduce manufacturing cost.

The illustrative examples recognize and take into account that composite materials include reinforcing fibers bound in resin matrix. The fibers can be unidirectional or can take the form of a woven cloth or fabric. The fibers and resins are arranged and cured or consolidated to form a composite material. The illustrative examples recognize and take into account that composite materials are not as flexible as metals without fracture.

Turning now to <FIG>, an illustration of an aircraft is depicted in accordance with an illustrative embodiment. Aircraft <NUM> has wing <NUM> and wing <NUM> attached to body <NUM>. Aircraft <NUM> includes engine <NUM> attached to wing <NUM> and engine <NUM> attached to wing <NUM>.

Body <NUM> has tail section <NUM>. Horizontal stabilizer <NUM>, horizontal stabilizer <NUM>, and vertical stabilizer <NUM> are attached to tail section <NUM> of body <NUM>.

Aircraft <NUM> is an example of an aircraft having large composite components that can be manufactured using structural gap filler and methods of use. For example, portions of body <NUM>, wing <NUM>, or wing <NUM> can be manufactured using the illustrative examples of a structural gap filler and methods of one-up assembly.

Turning now to <FIG>, an illustration of a block diagram of a manufacturing environment is depicted in which an illustrative embodiment may be implemented. Manufacturing environment <NUM> is a manufacturing environment in which structure <NUM> can be assembled using one-up assembly.

Structure <NUM> comprises first component <NUM>, second component <NUM>. When pulled up, gap <NUM> is present between first component <NUM> and second component <NUM>. Drilling through first component <NUM>, gap <NUM>, and second component <NUM> generates drilling debris.

Injection hole <NUM> is drilled through first component <NUM>, gap <NUM>, and second component <NUM> generating drilling debris <NUM> within gap <NUM>. Drilling debris <NUM> includes at least one of loose foreign object debris or burrs <NUM>.

Structural gap filler <NUM> is injected through injection hole <NUM> to fill gap <NUM>. As depicted, structural gap filler <NUM> encapsulates drilling debris <NUM> between first component <NUM> and second component <NUM>. Structural gap filler <NUM> has compressive strength <NUM> equivalent to or greater than compressive strength <NUM> of joint <NUM> between first component <NUM> and second component <NUM>.

Structural gap filler <NUM> can include at least one of a curable structural gap filler material, a hardening structural gap filler material, a resin, an epoxy, an epoxy resin, a two-part resin, an adhesive, an adhesive resin, a polymer, a polymeric material, or a curable composite material. Structural gap filler <NUM> is configured to be in a liquid or flowable state when structural gap filler <NUM> is within injector <NUM> and injected into gap <NUM>. Structural gap filler <NUM> is configured to cure, harden, solidify, and/or set into a structural material after being injected by injector <NUM>. Injector <NUM> is configured to inject any suitable type of structural gap filler <NUM>. In some illustrative examples, structural gap filler <NUM> may be referred to as a liquid shim material, or as a structural liquid shim material.

Structural gap filler <NUM> has material properties <NUM> selected to encapsulate drilling debris <NUM>. Structural gap filler <NUM> has material properties <NUM> selected to form joint <NUM>. In some illustrative examples, structural gap filler <NUM> has compressive strength <NUM> of at least <NUM> ksi. In some illustrative examples, structural gap filler <NUM> has a compressive strength <NUM> of at least <NUM> ksi.

By encapsulating drilling debris <NUM>, manufacturing steps are reduced for structure <NUM>. By encapsulating drilling debris <NUM>, drilling debris <NUM> remain within structure <NUM>. By encapsulating drilling debris <NUM>, first component <NUM> and second component <NUM> are not separated to remove drilling debris <NUM>. By encapsulating drilling debris <NUM>, clamp-up of first component <NUM> and second component <NUM> is maintained through later processing steps. Encapsulating drilling debris <NUM> eliminates cleaning steps that take apart first component <NUM> and second component <NUM>. Encapsulating drilling debris <NUM> saves manufacturing time and reduces manufacturing costs.

