Patent Description:
Adhesives are commonly used to bond surfaces of articles, structures, elements or the like together. For example, sealants (e.g., thermosetting polysulfide sealants or the like) or other thermosetting elastomeric adhesives are a type of adhesive that can be applied and subsequently cured to provide a very tough, high-strength bond between surfaces. This high-strength bonding is especially useful in preventing bonded constructions from coming apart, even in response to an applied load(s) that produces, for example, high tensile stresses and/or shear stresses.

However, because adhesives such as sealants or other thermosetting elastomeric adhesives provide such strong bonds between surfaces, if for some reason the surfaces need to be separated, it is often a challenge to subsequently sever the adhesive bond to decouple the surfaces after the adhesive has been applied and fully cured. Harsh liquid chemicals such as organic solvents and/or sharp tools such as utility knives (e.g., X-Acto knives and/or blades) or the like are often used to dissolve, soften, remove, and/or cut through the adhesive to sever the bond and decouple the surfaces. Unfortunately, these approaches can damage the bonded or adjacent surfaces, require protective gloves or respirators, and/or fatigue workers as such removal processes can be quite labor-intensive.

For example, it is known for a sealant adhesive to be used to bond T-shaped metal structures or elements to the outer skin surfaces of an aircraft such as wings, horizontal stabilizers, vertical stabilizers, control surfaces, or the like. In addition to being bonded to the aircraft surfaces, groups of adjacent T-shaped metal elements are also connected to a corresponding beam to form a beam construction commonly referred to as a whiffletree. The whiffletree can be operatively coupled to a mechanical device(s) such as a jack(s) or hydraulic cylinder(s) for tension and compression testing of the aircraft surfaces. This heavy load testing requires the use of high-strength adhesives to bond the metal T-shaped elements to the aircraft surfaces, making it difficult for workers to remove the elements after testing is complete, especially without incurring damage to the outer skin surfaces of the aircraft. Although organic solvents may help to soften or partially dissolve the cured sealant adhesive, the solvent can also remove or damage any paint on the outer skin surface of the aircraft and/or damage intentionally sealed aircraft parts. Also, the use of aggressive organic solvents to attack the adhesive, may require the workers to wear special gear to avoid any chemical exposure to the solvent. Further, using utility cutting tools such as X-Acto® knives and/or blades to sever the bond and decouple the elements from the outer skin surfaces of the aircraft is cumbersome and labor intensive for workers.

<CIT> relates to an apparatus for removing the windshield of a vehicle.

From <CIT> there is known an apparatus for decoupling an element that is bonded to a surface by adhesive, the apparatus comprising: a body, wherein the body includes a first body side portion and a second body side portion that is disposed opposite the first body side portion; a first spool that is rotationally coupled to the first body side portion; a second spool that is coupled also to the first body side portion; a first pulley coupled to the first body side portion adjacent to the first spool and a second pulley coupled also to the first body side portion adjacent to the second spool, wherein the first pulley and the second pulley are substantially aligned with parallel axes; and a cable having a first cable end portion that is coupled to the first spool, a second cable end portion that is coupled to the second spool, and a cable intermediate portion that is disposed between the first cable end portion and the second cable end portion, wherein the first pulley guides the cable to the first spool as the first spool rotates and the second pulley guides the cable to the second spool, wherein the apparatus is configured to be positioned adjacent to at least one of the element and the surface, and wherein the first and second pulleys are cooperatively configured to position the cable intermediate portion adjacent to the adhesive such that when the first spool is rotated, the cable wraps about the first spool, thereby pulling the cable intermediate portion through the adhesive.

<CIT> relates to repair or replacement of adhesively bonded articles. <CIT> relates to disassembling laminated substrates.

Accordingly, it is desirable to provide apparatuses and methods for decoupling elements that are bonded to a surface by adhesive that address one or more of the foregoing issues. Furthermore, other desirable features and characteristics of the various embodiments described herein will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and this background.

The invention is solved by an apparatus as defined in claim <NUM> and by a method as defined in claim <NUM>.

Various non-limiting embodiments of an apparatus and a method for decoupling an element that is bonded to a surface by adhesive are provided herein.

