Method of manufacturing a reinforced portion and reinforced

Abstract

The invention relates to a method of manufacturing a reinforced portion and a reinforced vehicle. A method of manufacturing a reinforcement portion of a vehicle includes applying a release film directly onto a surface of the vehicle, applying a first metal layer directly or indirectly onto the release film, applying a curable adhesive layer directly onto the first metal layer, and applying a second metal layer directly onto the curable adhesive layer. The method further includes applying pressure to the first metal layer, the curable adhesive layer, and the second metal layer to press the first metal layer, the curable adhesive layer, and the second metal layer against the surface. The method further includes curing the curable adhesive layer when pressure is applied to the curable adhesive layer to form the reinforced portion. The method additionally includes removing the reinforcement portion from the surface after curing the curable adhesive layer.

Description

Technical Field

[0001] The present disclosure relates generally to reinforcing vehicle surfaces and, more particularly, to making reinforcing portions for reinforcing vehicle surfaces by using the vehicle surface to form the reinforcing portions. Background Art

[0002] Vehicles, such as aircraft, may require reinforcement after use in the field of the vehicle. In some cases, the surface of the vehicle may experience damage or fatigue, which may manifest as cracking along the surface. In addition, some surfaces have features that may require reinforcement over time, such as areas around holes.

[0003] To help strengthen surfaces that are experiencing damage or fatigue, a patch may be applied to the surface. The patch helps absorb microcrack energy, thereby promoting stasis of existing damage or fatigue, extending the life of the vehicle.

[0004] Some conventional patches are formed from sheet metal. The sheet metal is formed at a distance from the surface by any of a variety of forming tools, such as an English wheel, and then attached to the surface. Typically, the forming of the sheet metal requires multiple forming and fitting on the surface until the fit is correct. Using this conventional trial and error method to form the sheet metal to fit the shape of the surface is difficult and time consuming. Summary of the invention

[0005] The subject matter of the present application is developed in view of the current state of the art, in particular, in view of the shortcomings of conventional surface strengthening techniques that have not been fully addressed by the prior art. Therefore, the subject matter of the present application is to provide a method for manufacturing a reinforcement portion and using the reinforcement portion to strengthen a surface, which overcomes at least some of the above-mentioned shortcomings of the prior art.

[0006] The following is a non-exhaustive list of examples of the subject matter disclosed herein, which may or may not be claimed.

[0007] Disclosed herein is a method for manufacturing a reinforcement portion of a vehicle. The method includes applying a release film directly to the surface of the vehicle so that the release film conforms to the shape of the surface. The method also includes applying a first metal layer directly or indirectly to the release film so that the first metal layer conforms to the shape of the surface. The method also includes applying a curable adhesive layer directly to the first metal layer so that the curable adhesive layer conforms to the shape of the surface. The method additionally includes applying a second metal layer directly to the curable adhesive layer so that the curable adhesive layer is inserted between the first metal layer and the second metal layer and conforms to the shape of the surface. The method also includes applying pressure to the first metal layer, the curable adhesive layer and the second metal layer so that the first metal layer, the curable adhesive layer and the second metal layer are pressed against the surface. The method also includes curing the curable adhesive layer when applying pressure to the curable adhesive layer to form a reinforcement portion. The method additionally includes removing the reinforcement portion from the surface after curing the curable adhesive layer. The aforementioned subject matter of this paragraph characterizes Example 1 of the present disclosure.

[0008] The curable bonding layer includes a fiber reinforced polymer layer. The foregoing subject matter of this paragraph characterizes Example 2 of the present disclosure, wherein Example 2 also includes subject matter according to Example 1 above.

[0009] The fiber reinforced polymer layer includes a prepreg material, and curing the curable adhesive layer includes heating the prepreg material. The foregoing subject matter of this paragraph characterizes Example 3 of the present disclosure, wherein Example 3 also includes subject matter according to Example 2 above.

[0010] Heating the prepreg material includes applying a heating blanket over the first metal layer, the fiber reinforced polymer layer, and the second metal layer, and activating the heating blanket.The foregoing subject matter of this paragraph characterizes Example 4 of the present disclosure, wherein Example 4 also includes subject matter according to Example 3 above.