Structure <NUM> also comprises hole <NUM> drilled through first component <NUM>, structural gap filler <NUM>, and second component <NUM>. Although hole <NUM> is depicted as separate from injection hole <NUM>, in some illustrative examples, hole <NUM> is drilled through injection hole <NUM>. In these illustrative examples, hole <NUM> has a greater diameter than injection hole <NUM> and injection hole <NUM> is drilled out by drilling hole <NUM>. In some illustrative examples, hole <NUM> and injection hole <NUM> are concentric.

In some illustrative examples, drilling hole <NUM> removes at least a portion of the structural gap filler <NUM> and at least a portion of drilling debris <NUM> encapsulated by structural gap filler <NUM>. When drilling debris <NUM> are encapsulated by structural gap filler <NUM>, drilling debris <NUM> can be referred to as encapsulated drilling debris. In some illustrative examples, drilling hole removes burrs <NUM> of at least one of first component <NUM> or second component <NUM> formed by drilling injection hole <NUM>.

In some illustrative examples, drilling hole <NUM> comprises drilling hole <NUM> offset from injection hole <NUM>. In some of these illustrative examples, drilling hole <NUM> removes structural gap filler <NUM> and drilling debris <NUM>. In some illustrative examples, when hole <NUM> is drilled offset from injection hole <NUM>, hole <NUM> is drilled offset from a center of injection hole <NUM>. In some illustrative examples, when hole <NUM> is drilled offset from injection hole <NUM>, hole <NUM> is drilled such that hole <NUM> is not concentric with injection hole <NUM>. In some illustrative examples, when hole <NUM> is drilled offset from injection hole <NUM>, a portion of injection hole <NUM> is encompassed by hole <NUM>. In some illustrative examples, when hole <NUM> is drilled offset from injection hole <NUM>, injection hole <NUM> remains in first component <NUM> and second component <NUM>.

In some illustrative examples, structural gap filler <NUM> propels fragments <NUM> of first component <NUM> away from structural gap filler <NUM> during drilling of hole <NUM>. In some illustrative examples, structural gap filler <NUM> reduces burr production <NUM> during drilling of hole <NUM>. In some illustrative examples, structural gap filler <NUM> reduces burr production <NUM> by filling gap <NUM>.

In some illustrative examples, first component <NUM> is formed of at least one of composite <NUM> or metal <NUM>. In some illustrative examples, second component <NUM> is formed of at least one of composite <NUM> or metal <NUM>. In some illustrative examples, at least one of first component <NUM> or second component <NUM> is formed of a composite material, composite <NUM> or composite <NUM>.

In some illustrative examples, at least one of first component <NUM> or second component <NUM> comprises metal, metal <NUM> or metal <NUM>. In some illustrative examples, first component <NUM> and second component <NUM> are parts of aircraft <NUM>. In these illustrative examples, first component <NUM> and second component <NUM> are aircraft components.

Structural gap filler <NUM> is selected to be compatible with the material of first component <NUM> and second component <NUM>. Structural gap filler <NUM> is selected such that structural gap filler <NUM> does not undesirably chemically react with the material of first component <NUM> and second component <NUM>.

Structural gap filler <NUM> has material properties <NUM> configured to allow for injection by injector <NUM>. Structural gap filler <NUM> has material properties <NUM> configured to encapsulate drilling debris <NUM>. In some illustrative examples, material properties <NUM> include shrinkage <NUM> configured to continue to fill gap <NUM> after curing structural gap filler <NUM>. In some illustrative examples, material properties <NUM> include shear thinning <NUM> configured to encapsulate drilling debris <NUM>. Shear thinning <NUM> is configured to enable structural gap filler <NUM> to flow into gap <NUM> when energy, such as pressure from injection, is applied to structural gap filler <NUM>. Once injection pressure is removed from structural gap filler <NUM>, shear thinning <NUM> of structural gap filler <NUM> maintains structural gap filler <NUM> within gap <NUM>. In some illustrative examples, shear thinning <NUM> of structural gap filler <NUM> substantially stops movement of structural gap filler <NUM> such that structural gap filler <NUM> does not flow outside of gap <NUM>.