In a first non-limiting embodiment, the apparatus includes, but is not limited to, a body. The apparatus further includes, but is not limited to, a first spool that is rotationally coupled to the body. The apparatus further includes, but is not limited to, a cable having a first cable end portion that is coupled to the first spool, a second cable end portion that is coupled to the body, and a cable intermediate portion that is disposed between the first cable end portion and the second cable end portion. The apparatus is configured to be positioned adjacent to at least one of the element and the surface with the cable intermediate portion disposed adjacent to the adhesive such that when the first spool is rotated, the cable wraps about the first spool, thereby pulling the cable intermediate portion through the adhesive.

In another non-limiting embodiment, the method includes, but is not limited to, positioning an apparatus adjacent to at least one of the element and the surface. The apparatus includes a body, a spool that is rotationally coupled to the body, and a cable. The cable has a first cable end portion that is coupled to the spool, a second cable end portion that is coupled to the body, and a cable intermediate portion that is disposed between the first cable end portion and the second cable end portion. The method further includes, but is not limited to, rotating the spool such that the cable wraps around the spool, thereby pulling the cable intermediate portion through the adhesive.

The following Detailed Description is merely exemplary in nature and is not intended to limit the various embodiments or the application and uses thereof. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description.

Various embodiments contemplated herein relate to apparatuses and methods for decoupling an element that is bonded to a surface by adhesive. The exemplary embodiments taught herein provide an apparatus that includes a body, a spool that is rotationally coupled to the body, and a cable having a first cable end portion that is coupled to the spool, a second cable end portion that is coupled to the body, and a cable intermediate portion that is disposed between the first cable end portion and the second cable end portion. The apparatus is configured to be positioned adjacent to the element and/or the surface with the cable intermediate portion disposed adjacent to the adhesive such that when the spool is rotated, the cable wraps around the spool, thereby pulling the cable intermediate portion through the adhesive.

In an exemplary embodiment, advantageously, by pulling the cable intermediate portion through the adhesive, the apparatus efficiently and effectively decouples the element from the surface without the need for labor-intensive efforts by workers. In one example, one worker operates the apparatus to pull the cable intermediate portion through the adhesive to decouple one or more elements from the surface while another worker collects the one or more decoupled element(s) as they fall or otherwise separate from the surface. As such, there is no need for the use of chemical solvents that can damage the element and/or the surface, and/or there is no need for the use of more labor-intensive manual processes that employ utility tools or the like that are ergonomically taxing on the workers.

<FIG> illustrates a perspective bottom view of elements <NUM> that are bonded to a surface <NUM> by adhesive <NUM>. In an exemplary embodiment, the surface <NUM> is a vehicle surface, for example, an aircraft surface such as the underside of an aircraft wing, a portion of a fuselage, or the like. The adhesive <NUM> may be in the form of an adhesive pad or layer and each element <NUM> may be bonded to the surface <NUM> by a distinct or separate adhesive pad or layer. Alternatively, a plurality of elements <NUM> may collectively be bonded to the surface <NUM> by a single continuous adhesive layer.

As illustrated, the elements <NUM> are made of metal and have a general T-shape extruded form. For example, each of the elements <NUM> includes a plate portion <NUM> that is bonded to the surface <NUM> via the adhesive <NUM> and a rib portion <NUM> that extends from the plate portion <NUM> in a direction generally away from the surface <NUM>. The rib portion <NUM> has an aperture <NUM> formed therethrough that allows for additional devices and/or constructions to be removably coupled to one or more of the element(s) <NUM>. As illustrated, pairs of metal beams <NUM> are removably coupled to the elements <NUM> via fasteners <NUM> that extend through the apertures <NUM> and form a whiffletree construction <NUM>. The whiffletree construction(s) <NUM> can be operatively coupled to a mechanical device(s) such as a jack(s) or hydraulic cylinder(s), for example, for distributing force substantially equally between the elements <NUM> for transfer through the adhesive <NUM> to the surface <NUM> for aircraft performance testing.

Referring to <FIG> and <FIG>, in an exemplary embodiment, the metal beams <NUM> illustrated in <FIG> are removed from the elements <NUM>, for example, after aircraft performance testing has been completed. An apparatus <NUM> for decoupling the elements <NUM> from the surface <NUM> is disposed adj acent to the surface <NUM> and, as will be discussed in further detail below, is removably coupled to one of the elements <NUM>.

In an exemplary embodiment, the apparatus <NUM> includes a body <NUM> that has a body side portion <NUM> and a body side portion <NUM> that is disposed opposite the body side portion <NUM>. The body side portions <NUM>, <NUM> each includes a wall <NUM>, <NUM> that are spaced apart from each other. The walls <NUM> and <NUM> have surfaces <NUM> and <NUM> that face towards each other and surfaces <NUM> and <NUM> that face away from and/or opposite each other.

