Heat shrink laminated composite patch for repairing composite components

Number: 10272652
Published: 2019-04-30
Filed: 2015-08-12
Assignee: DISNEY ENTERPRISES, INC.
Inventors: Skaggs; Laurel Lindsey, Tripp; Mark E., Naylor; Mark Alan
CPC: B32B27/12; B32B27/38; B29C61/02; B32B7/12; B32B5/02; B32B27/06; B29C73/10; B32B27/08; B32B27/32
Verdict: Medium Hardware
Source: Google Patents · FreePatentsOnline

The keeper's note

Heat shrink laminated composite patch repairing composite components.

Abstract

A sheet of heat shrink laminated composite for use creating repair patches for repairing or building up a surface formed of a composite material such as fiberglass-reinforced plastic. The sheet includes first and second layers of a heat-curable adhesive. The sheet includes a reinforcement layer sandwiched between the first and second layers of the adhesive. The sheet further includes a pressure application layer, which is formed of a heat-activated shrink wrap film, abutting an outer surface of the first layer of the adhesive. The reinforcement layer may include a sheet of a porous fabric or cloth, which may be fibers of carbon or glass such as unidirectional e-glass fibers. The adhesive is cured when heated to a temperature in a curing temperature range, and the shrink wrap film is activated when heated to a temperature in an activation temperature range that overlaps the curing temperature range of the adhesive.

Background

BACKGROUND1. Field of the Description(1) The present invention relates, in general, to materials for and methods of repairing damaged surfaces of components (e.g., structural or mechanical elements) that are formed of a composite material or a laminate with such a composite material such as a tube or rod with at least its outer surfaces formed of fiberglass-reinforced plastic (or fiber-reinforced polymer) (FRP), which may also be labeled as glass-fiber reinforced plastic or GRP, or other composite, and, more particularly, to methods of fabricating and applying repair material to a composite component that may include a curved surface in a manner that applies pressure in a uniform and constant manner during curing processes (e.g., during curing of adhesives or resins used to apply a layer or thickness of a composite onto a damaged, curved or planar surface of the composite component or component with an outer layer formed of a composite material such as FRP).2. Relevant Background(2) Over the years, there have been many demands for new materials that have particular characteristics that would be useful for a particular application. To this end, material scientists have created many composites or composite materials by combining two or more natural or artificial materials to maximize their useful properties and to minimize their weaknesses. For example, fiberglass-reinforced plastic (FRP) combines fiberglass fibers that are strong but relatively brittle with plastic that is fle

Claims

1. A multi-layer sheet for use in repairing and building up a surface formed of a composite material, comprising: a first layer comprising a resin; a second layer comprising the resin, wherein the resin comprises a heat activated adhesive; a reinforcement layer sandwiched between the first and second layers of the resin; and a pressure application layer comprising a heat-activated shrink wrap film abutting a surface of the first layer of the resin opposite the reinforcement layer, wherein the adhesive is cured when heated to temperatures in a curing temperature range and wherein the heat-activated shrink wrap film has an activation temperature range at least partially overlapping the curing temperature range of the adhesive. 12. A laminate for field repair of damaged surfaces, comprising: first and second films of an adhesive reacting when heated to a temperature in a first temperature range; a porous fabric layer between the first and second films of heat activated adhesive; and a heat shrink film, wherein the first film of the heat activated adhesive is sandwiched between the heat shrink film and the porous fabric layer, wherein the heat shrink film is activated to shrink and apply pressure on the first film of the heat activated adhesive when heated to a temperature in a second temperature range that overlaps with the first temperature range, and wherein the first and second films, the porous fabric layer, and the heat shrink film are laminated into a unitary sheet. 16. A multi-layer sheet for use in repairing and building up a surface formed of a composite material, comprising: a first layer comprising a resin; a second layer comprising the resin, wherein the resin comprises an adhesive; a reinforcement layer, comprising a fabric sheet, sandwiched between the first and second layers of the resin; and a pressure application layer comprising a heat-activated shrink wrap film abutting a surface of the first layer of the resin opposite the reinforcement layer, wherein the adhesive is cured with temperatures in a curing temperature range having a minimum temperature greater than 150° F. and wherein the first and second layers of the resin have a thickness that is at least one half of a thickness of the reinforcement layer.