Material properties <NUM> of structural gap filler <NUM> are configured to provide encapsulation of drilling debris <NUM>. In some illustrative examples, the viscosity measurement range at room temperature (75F) can be from <NUM> Poise at <NUM> rad/s to <NUM> Poise at <NUM> rad/s. Thixotropic Index is a test for shear thinning materials. The Thixotropic Index measures the material viscosity at a slow rotation speed and divides the result by the viscosity at a higher rotation speed that is typically a factor of <NUM> higher from the slower speed rotation. For Thixotropic Indexes, higher numbers indicate a greater amount of shear thinning. In some illustrative examples, structural gap filler <NUM> can have Thixotropic Indexes of approximately <NUM> to approximately <NUM>.

In some illustrative examples, structural gap filler <NUM> has compressive strength <NUM> equal to or greater than at least one of compressive strength <NUM> of first component <NUM> or compressive strength <NUM> of second component <NUM>. Gap <NUM> is present between first surface <NUM> of first component <NUM> and second surface <NUM> and second component <NUM>. In some illustrative examples, first component <NUM> and second component <NUM> are components of fuselage <NUM> of aircraft <NUM>. In some illustrative examples, first component <NUM> and second component <NUM> are components of wing <NUM>. Structural gap filler <NUM> is configured to meet structural loading <NUM> of joint <NUM> dependent on location and functioning of joint <NUM>. Material properties <NUM> of structural gap filler <NUM> within wing <NUM> could be different than material properties of structural gap filler <NUM> within fuselage <NUM> due to different structural loading <NUM> of wing <NUM> and fuselage <NUM>. In some illustrative examples, joint <NUM> is in fuel tank <NUM> within wing <NUM>. In some illustrative examples, when joint <NUM> is in fuel tank <NUM>, structural gap filler <NUM> is configured to reduce or prevent leaks <NUM> from fuel tank <NUM>. In these illustrative examples, material properties <NUM> of structural gap filler <NUM> are also selected to reduce or prevent leaks.

In some illustrative examples, first component <NUM> comprises skin <NUM>. When first component <NUM> comprises skin <NUM>, gap <NUM> is part of inaccessible portions of structure <NUM>. In some illustrative examples, skin <NUM> is part of one of fuselage <NUM> or wing <NUM>.

In some illustrative examples, injection hole <NUM> is a pilot hole. In some illustrative examples, hole <NUM> is configured to receive fastener <NUM> to join first component <NUM> and second component <NUM>.

In some illustrative examples, gap <NUM> is identified using inspector <NUM>. In some illustrative examples, inspector <NUM> comprises camera <NUM>. Camera <NUM> can be inserted into injection hole <NUM> to detect gap <NUM>. In some illustrative examples, inspector <NUM> comprises ultrasonic inspector <NUM>. In some illustrative examples, gap <NUM> is detected using ultrasonic inspector <NUM>.

The illustration of manufacturing environment <NUM> in <FIG> is not meant to imply physical or architectural limitations to the manner in which an illustrative embodiment may be implemented. Other components in addition to or in place of the ones illustrated may be used. Some components may be unnecessary. Also, the blocks are presented to illustrate some functional components. One or more of these blocks may be combined, divided, or combined and divided into different blocks when implemented in an illustrative embodiment.

For example, although only one injection hole <NUM> is depicted, any desirable quantity of injection holes can be drilled into first component <NUM> and second component <NUM>. In some illustrative examples, multiple injection holes can be drilled through first component <NUM>, gap <NUM>, and second component <NUM>. In some of these illustrative examples, structural gap filler <NUM> is injected through multiple injection holes into gap <NUM>.

Turning now to <FIG> is an illustration of a cross-sectional view of a structure with structural gap filler is depicted in accordance with an illustrative embodiment. Structure <NUM> is a physical implementation of structure <NUM> of <FIG>. Structure <NUM> comprises first component <NUM> and second component <NUM> joined together by fasteners <NUM>. First component <NUM> is a physical implementation of first component <NUM> of <FIG>. Second component <NUM> is a physical implementation of second component <NUM> of <FIG>. As depicted, fasteners <NUM> comprise fastener <NUM>, fastener <NUM>, fastener <NUM>, and fastener <NUM>. Fasteners <NUM> extend through holes <NUM> including hole <NUM>, hole <NUM>, hole <NUM>, and hole <NUM>.