The apparatus <NUM> includes an attachment member <NUM> that includes spacers <NUM> and <NUM> that are coupled to the walls <NUM> and <NUM> and that extend from the surfaces <NUM> and <NUM>, respectively, towards each other and are spaced apart to define a gap <NUM> therebetween. In an exemplary embodiment, the spacers <NUM> and <NUM> are cylindrically shaped. The spacers <NUM> and <NUM> are hollow to define channels or holes <NUM> and <NUM> formed therethrough that extend through the walls <NUM> and <NUM>, respectively. In an exemplary embodiment, the spacers <NUM> and <NUM> including the holes <NUM> and <NUM> are substantially aligned about a common axis. The attachment member <NUM> further includes a shaft <NUM> that is disposed in the holes <NUM> and <NUM> extending between the surfaces <NUM> and <NUM>. The shaft <NUM> is removably coupled to the body <NUM> of the apparatus <NUM> by, for example, fasteners <NUM> and <NUM> that when are attached to the ends of the shaft <NUM>, secure the shaft to the body <NUM> and that when one or both of the fasteners <NUM> and <NUM> are removed, allow the shaft <NUM> to slide or otherwise move through the holes <NUM> and <NUM>. As such, the apparatus <NUM> may be attached or otherwise coupled to one of the element <NUM>, for example, by positioning the apparatus <NUM> with the shaft <NUM> fully or partially retracted (e.g., fully or partially outside of the holes <NUM> and <NUM>) and the rib portion <NUM> disposed between the gap <NUM> with the aperture <NUM> and the holes <NUM> and <NUM> substantially aligned, then sliding the shaft <NUM> to extend through the aperture <NUM> and the holes <NUM> and <NUM>, and securing the shaft <NUM> to the body <NUM> via fasteners <NUM> and <NUM>.

In an exemplary embodiment, each of the surfaces <NUM>, <NUM> of the walls <NUM> and <NUM> has a track <NUM>, <NUM> formed therein. As illustrated, the apparatus <NUM> includes spacers <NUM> and <NUM> that are configured as plates or blocks and that are disposed in the tracks <NUM> and <NUM>, respectively. As such, the spacers <NUM> and <NUM> are disposed between the surfaces <NUM> and <NUM> of the walls <NUM> and <NUM>, respectively. In an exemplary embodiment, the spacers <NUM> and <NUM> are substantially aligned along a common plane and define a gap <NUM> therebetween. The spacers <NUM> and <NUM> are disposed adjacent to the spacers <NUM> and <NUM>, respectively, with the gap <NUM> substantially aligned with the gap <NUM>. As such, the gaps <NUM> and <NUM> together form an opening to receive the rib portion <NUM> of the element <NUM> for attaching the apparatus <NUM> to one of the elements <NUM>. In particular and without wishing to be bound by theory, it is believed that the spacers <NUM> and <NUM> provide additional stability to the apparatus <NUM> when it is coupled to the element <NUM> by providing elongated contact surfaces against opposite sides of the rib portion <NUM> to limit rotational movement between the apparatus <NUM> and the element <NUM> about the shaft <NUM> and secure the position of the apparatus <NUM> relative to the corresponding element <NUM>.

Referring also to <FIG>, in an exemplary embodiment, the apparatus <NUM> includes brackets <NUM> and <NUM> to provide additional support or structure to the body <NUM> of the apparatus <NUM>. As illustrated, the brackets <NUM> and <NUM> are spaced apart from each other, each extending between and coupled to the walls <NUM> and <NUM>, thereby securing the body side portions <NUM> and <NUM> to each other.