[0011] The curable adhesive layer includes a dry fiber sheet infused with a liquid resin. Applying the curable adhesive layer includes applying the dry fiber sheet directly to the first metal layer and infusing the liquid resin into the dry fiber sheet when applying the dry fiber sheet to the first metal layer. The foregoing subject matter of this paragraph characterizes Example 5 of the present disclosure, wherein Example 5 also includes subject matter according to any one of the above Examples 2-4.

[0012] The liquid resin cures at room temperature. The foregoing subject matter of this paragraph characterizes Example 6 of the present disclosure, wherein Example 6 also includes subject matter according to Example 5 above.

[0013] The method further comprises curing the fiber reinforced polymer layer at a temperature above room temperature after removing the reinforcement portion from the surface.The foregoing subject matter of this paragraph characterizes Example 7 of the present disclosure, wherein Example 7 also comprises subject matter according to Example 6 above.

[0014] Injecting the liquid resin into the dry fiber sheet includes applying a vacuum bag over the first metal layer, the fiber reinforced polymer layer, and the second metal layer, sealing the vacuum bag to the surface so that the first metal layer, the fiber reinforced polymer layer, and the second metal layer are sealed in a cavity defined between the vacuum bag and the surface, and reducing the pressure in the cavity. The foregoing subject matter of this paragraph characterizes Example 8 of the present disclosure, wherein Example 8 also includes subject matter according to any of the above Examples 5-7.

[0015] Curing the curable adhesive layer includes applying a heating blanket over the vacuum bag, the first metal layer, the fiber reinforced polymer layer, and the second metal layer. Applying pressure to the first metal layer, the fiber reinforced polymer layer, and the second metal layer includes applying a second vacuum bag over the heating blanket, the vacuum bag, the first metal layer, the fiber reinforced polymer layer, and the second metal layer, sealing the second vacuum bag to the surface so that the heating blanket, the vacuum bag, the first metal layer, the fiber reinforced polymer layer, and the second metal layer are sealed in a second cavity defined between the second vacuum bag and the surface, and reducing the pressure in the second cavity. The foregoing subject matter of this paragraph characterizes Example 9 of the present disclosure, wherein Example 9 also includes subject matter according to the above-mentioned Example 8.

[0016] Applying pressure to the first metal layer, the curable adhesive layer, and the second metal layer includes applying a vacuum bag over the first metal layer, the curable adhesive layer, and the second metal layer, sealing the vacuum bag to the surface so that the first metal layer, the curable adhesive layer, and the second metal layer are sealed in a cavity defined between the vacuum bag and the surface, and reducing the pressure in the cavity. The foregoing subject matter of this paragraph characterizes Example 10 of the present disclosure, wherein Example 10 also includes subject matter according to any of the foregoing Examples 1-9.

[0017] The curable adhesive layer is composed of a non-fibrous adhesive layer. The foregoing subject matter of this paragraph characterizes Example 11 of the present disclosure, wherein Example 11 also includes subject matter according to any one of the foregoing Examples 1-10.

[0018] The curable adhesive layer includes a first non-fibrous adhesive layer, a second non-fibrous adhesive layer, and a fiber-reinforced polymer layer interposed between the first non-fibrous adhesive layer and the second non-fibrous adhesive layer. The foregoing subject matter of this paragraph characterizes Example 12 of the present disclosure, wherein Example 12 also includes subject matter according to any one of the above Examples 1-11.

[0019] Each of the first metal layer and the second metal layer has a thickness between 0.01 inches and 0.04 inches, inclusive. The foregoing subject matter of this paragraph characterizes Example 13 of the present disclosure, wherein Example 13 also includes subject matter according to any of the foregoing Examples 1-12.

[0020] The shape of the surface to which the release film, the first metal layer, the fiber reinforced polymer layer, and the second metal layer conform is non-planar.The foregoing subject matter of this paragraph characterizes Example 14 of the present disclosure, wherein Example 14 also includes subject matter according to any of the above Examples 1-13.

[0021] The vehicle is an aircraft, and the surface is an outer surface of an aircraft skin.The foregoing subject matter of this paragraph characterizes Example 15 of the present disclosure, wherein Example 15 also includes subject matter according to any of the above Examples 1-14.

[0022] One of the first metal layers is applied directly to the release film, or the method further includes applying a second curable adhesive layer directly to the release film, such that the second curable adhesive layer conforms to the shape of the surface, and the first metal layer is applied directly to the second curable adhesive layer. The foregoing subject matter of this paragraph characterizes Example 16 of the present disclosure, wherein Example 16 also includes subject matter according to any of the above Examples 1-15.