Injection hole <NUM> and injection hole <NUM> were drilled through first component <NUM> and second component <NUM>. Prior to drilling injection hole <NUM> and injection hole <NUM>, first component <NUM> and second component <NUM> were pulled up for performing manufacturing processes. As can be seen in view <NUM>, after clamping up first component <NUM> and second component <NUM>, gap <NUM> and gap <NUM> were present between first component <NUM> and second component <NUM>.

Gap <NUM> and gap <NUM> are outside of manufacturing tolerances. In some illustrative examples, gaps greater than <NUM>" are outside of manufacturing tolerances. Structural gap filler <NUM> is present in gap <NUM> to bring gap <NUM> within tolerance. Structural gap filler <NUM> is present in gap <NUM> to bring gap <NUM> within tolerance.

In view <NUM>, structural gap filler <NUM> in gap <NUM> and structural gap filler <NUM> in gap <NUM> are visible. Structural gap filler <NUM> encapsulates drilling debris (not visible) from drilling injection hole <NUM>. Structural gap filler <NUM> is injected through injection hole <NUM> prior to drilling hole <NUM> and hole <NUM>. Hole <NUM> and hole <NUM> are drilled through first component <NUM>, structural gap filler <NUM>, and second component <NUM>.

In some illustrative examples, structural gap filler <NUM> reduces burr production during drilling of hole <NUM> and hole <NUM>. In some illustrative examples, structural gap filler <NUM> propels fragments of first component <NUM> away from structural gap filler <NUM> during drilling of hole <NUM> and hole <NUM>.

Structural gap filler <NUM> encapsulates drilling debris (not visible) from drilling injection hole <NUM>. Structural gap filler <NUM> is injected through injection hole <NUM> prior to drilling hole <NUM> and hole <NUM>. In some illustrative examples, structural gap filler <NUM> reduces burr production during drilling of hole <NUM> and hole <NUM>. In some illustrative examples, structural gap filler <NUM> propels fragments of first component <NUM> away from structural gap filler <NUM> during drilling of hole <NUM> and hole <NUM>.

In some illustrative examples, structural gap filler <NUM> and structural gap filler <NUM> are the same material. In some illustrative examples, structural gap filler <NUM> and structural gap filler <NUM> are different materials. Structural gap filler <NUM> and structural gap filler <NUM> are present in joint <NUM> between first component <NUM> and second component <NUM>.

Structural gap filler <NUM> and structural gap filler <NUM> each have a compressive strength equivalent to or greater than a compressive strength of joint <NUM> between first component <NUM> and second component <NUM>. Structural gap filler <NUM> and structural gap filler <NUM> have material properties configured to provide encapsulation of the drilling debris. For example, structural gap filler <NUM> and structural gap filler <NUM> have shear thinning and fixotropic characteristics configured to encapsulate the drilling debris (not depicted).

Turning now to <FIG>, an illustration of a top view of a structure with structural gap filler is depicted in accordance with an illustrative embodiment. In view <NUM>, extents of structural gap filler <NUM> and structural gap filler <NUM> are illustrated. In view <NUM> hole <NUM> and hole <NUM> extend through structural gap filler <NUM>. In view <NUM> hole <NUM> and hole <NUM> extend through structural gap filler <NUM>. Structural gap filler <NUM> and structural gap filler <NUM> reduce gap <NUM> and gap <NUM> respectively to within tolerance.

In some illustrative examples, at least one of hole <NUM>, hole <NUM>, hole <NUM>, or hole <NUM> can extend through first component <NUM> and second component <NUM> (not visible) without a structural gap filler. When a gap is not present, a hole can be drilled through first component <NUM> and second component <NUM> without a structural gap filler. When a gap between first component <NUM> and second component <NUM> is within tolerance, a hole can be drilled through first component <NUM> and second component <NUM> without a structural gap filler. Any combination of holes with and without structural gap filler can be present in structure <NUM>.