In an exemplary embodiment, the apparatus <NUM> includes pulleys <NUM> and <NUM> that are configured as wheels each having an upper pulley area <NUM>, <NUM> and a lower pulley area <NUM>, <NUM> and an annular track <NUM>, <NUM> formed in the rim suurounding the upper and lower pulley areas <NUM> and <NUM>, <NUM> and <NUM>. A cable <NUM> is disposed on the pulleys <NUM> and <NUM> in the annular tracks <NUM> and <NUM> and is operatively coupled to a spool <NUM> that is rotationally coupled to the body <NUM> of the apparatus <NUM>. As illustrated, the pulleys <NUM> and <NUM> are coupled to the body side portions <NUM> and <NUM>, respectively. For example, the pulley <NUM> is coupled to the wall <NUM> and the surface <NUM> faces towards the pulley <NUM>. Similarly, the pulley <NUM> is coupled to the wall <NUM> with the surface <NUM> facing towards the pulley <NUM>. The pulleys <NUM> and <NUM> are correspondingly rotationally coupled to the walls <NUM> and <NUM> by fasteners <NUM>. In an exemplary embodiment, the pulleys <NUM> and <NUM> are substantially aligned about a common axis.

As will be discussed in further detail below, in accordance with an exemplary embodiment, the spool <NUM> is rotationally coupled to the body side portion <NUM> adjacent to the pulley <NUM> with the surface <NUM> facing towards the spool <NUM>. As illustrated, a bracket <NUM> (e.g., "U-shaped" bracket) is coupled to the body side portion <NUM> and extends from the surface <NUM> of the wall <NUM>. The spool <NUM> is disposed between flanges of the bracket <NUM> and is rotationally coupled to the bracket <NUM> by a pin <NUM> that extends through the center of the spool <NUM> and is coupled to the flanges of the bracket <NUM>. As such, the spool <NUM> is configured to rotate in directions (indicated by double headed arrow <NUM>) about the pin <NUM>.

In an exemplary embodiment, the apparatus <NUM> includes a spool <NUM> that is coupled to the body side portion <NUM>. As illustrated, the spool <NUM> is disposed adjacent to the pulley <NUM> with the surface <NUM> facing towards the spool <NUM>. In an exemplary embodiment, the spool <NUM> is fixedly coupled to the body side portion <NUM> to prevent rotation of the spool <NUM>. For example, the spool <NUM> may be coupled to the wall <NUM> by a bracket <NUM> (e.g., "U-shaped" bracket) that is coupled to and extends from the surface <NUM> of the wall <NUM>.

With continuing reference to <FIG> and <FIG>, the cable <NUM> has a cable end portion <NUM> that is coupled to the spool <NUM>, a cable end portion <NUM> that is coupled to the body side portion <NUM>, and a cable intermediate portion <NUM> that is disposed therebetween. In an exemplary embodiment, the cable end portion <NUM> is coupled to the spool <NUM>. In an exemplary embodiment, the pulleys <NUM> and <NUM> are cooperatively configured to position the cable intermediate portion <NUM> substantially level with the adhesive <NUM> when the apparatus <NUM> is coupled to the element <NUM>. The cable intermediate portion <NUM> extends from the upper pulley areas <NUM> and <NUM> generally in a direction (indicated by single-headed arrow <NUM>) to wrap at least partially around the adhesive <NUM>. The cable <NUM> is guided from the upper pulley areas <NUM> and <NUM> to the lower pulley areas <NUM> and <NUM> by wrapping around the annular tracks <NUM> and <NUM>, respectively. Further, the cable <NUM> is guided from the lower pulley areas <NUM> and <NUM> to the spools <NUM> and <NUM>, respectively, generally in the direction <NUM>.

Referring also to <FIG> and <FIG>, the spool <NUM> is configured to be rotated by a driver <NUM>. In an exemplary embodiment, the spool <NUM> includes flanges <NUM> and <NUM> and a drum <NUM> that is disposed between the flanges <NUM> and <NUM>. As illustrated, the flange <NUM> includes teeth <NUM> disposed on the outer periphery thereof and is configured as a gear <NUM>. Although the flange <NUM> is illustrated as being configured as a gear <NUM>, various alternate embodiments of the spool <NUM> include the flange <NUM> as not being configured as a gear and a separate gear <NUM> being coupled to the spool <NUM> either directly or indirectly to cause rotation of the drum <NUM>. In an exemplary embodiment, the cable end portion <NUM> is coupled to the drum <NUM>.

In an exemplary embodiment, the apparatus <NUM> includes a gear <NUM> that has a threaded portion that couples with the gear <NUM> and a receiver portion <NUM> that is configured to receive the driver <NUM> to rotate the gear <NUM>. As illustrated, the gear <NUM> is configured as a worm gear and the gear <NUM> is configured as a worm. As such, the gears <NUM> and <NUM> cooperate as a worm drive. When the driver <NUM> rotates the gear <NUM>, the threaded portion of the gear <NUM> meshes with the teeth <NUM> of the gear <NUM>, thereby rotating the gear <NUM> and, consequently, rotating the spool <NUM>.