[0023] Further disclosed herein is a method for strengthening a vehicle. The method includes applying a release film directly to the surface of the vehicle so that the release film conforms to the shape of the surface. The method also includes applying a first metal layer directly or indirectly to the release film so that the first metal layer conforms to the shape of the surface. The method also includes applying a curable adhesive layer directly to the first metal layer so that the curable adhesive layer conforms to the shape of the surface. The method additionally includes applying a second metal layer directly to the curable adhesive layer so that the curable adhesive layer is inserted between the first metal layer and the second metal layer and conforms to the shape of the surface. The method also includes applying pressure to the first metal layer, the curable adhesive layer, and the second metal layer so that the first metal layer, the curable adhesive layer, and the second metal layer are pressed against the surface. The method also includes curing the curable adhesive when applying pressure to the curable adhesive layer to form a reinforcement portion including the first metal layer, the curable adhesive layer, and the second metal layer. The method additionally includes removing the reinforcement portion from the surface and removing the release film from the surface after curing the curable adhesive layer. The method also includes attaching the reinforcement portion to the surface after removing the reinforcement portion and the release film from the surface. The foregoing subject matter of this paragraph characterizes Example 17 of the present disclosure.

[0024] A release film is applied directly to the first portion of the surface above or adjacent to a feature damage on the first portion of the surface. The first metal layer, the curable adhesive layer, and the second metal layer conform to the shape of the first portion of the surface. The reinforcement portion is attached to the first portion of the surface above or adjacent to the feature damage on the first portion of the surface. The aforementioned subject matter of this paragraph characterizes Example 18 of the present disclosure, wherein Example 18 also includes subject matter according to Example 17 above.

[0025] A release film is applied directly to a first portion of a surface. The first metal layer, the curable adhesive layer, and the second metal layer conform to the shape of the first portion of the surface. The reinforcing portion is attached to a second portion of the surface over or adjacent to a feature damage on the second portion of the surface, the second portion being spaced apart from the first portion of the surface, and the first portion of the surface having a profile that matches the profile of the second portion of the surface. The foregoing subject matter of this paragraph characterizes Example 19 of the present disclosure, wherein Example 19 also includes subject matter according to any of Examples 17-18 above.

[0026] Attaching the reinforcing portion to the surface includes bonding the reinforcing portion to the surface.The foregoing subject matter of this paragraph characterizes Example 20 of the present disclosure, wherein Example 20 also includes subject matter according to any of the above Examples 17-19.

[0027] Attaching the reinforcement portion to the surface further comprises bolting the reinforcement portion to the surface.The foregoing subject matter of this paragraph characterizes Example 21 of the present disclosure, wherein Example 21 further comprises subject matter according to Example 20 above.

[0028] Attaching the reinforcement portion to the surface includes bolting the reinforcement portion to the surface.The foregoing subject matter of this paragraph characterizes Example 22 of the present disclosure, wherein Example 22 also includes subject matter according to any of the above Examples 17-21.

[0029] The described features, structures, advantages and / or characteristics of the subject matter of the present disclosure may be combined in any suitable manner in one or more examples and / or embodiments. In the following description, many specific details are provided to impart a thorough understanding of the examples of the subject matter of the present disclosure. Those skilled in the relevant art will recognize that the subject matter of the present disclosure may be practiced without one or more of the specific features, details, components, materials and / or methods of a particular example or embodiment. In other cases, it may be recognized that the additional features and advantages in certain examples and / or embodiments may not be present in all examples or embodiments. In addition, in some cases, known structures, materials or operations are not shown or described in detail to avoid blurring the various aspects of the subject matter of the present disclosure. The features and advantages of the subject matter of the present disclosure will become more apparent from the following description and the appended claims, or may be learned by the practice of the subject matter described below. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] In order that the advantages of the present subject matter may be more readily understood, a more particular description of the subject matter briefly described above will be presented with reference to specific examples shown in the accompanying drawings. Understanding that these drawings, which are not necessarily drawn to scale, depict only certain examples of the subject matter and are therefore not to be considered limiting of its scope, the subject matter will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which:

[0031] Figure 1is a perspective view of an aircraft according to one or more examples of the present disclosure;