Turning now to <FIG>, an illustration of a cross-sectional view of a structure with a gap in accordance with an illustrative embodiment. Structure <NUM> is a physical implementation of structure <NUM> of <FIG>. Structure <NUM> comprises first component <NUM> and second component <NUM> pulled up to receive drilling operations. First component <NUM> is a physical implementation of first component <NUM> of <FIG>. Second component <NUM> is a physical implementation of second component <NUM> of <FIG>. Gap <NUM> is present between first component <NUM> and second component <NUM>. Gap <NUM> is an out of tolerance gap. Due to presence of gap <NUM>, drilling debris will be generated between first component <NUM> and second component <NUM> during drilling.

Turning now to <FIG>, an illustration of a cross-sectional view of a structure with a gap is depicted in accordance with an illustrative embodiment. In view <NUM> injection hole <NUM> has been drilled through first component <NUM> and second component <NUM>. In drilling injection hole <NUM>, drilling debris <NUM> were generated within gap <NUM>. Drilling debris <NUM> includes at least one of loose foreign object debris or burrs.

Turning now to <FIG>, an illustration of a cross-sectional view of a structure with a filled gap is depicted in accordance with an illustrative embodiment. In view <NUM> structural gap filler <NUM> has been injected into injection hole <NUM>. Structural gap filler <NUM> fills gap <NUM>. Structural gap filler <NUM> encapsulates drilling debris <NUM> between first component <NUM> and second component <NUM>. Drilling debris <NUM> encapsulated by structural gap filler <NUM> can be referred to as encapsulated drilling debris <NUM>. By encapsulating drilling debris <NUM>, structural gap filler <NUM> can reduce the number of cleaning or debris removal steps. By encapsulating drilling debris <NUM> in structural gap filler <NUM>, drilling debris <NUM> do not undesirably affect first component <NUM> or second component <NUM>. Use of structural gap filler <NUM> to encapsulate drilling debris <NUM> can reduce at least one of manufacturing time or manufacturing cost. By encapsulating drilling debris <NUM>, clamp-up of first component <NUM> and the second component <NUM> is maintained between drilling injection hole <NUM> and subsequent steps. In some illustrative examples, by encapsulating drilling debris <NUM>, taking apart first component <NUM> and second component <NUM> and cleaning out burrs or drilling debris is eliminated.

Turning now to <FIG>, an illustration of a cross-sectional view of a structure with a filled gap is depicted in accordance with an illustrative embodiment. In view <NUM> hole <NUM> has been drilled through first component <NUM>, structural gap filler <NUM>, and second component <NUM>. In this illustrative example, hole <NUM> has been drilled through injection hole <NUM> of <FIG>.

In some illustrative examples, structural gap filler <NUM> reduces burr production during drilling of hole <NUM>. In some illustrative examples, structural gap filler <NUM> propels fragments of first component <NUM> away from structural gap filler <NUM> during drilling of hole <NUM>.

In some illustrative examples, drilling hole <NUM> removes at least a portion of structural gap filler <NUM> and at least a portion of encapsulated drilling debris <NUM>. In some illustrative examples, drilling hole <NUM> removes burrs on at least one of first component <NUM> or second component <NUM> from drilling hole <NUM>.

Turning now to <FIG>, an illustration of a cross-sectional view of a structure with a filled gap is depicted in accordance with an illustrative embodiment. In view <NUM> hole <NUM> has been drilled through first component <NUM>, structural gap filler <NUM>, and second component <NUM>. In this illustrative example, hole <NUM> has been drilled offset from injection hole <NUM>. Hole <NUM> and hole <NUM> of <FIG> are two implementations for placement of hole <NUM> of <FIG>.

In some illustrative examples, structural gap filler <NUM> reduces burr production during drilling of hole <NUM>. In some illustrative examples, structural gap filler <NUM> propels fragments of first component <NUM> away from structural gap filler <NUM> during drilling of hole <NUM>. In some illustrative examples, drilling hole <NUM> removes at least a portion of structural gap filler <NUM> and at least a portion of encapsulated drilling debris <NUM>.

