Bonded nutplate rapid cure system with fixtured heater

{
  "publication_number": "US12304153B1",
  "country": "US",
  "kind": "B1",
  "title": "Bonded nutplate rapid cure system with fixtured heater",
  "abstract": "Embodiments of systems and methods for positioning and bonding a nutplate to a substrate comprising at least one aperture, wherein the system includes a nutplate retention fixture formed from a threaded insert and an elastomeric tube engaged with the threaded insert; a heater assembly formed from a heating element, a temperature sensor operable to measure the temperature of the heating element, and a heater housing; a heater retention fixture operable to engage with the nutplate retention fixture and maintain the heater assembly in contact with the substrate; and a heater controller operable to control the output from the heating element. The heater retention fixture includes a cam-lock clamp provided concentrically around the nutplate retention fixture and configured to provide a circumferential clamping force to secure the heater retention fixture to the nutplate retention fixture.",
  "claims": [
    "1. A system for positioning and bonding a nutplate to a substrate comprising at least one aperture, the system comprising: a nutplate retention fixture comprising a threaded insert and an elastomeric tube engaged with the threaded insert, wherein the threaded insert is operable to engage the nutplate at one end and extend through one aperture of the substrate, and the elastomeric tube is configured to anchor the nutplate retention fixture at the aperture and secure the nutplate in contact with the substrate; a heater assembly disposed concentrically around the nutplate retention fixture and operable to deliver heat to a bonding surface of the nutplate, wherein the heater assembly comprises: a heating element, a temperature sensor operable to measure the temperature of the heating element, and a heater housing, the heater housing comprising a hollow interior to encase the heating element; a heater controller operable to control an output from the heating element; and a heater retention fixture operable to engage with the nutplate retention fixture and maintain the heater assembly in contact with the substrate, wherein the heater retention fixture comprises: a cam-lock clamp provided concentrically around the nutplate retention fixture at a position distal the substrate relative to the heater assembly and configured to provide a circumferential clamping force to secure the heater retention fixture to the nutplate retention fixture.",
    "2. The system of claim 1, wherein the threaded insert comprises external threads configured for threaded engagement with internal threads on the nutplate.",
    "3. The system of claim 1, wherein the system further comprises a substrate temperature sensor operable to measure the temperature of the heater housing proximal the substrate.",
    "4. The system of claim 1, wherein the heater housing forms a conformal heat sink and comprises a first segment configured to be positioned proximal the substrate and a second segment configured to be positioned distal the substrate.",
    "5. The system of claim 4, wherein the first segment is formed from a thermally conductive material and the second segment is formed from a substantially thermally non-conductive material.",
    "6. The system of claim 4, wherein the first segment of the heater housing comprises one or more compliant spring members positioned on a bottom surface of the heater housing to allow the bottom surface of the heater housing to contour to non-flat surfaces.",
    "7. The system of claim 4, wherein the first segment of the heater housing comprises a compliant, thermally conductive gasket positioned on a bottom surface of the heater housing to allow the bottom surface of the heater housing to contour to the substrate.",
    "8. The system of claim 7, wherein the compliant, thermally conductive gasket comprises a metal felt.",
    "9. The system of claim 4, wherein the first segment, the second segment, or both comprise grooves or channels for routing the temperature sensor and/or power wires for the heating element.",
    "10. The system of claim 1, wherein the heater assembly substantially comprises an “O” shape, a “U”-shape, or a “C”-shape.",
    "11. The system of claim 1, wherein the cam-lock clamp comprises a clamping ring formed from at least two jaw elements and a cam connected at pivot points such that operation of the cam closes the clamping ring to reduce an inner diameter of a centrally located passage formed by the clamping ring and locks the clamping ring in a closed position.",
    "12. The system of claim 1, wherein the cam-lock clamp further comprises at least two spring loaded selectively actuated plunger pins configured to translate between a retracted and an extended position, wherein the plunger pins extend beyond a bottom face of the cam-lock clamp when in the extended position.",