[0032] Figure 2 is a flow chart depicting a plurality of steps of a method of reinforcing a surface of a vehicle according to one or more examples of the present disclosure using schematic cross-sectional representations of the vehicle and the reinforcing portion;

[0033] Figure 3A-3G is a cross-sectional side view schematically illustrating various steps of a method of manufacturing a reinforcement portion according to one or more examples of the present disclosure;

[0034] Figure 4 is a cross-sectional side view of a reinforcement portion according to one or more examples of the present disclosure;

[0035] Figure 5 is a cross-sectional side view of a reinforcement portion according to one or more examples of the present disclosure;

[0036] Figure 6 is a cross-sectional side view of a reinforcement portion according to one or more examples of the present disclosure;

[0037] Figure 7 is a cross-sectional side view of a reinforcement portion according to one or more examples of the present disclosure;

[0038] Figure 8 is a cross-sectional side view of a reinforcement portion according to one or more examples of the present disclosure;

[0039] Figure 9A-9D is a cross-sectional side view schematically illustrating various steps of a method of manufacturing a reinforcement portion according to one or more examples of the present disclosure;

[0040] Fig.10 is a cross-sectional side view of a reinforcement portion formed on a surface of a vehicle having multiple contours according to one or more examples of the present disclosure;

[0041] Fig.11 is a cross-sectional side view of a reinforcement portion attached to a surface of a vehicle using a first method according to one or more examples of the present disclosure;

[0042] Fig.12 is a cross-sectional side view of a reinforcement portion attached to a surface of a vehicle using a second method according to one or more examples of the present disclosure;

[0043] Fig.13 is a cross-sectional side view of a reinforcement portion attached to a surface of a vehicle using a third method according to one or more examples of the present disclosure;

[0044] Fig.14is a cross-sectional side view of a reinforcement portion attached to a surface of a vehicle using a fourth method according to one or more examples of the present disclosure; and

[0045] Fig.15 is a schematic flow chart of a method of manufacturing a reinforced portion and a reinforced vehicle according to one or more examples of the present disclosure. DETAILED DESCRIPTION

[0046] References in this specification to "one example," "example," or similar language mean that a particular feature, structure, or characteristic described in conjunction with the example is included in at least one example of the present disclosure. The phrases "in one example," "in an example," and similar language appearing in this specification may, but do not necessarily, all refer to the same example. Similarly, use of the term "embodiment" refers to an embodiment having a particular feature, structure, or characteristic described in conjunction with one or more examples of the present disclosure, however, an embodiment may be associated with one or more examples if there is no clear correlation to indicate otherwise.

[0047] The present disclosure includes a plurality of examples that overcome the shortcomings of conventional methods of reinforcing the surface of a vehicle by using the surface of the vehicle as a tooling or molding surface to form a reinforcement portion that is attached separately to the surface. In this way, the matching of the profile of the reinforcement portion with the surface of the vehicle is ensured without the need for auxiliary forming tools (such as inch wheels or molds) and related trial and error forming methods. The reinforcement portion can be formed using a damaged surface (or a surface that needs to be strengthened) to which the reinforcement portion is to be attached. Alternatively, an undamaged surface having a profile that matches the profile of the damaged surface can be used to form the reinforcement portion. By using the surface of the vehicle as a tooling surface, the reinforcement portion can be manufactured in a timely and efficient manner without the need for separate tooling and post-forming heat treatment.

[0048] refer to Figure 1 , showing an example of a vehicle. Figure 1 The vehicle shown in the illustration is an aircraft 100, which represents any of various types of aircraft, such as commercial aircraft for transporting passengers, military aircraft for military operations, personal aircraft, fighter jets, etc. In addition, although an aircraft is depicted in the illustrated example, in other examples, other types of vehicles (e.g., helicopters, ships, spacecraft, automobiles, etc.) may be used.

[0049] The depicted aircraft 100 includes a body 112 (e.g., a fuselage), a pair of wings 114 coupled to and extending from the body 112, a vertical stabilizer 116 coupled to the body 112, and a pair of horizontal stabilizers 118 coupled to the body 112 and / or the vertical stabilizers 116. As shown, the aircraft 100 represents a passenger aircraft. Any of the various parts of the aircraft 100 (such as part 130 (see, e.g., Figure 2 )) includes surfaces that may be damaged or otherwise require reinforcement. As used herein, reinforcement refers to repair or strengthening. Thus, a reinforcement portion may refer to a repaired portion or a reinforcement portion, and a reinforcement method may refer to a repair or reinforcement method. In one example, portion 130 is body 112 of aircraft 100, and surface 132 of portion 130 (e.g., see Figure 2 ) is an outer skin of body 112. Thus, in some examples, surface 132 of portion 130 is an outer surface of the vehicle. For example, surface 132 of portion 130 may be an outer surface or skin of wing 114, vertical stabilizer 116, and / or horizontal stabilizer 118.