Turning now to <FIG>, a flowchart of a method of performing one-up assembly of a structure is depicted in accordance with an illustrative embodiment. Method <NUM> can be performed to form a structure of aircraft <NUM> of <FIG>. Method <NUM> can be performed to form structure <NUM> of <FIG>. Method <NUM> can be performed to form structure <NUM> of <FIG>. Method <NUM> can be performed in forming structure <NUM> of <FIG>.

Method <NUM> drills an injection hole through the first component and second component (operation <NUM>). Method <NUM> encapsulates drilling debris generated between the first component and the second component during drilling of the injection hole by injecting a structural gap filler through the injection hole and between the first component and the second component to form encapsulated drilling debris (operation <NUM>). Method <NUM> drills a hole through the injection hole and through the first component, the structural gap filler, and the second component (operation <NUM>). In some illustrative examples, the hole is drilled concentric through the injection hole. In some other illustrative examples, the hole is drilled through the injection hole but not concentric with the injection hole. When the hole is drilled through the injection hole, the hole occupies the space previously including the injection hole. When the hole is drilled through the injection hole, the hole encompasses the injection hole. Method <NUM> maintains clamp-up of the first component and the second component between drilling the injection hole and drilling the hole (operation <NUM>). Afterwards, method <NUM> terminates.

In some illustrative examples, drilling the hole removes at least a portion of the structural gap filler and at least a portion of the encapsulated drilling debris (operation <NUM>). In some illustrative examples, the at least a portion of the encapsulated drilling debris includes burrs.

In some illustrative examples, method <NUM> cures the structural gap filler prior to drilling the hole (operation <NUM>). The structural gap filler can be cured through any desirable method. In some illustrative examples, the structural gap filler is heat cured. In some illustrative examples, the structural gap filler is cured by applying heat to the structural gap filler. In some illustrative examples, the structural gap filler is cured by leaving the structural gap filler at ambient temperature for a set period of time.

In some illustrative examples, drilling the hole through the structural gap filler propels fragments of the first component away from the structural gap filler (operation <NUM>). In some illustrative examples, drilling the hole through the structural gap filler reduces burr production during drilling of the hole (operation <NUM>).

In some illustrative examples, method <NUM> positions the first component relative to the second component (operation <NUM>) and clamps up the first component and second component prior to drilling the injection hole (operation <NUM>).

Method <NUM> drills an injection hole through a first component and a second component (operation <NUM>). Method <NUM> encapsulates drilling debris generated between the first component and the second component during drilling of the injection hole by injecting a structural gap filler through the injection hole and between the first component and the second component to form encapsulated drilling debris (operation <NUM>). Method <NUM> drills a hole through the first component, the structural gap filler, and the second component, the hole offset from the injection hole (operation <NUM>). In some illustrative examples, when the hole is drilled offset from the injection hole, a portion of the injection hole is encompassed by the hole. In some illustrative examples, when the hole is drilled offset from injection hole, the injection hole remains in the first component and the second component.

Method <NUM> maintains clamp-up of the first component and the second component between drilling the injection hole and drilling the hole (operation <NUM>). Afterwards, method <NUM> terminates.

In some illustrative examples, method positions the first component relative to the second component (operation <NUM>) and clamping up the first component and second component prior to drilling the injection hole (operation <NUM>). In some illustrative examples, method <NUM> cures the structural gap filler prior to drilling the hole (operation <NUM>).

Method <NUM> drills an injection hole through the first component and second component (operation <NUM>). Method <NUM> injects a structural gap filler through the injection hole and between the first component and the second component to fill a gap between the first component and the second component (operation <NUM>). Method <NUM> maintains clamp-up of the first component and the second component between drilling the injection hole and injecting the structural gap filler (operation <NUM>). Afterwards, method <NUM> terminates.

In some illustrative examples, method <NUM> further comprises positioning the first component relative to the second component (operation <NUM>). In some illustrative examples, method <NUM> clamps up the first component and the second component prior to drilling the injection hole (operation <NUM>).