    "13. A method of positioning and bonding a nutplate to a substrate comprising at least one aperture, the method comprising: coupling a nutplate with a nutplate retention fixture, the nutplate retention fixture comprising a threaded insert and an elastomeric tube engaged with the threaded insert, wherein the threaded insert is operable to engage the nutplate at one end and extend through one aperture of the substrate, and the elastomeric tube is configured to anchor the nutplate retention fixture at the aperture and secure the nutplate in contact with the substrate; applying adhesive onto a bonding surface of the nutplate; inserting the nutplate retention fixture through the aperture until a surface of the substrate contacts the bonding surface having adhesive applied thereon; positioning a heater assembly concentrically around the nutplate retention fixture in a position operable to deliver heat to the bonding surface of the nutplate, wherein the heater assembly comprises: a heating element, a temperature sensor operable to measure the temperature of the heating element, and a heater housing, the heater housing comprising a hollow interior to encase the heating element; securing a heater retention fixture to the nutplate retention fixture to maintain the heater assembly in contact with the substrate, wherein the heater retention fixture comprises: a cam-lock clamp provided concentrically around the nutplate retention fixture at a position distal the substrate relative to the heater assembly and configured to provide a circumferential clamping force to secure the heater retention fixture to the nutplate retention fixture; and adhering the nutplate to the substrate by applying heat through the heater assembly.",
    "14. The method of claim 13, wherein the threaded insert comprises external threads configured for threaded engagement with internal threads on the nutplate.",
    "15. The method of claim 14, wherein the heater assembly substantially comprises an “O” shape, a “U”-shape, or a “C”-shape.",
    "16. The method of claim 14, wherein the cam-lock clamp comprises a clamping ring formed from at least two jaw elements and a cam connected at pivot points such that operation of the cam closes the clamping ring to reduce an inner diameter of a centrally located passage formed by the clamping ring and locks the clamping ring in a closed position.",
    "17. The method of claim 14, wherein the cam-lock clamp further comprises at least two spring loaded selectively actuated plunger pins configured to translate between a retracted and an extended position, wherein the plunger pins extend beyond a bottom face of the cam-lock clamp when in the extended position, the method further comprising actuating the plunger pins after securing the heater retention fixture to the nutplate retention fixture to extend the plunger pins into the extended positon and apply a tension force on the nutplace retention fixture to compress the nutplate against the substrate at the bonding surface.",
    "18. The method of claim 13, wherein the heater housing forms a conformal heat sink and comprises a first segment configured to be positioned proximal the substrate and a second segment configured to be positioned distal the substrate.",
    "19. The method of claim 18, wherein the first segment of the heater housing comprises one or more compliant spring members positioned on a bottom surface of the heater housing to allow the bottom surface of the heater housing to contour to non-flat surfaces.",
    "20. The method of claim 18, wherein the first segment of the heater housing comprises a compliant, thermally conductive gasket positioned on a bottom surface of the heater housing to allow the bottom surface of the heater housing to contour to the substrate."
  ],
  "description_excerpt": "Embodiments described herein relate generally to rapid curing systems for bonding hardware to substrates or substructures and more particularly to a bonded nutplate rapid cure system with a fixture heater and methods of using the same.\n\nAdhesively bonded hardware, which are fasteners such as nutplates, bushings, threaded inserts, sleeves, mounts, brackets, etc., are commonly used to secure structural elements during installation or repair. Bonded hardware is used on a variety of systems including: aircraft, spacecraft, watercraft, automobiles, and industrial equipment. Adhesively bonded hardware is also used to join components of dissimilar materials or when welding or riveting is not an option. Bonded hardware typically experiences failure in the form of mechanical wear, structural deformation, or separation of the hardware from the mounting substrate (i.e., disbond).\n\nDamaged hardware found during routine maintenance requires timely replacement and approved repair techniques often mandate the use of certified adhesives. Unfortunately, approved repair adhesives are typically those used during original factory installation. Approved hardware adhesives are generally two-part epoxies whose performance specifications are determined by a lengthy cure (e.g. 24 hour) at room temperature. This specific curing time is necessary for the adhesive to develop the strength required to hold the hardware in place for attaching other components (e.g., reattaching an access panel to an aircraft). This long cure time can negatively impact the system's availability.",
  "cpc": [
    "B29C 65/7811",
    "B29C 65/46",
    "B29C 65/4835",
    "B29C 66/742",
    "F16B 11/006",
    "F16B 37/048"
  ],
  "ipc": [
    "B29C 65/00",
    "B29C 65/46",
    "B29C 65/48",
    "B29C 65/78"
  ],
  "assignees": [
    "Kineticure LLC"
  ],
  "inventors": [
    "Jason P. Rice",
    "Michael J. Hood"
  ],
  "filing_date": "2023-08-25",
  "publication_date": "2025-05-20",
  "grant_date": "2025-05-20",
  "priority_date": "2022-08-30",
  "application_number": "US-202318456108-A",
  "family_id": "95717267",
  "cited_by_count": 0,
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}