HEAT SHRINK LAMINATED COMPOSITE PATCH FOR REPAIRING COMPOSITE COMPONENTS

Number: 20170043564
Published: 2017-02-16
Filed: 2015-08-12
Assignee: DISNEY ENTERPRISES, INC.
Inventors: SKAGGS; LAUREL LINDSEY et al.
CPC: B32B27/12; B32B27/38
Verdict: Low Hardware
Source: Google Patents · FreePatentsOnline

The keeper's note

Heat-shrink laminated composite patch material/process for repairing composite components (prop/vehicle repair hardware).

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-activatedshrink 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 atemperature 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

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a schematic side view of a sheet of a heat shrink laminated composite or repair laminate useful for fabricating composite repair patches of thepresent description;

FIG. 2 illustrates a sheet of a heat shrink laminated composite or composite repair laminate;

FIG. 3 illustrates a sectional view of the laminatedsheet of FIG. 2 taken at line 3-3;

FIG. 4 illustrates a sectional view, similar to that of FIG. 3, after heating is used or applied to the sheet of the heat shrink laminatedcomposite (e.g., when the material is used as a patch for a surface of a composite structure or component) so as to form a cured product (or installed/applied patch);

FIG. 5is a flow diagram for a method of repairing a surface of a component/structure formed of a composite material using a repair patch formed from a sheet of heat shrink laminated composite such as those described in FIGS. 1-4; and

FIGS. 6A-6C illustrate exemplary implementation of a number of the steps of the method of FIG. 5 illustrating repair of a composite material rod with a repair patch formed from a sheet of heat shrink laminated composite.DETAILED DESCRIPTION

Briefly, a heat shrink laminated composite is taught herein that can be sized, shaped, and applied in the field to repair or buildup surfaces of a structure or component formed of a composite material such as, but not limited to, fiber glass-reinforced plastic (FRP). The heat

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; 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. 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 activatedadhesive 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 method for repairinga surface formed of a composite material, comprising: applying a repair patch over the surface, wherein the repair patch comprises an outer film of a heat-activated adhesive, an inner film of a heat-activated adhesive, a reinforcement layer comprising sandwiched between the inner and outer films of the heat-activated adhesive, and a heat shrink film covering the outer film of the heat-activated adhesive and further wherein the applying of the repair patch comprises placing the inner film of the heat-activated adhesive in contact withthe surface formed of the composite material; and for a period of time in a curing time range for the heat-activated adhesive, heating the repair patch to a temperature in a curing temperature range for the heat-activated adhesive.