In some illustrative examples, injecting the structural gap filler encapsulates drilling debris generated between the first component and the second component during drilling of the injection hole to form encapsulated drilling debris (operation <NUM>). In some illustrative examples, injecting the structural gap filler pushes some drilling debris generated between the first component and the second component during drilling of the injection hole away from the injection hole (operation <NUM>).

In some illustrative examples, method <NUM> drills a hole through the first component, the structural gap filler, and the second component (operation <NUM>).

In some illustrative examples, drilling the hole removes at least a portion of the structural gap filler and at least a portion of the encapsulated drilling debris (operation <NUM>). In some illustrative examples, drilling the hole through the structural gap filler reduces burr production during drilling of the hole (operation <NUM>). In some illustrative examples, drilling the hole through the structural gap filler propels fragments of the first component away from the structural gap filler (operation <NUM>).

In some illustrative examples, drilling the hole comprises drilling the hole offset from the injection hole (operation <NUM>). In some illustrative examples, drilling the hole comprises drilling the hole through the injection hole (operation <NUM>). In some illustrative examples, method <NUM> cures the structural gap filler prior to drilling the hole (operation <NUM>).

Method <NUM> positions the first component relative to the second component (operation <NUM>). Method <NUM> clamps up the first component and second component to reduce space between the first component and the second component (operation <NUM>). Method <NUM> drills an injection hole through the first component and the second component (operation <NUM>). Method <NUM> encapsulates drilling debris generated between the first component and the second component during drilling of the injection hole by injecting a structural gap filler through the injection hole and between the first component and the second component to form encapsulated drilling debris (operation <NUM>). Method <NUM> drills a hole through the injection hole and through the first component, the structural gap filler, and the second component, drilling the hole through the structural gap filler reduces burr production during drilling of the hole (operation <NUM>). Method <NUM> maintains clamp-up of the first component and the second component between drilling the injection hole and drilling the hole (operation <NUM>). Afterwards, method <NUM> terminates.

In some illustrative examples, drilling the hole comprises drilling the hole offset from the injection hole (operation <NUM>). In some illustrative examples, drilling the hole comprises drilling the hole through the injection hole (operation <NUM>).

In some illustrative examples, drilling the hole removes at least a portion of the structural gap filler and at least a portion of the encapsulated drilling debris (operation <NUM>). In some illustrative examples, method <NUM> cures the structural gap filler prior to drilling the hole (operation <NUM>). In some illustrative examples, drilling the hole through the structural gap filler reduces burr production during drilling of the hole (operation <NUM>).

As used herein, the phrase "at least one of," when used with a list of items, means different combinations of one or more of the listed items may be used and only one of each item in the list may be needed. For example, "at least one of item A, item B, or item C" may include, without limitation, item A, item A and item B, or item B. Of course, any combinations of these items may be present. In other examples, "at least one of" may be, for example, without limitation, two of item A; one of item B; and ten of item C; four of item B and seven of item C; or other suitable combinations. The item may be a particular object, thing, or a category. In other words, at least one of means any combination items and number of items may be used from the list but not all of the items in the list are required.

The flowcharts and block diagrams in the different depicted embodiments illustrate the architecture, functionality, and operation of some possible implementations of apparatuses and methods in an illustrative embodiment. In this regard, each block in the flowcharts or block diagrams may represent at least one of a module, a segment, a function, or a portion of an operation or step.

In some alternative implementations of an illustrative embodiment, the function or functions noted in the blocks may occur out of the order noted in the figures. For example, in some cases, two blocks shown in succession may be executed substantially concurrently, or the blocks may sometimes be performed in the reverse order, depending upon the functionality involved. Also, other blocks may be added in addition to the illustrated blocks in a flowchart or block diagram. Some blocks may be optional. For example, any of operation <NUM> through operation <NUM> may be optional.

Illustrative embodiments of the present disclosure may be described in the context of aircraft manufacturing and service method <NUM> as shown in <FIG> and aircraft <NUM> as shown in <FIG>. Turning first to <FIG>, an illustration of an aircraft manufacturing and service method in a form of a block diagram is depicted in accordance with an illustrative embodiment. During pre-production, aircraft manufacturing and service method <NUM> may include specification and design <NUM> of aircraft <NUM> in <FIG> and material procurement <NUM>.