Referring also to <FIG>, when the apparatus <NUM> is coupled to the element <NUM> such that the apparatus <NUM> is positioned adjacent to the surface <NUM> and the cable intermediate portion <NUM> is wrapped around the adhesive <NUM> and the driver <NUM> rotates the spool <NUM>, the cable <NUM> progressively wraps around the drum <NUM>, thereby pulling the cable intermediate portion <NUM> in a direction (indicated by single headed arrow <NUM>) through the adhesive <NUM>. In an exemplary embodiment, the adhesive <NUM> is thicker than the diameter of the cable <NUM> such that when the cable <NUM> is pulled through the adhesive <NUM>, the cable <NUM> does not contact with the surface <NUM> to further protect the surface <NUM> from incurring any damage. Once the adhesive <NUM> has been cut by the cable <NUM>, the elements <NUM> are fully decoupled from the surface <NUM> and may fall or otherwise separate from the surface <NUM>. Any residual adhesive <NUM> that remains on the surface <NUM> is now fully exposed and can be more readily accessed for easier removal by a worker(s) than with the elements <NUM> in place adhesively bonded to the surface <NUM>.

Referring to <FIG>, a method <NUM> for decoupling an element that is bonded to a surface by adhesive is provided. The method <NUM> includes positioning (STEP <NUM>) an apparatus adjacent to at least one of the element and the surface. The apparatus includes a body, a spool that is rotationally coupled to the body, and a cable having a first cable end portion that is coupled to the first spool, a second cable end portion that is coupled to the body, and a cable intermediate portion that is disposed between the first cable end portion and the second cable end portion. The cable intermediate portion is disposed (STEP <NUM>) adjacent to the adhesive. The spool is rotated (STEP <NUM>) such that the cable wraps around the spool, thereby pulling the cable intermediate portion through the adhesive.

Referring to <FIG>, another exemplary embodiment of the apparatus <NUM> is provided. The apparatus <NUM> is similarly configured to the apparatus <NUM>, but with the exception that the spool <NUM> is rotationally coupled to the body side portion <NUM> via bracket <NUM> and the spool <NUM> is fixedly coupled to the body side portion <NUM> via bracket <NUM>. Further, spacers <NUM> and <NUM> depicted in <FIG> are wider than the spacers <NUM> and <NUM> depicted in <FIG>.

Claim 1:
An apparatus (<NUM>) for decoupling an element (<NUM>) that is bonded to a surface (<NUM>) by adhesive (<NUM>), the apparatus (<NUM>) comprising:
a body (<NUM>), wherein the body includes a first body side portion (<NUM>) and a second body side portion (<NUM>) that is disposed opposite the first body side portion (<NUM>);
a first spool (<NUM>) that is rotationally coupled to the first body side portion (<NUM>);
a second spool (<NUM>) that is coupled to the second body side portion (<NUM>);
a first pulley (<NUM>) coupled to the first body side portion (<NUM>) adjacent to the first spool (<NUM>) and a second pulley (<NUM>) coupled to the second body side portion (<NUM>) adjacent to the second spool (<NUM>), wherein the first pulley (<NUM>) and the second pulley (<NUM>) are substantially aligned about a common axis; and
a cable (<NUM>) having a first cable end portion (<NUM>) that is coupled to the first spool (<NUM>), a second cable end portion (<NUM>) that is coupled to the second spool (<NUM>), and a cable intermediate portion (<NUM>) that is disposed between the first cable end portion (<NUM>) and the second cable end portion (<NUM>),
wherein the first pulley (<NUM>) guides the cable (<NUM>) to the first spool (<NUM>) as the first spool (<NUM>) rotates and the second pulley (<NUM>) guides the cable (<NUM>) to the second spool (<NUM>),
wherein the apparatus (<NUM>) is configured to be positioned adjacent to at least one of the element (<NUM>) and the surface (<NUM>), and
wherein the first (<NUM>) and second (<NUM>) pulleys are cooperatively configured to position the cable intermediate portion (<NUM>) adjacent to the adhesive (<NUM>) such that when the first spool (<NUM>) is rotated, the cable (<NUM>) wraps about the first spool (<NUM>), thereby pulling the cable intermediate portion (<NUM>) through the adhesive (<NUM>).