During production, component and subassembly manufacturing <NUM> and system integration <NUM> of aircraft <NUM> takes place. Thereafter, aircraft <NUM> may go through certification and delivery <NUM> in order to be placed in service <NUM>. While in service <NUM> by a customer, aircraft <NUM> is scheduled for routine maintenance and service <NUM>, which may include modification, reconfiguration, refurbishment, or other maintenance and service.

With reference now to <FIG>, an illustration of an aircraft in a form of a block diagram is depicted in which an illustrative embodiment may be implemented. In this example, aircraft <NUM> is produced by aircraft manufacturing and service method <NUM> of <FIG> and may include airframe <NUM> with plurality of systems <NUM> and interior <NUM>. Examples of systems <NUM> include one or more of propulsion system <NUM>, electrical system <NUM>, hydraulic system <NUM>, and environmental system <NUM>. Any number of other systems may be included.

Apparatuses and methods embodied herein may be employed during at least one of the stages of aircraft manufacturing and service method <NUM>. One or more illustrative embodiments may be manufactured or used during at least one of component and subassembly manufacturing <NUM>, system integration <NUM>, in service <NUM>, or maintenance and service <NUM> of <FIG>.

A portion of airframe <NUM> of aircraft <NUM> can be formed by one of method <NUM>, method <NUM>, method <NUM>, or method <NUM>. At least one of method <NUM>, method <NUM>, method <NUM>, or method <NUM> can be performed during component and subassembly manufacturing <NUM>. A composite structure formed using one of method <NUM>, method <NUM>, method <NUM>, or method <NUM> can be present and utilized during in service <NUM>. At least one of method <NUM>, method <NUM>, method <NUM>, or method <NUM> can be performed during maintenance and service <NUM> to form a replacement part.

The illustrative examples provide methods to enable one up assembly for components with gaps between the mating surfaces. The illustrative examples can reduce or eliminate the step of taking apart structures (assemblies) and removing burrs within a gap after drilling. The illustrative examples can reduce burr generation in assembly gaps. The illustrative examples can encapsulate burrs from injection hole drilling operations. The illustrative examples reduce manufacturing time by reducing or eliminating disassembly and cleaning steps.

The illustrative examples enable one up assembly by allowing for fastener insertion after drilling without taking apart structures for cleaning. The illustrative examples can enable one up assembly on airplane members with gaps larger than <NUM>" where a chip or burr can result from the drilling with a gap between the skin and the substructure.

A structural gap filler material is injected into a gap present between components, such as aircraft components, through an injection hole. In some illustrative examples, the injection hole is a fastener pilot hole.

Burrs that occur during the injection hole drilling process are encapsulated in the structural gap filler material. Once the structural gap filler is cured, a fastener hole is drilled into the components. The cured structural gap filler material reduces or prevents burrs from developing during the final drilling process as there is not a gap between the components.

In some illustrative examples, a fastener hole is drilled to size over the injection hole. In these illustrative examples, final hole sizing is larger than the injection hole and thus burrs from pilot hole drilling that were encapsulated by structural gap filler can be eliminated (drilled out) when the final hole sizing is completed.

Claim 1:
A method (<NUM>) of assembling a structure (<NUM>), the method comprising:
drilling (<NUM>) an injection hole (<NUM>) through a first component (<NUM>) and a second component (<NUM>);
encapsulating (<NUM>) drilling debris (<NUM>) generated between the first component (<NUM>) and the second component (<NUM>) during drilling of the injection hole (<NUM>) by injecting a structural gap filler (<NUM>) through the injection hole (<NUM>) and between the first component (<NUM>) and the second component (<NUM>) to form encapsulated drilling debris (<NUM>);
drilling (<NUM>) a hole (<NUM>) through the injection hole (<NUM>) and through the first component (<NUM>), the structural gap filler (<NUM>), and the second component (<NUM>); and
maintaining (<NUM>) clamp-up of the first component (<NUM>) and the second component (<NUM>) between drilling the injection hole (<NUM>) and drilling the hole (<NUM>).