[0050] The surface 132 of the portion 130 can be made of any of a variety of materials, such as a metallic material (e.g., an aluminum alloy or a steel alloy), or a composite material, such as a carbon fiber or glass fiber reinforced polymer material. The portion 130 can have a laminated construction. In addition, the thickness of the portion 130 is defined as the distance between the surface 132 and the opposite surface of the portion 130.

[0051] refer to Figure 1 and Figure 2 , the present disclosure proposes a method of using the surface 132 of the portion 130 of the vehicle as a tooling surface to manufacture the reinforcing portion 120, and then attaching the reinforcing portion 120 to the surface 132 of the vehicle. Figure 2 As shown, in one example, the reinforcing portion 120 is formed on the surface 132 of the reinforcing portion 120. In some examples, the reinforcing portion 120 is formed over the damage 134 in the surface 132 of the reinforcing portion 120, removed from the surface 132, and then attached back to the surface 132 over the damage 134. However, in alternative examples, the reinforcing portion 120 is formed on a portion of the surface 132 of the reinforcing portion 120 that does not have the damage 134, removed from the portion of the surface 132, and then attached to the portion of the surface 132 that has the damage 134. The attachment of the reinforcing portion 120 to the surface 132 is performed separately and by a different process than the formation of the reinforcing portion 120 on the surface 132.

[0052] The reinforcement portion 120 formed on the surface 132 has at least a first metal layer 122A, a second metal layer 122B, and a curable adhesive layer 124 interposed between the first metal layer 122A and the second metal layer 122B. The curable adhesive layer 124 bonds the first metal layer 122A and the second metal layer 122B together to create a laminated structure. The laminated construction of the reinforcement portion 120 helps reduce fatigue by absorbing and distributing microcrack energy. In addition, the isolation provided by the staggered adhesive layers reduces the possibility of corrosion, which limits corrosion to the outermost layer of the reinforcement portion 120.

[0053] refer to Fig.15 , a method 200 for making a reinforcement portion and reinforcing a surface of a vehicle is shown. The method 200 includes (block 202) applying a release film 136 directly to a surface 132 of a vehicle (e.g., a portion 130 of an aircraft 100) such that the release film 136 conforms to the shape of the surface 132. Figure 3A As shown, the release film 136 is applied directly to the surface 132 of the portion 130 and takes on the same shape as the surface 132. In the example shown, the shape of the surface 132, and therefore the shape of the release film 136, is convex, but can be any of a variety of non-planar shapes, such as concave or a complex contour shape with multiple inflection points (see, for example, Fig.10 ). However, in other examples, the surface 132 may have a planar shape without departing from the essence of the present disclosure. The release film 136 may be any of a variety of non-stick release films or pads configured to reduce adhesion or adhesion between two parts, such as a siliconized film, a polyester film, a Teflon sheet, a polytetrafluoroethylene (PTFE) sheet, etc. In addition, the release film 136 is deformable or flexible, which enables the release film 136 to take on the same shape as the surface 132.

[0054] In some examples, release film 136 is applied directly to surface 132 over damage 134 (e.g., cracks) in surface 132. In these examples, if damage 134 passes completely through the thickness of portion 130, blocking may be required to enable negative pressure to be generated, as described in more detail below. However, in other examples, release film 136 is applied directly to surface 132 adjacent to damage 134 so that release film 136 is not applied over damage 134. In these other examples, even if damage 134 passes completely through the thickness of portion 130, blocking of damage 134 is not required.

[0055] Method 200 also includes (block 204) applying first metal layer 122A directly or indirectly to release film 136 such that first metal layer 122A conforms to the shape of surface 132. As used herein, applying a given layer directly to another object means that no other layers are interposed between the given layer and the object. Conversely, applying a given layer indirectly to another object means that another layer may be interposed between the given layer and the object. Figure 3B In some examples, the first metal layer 122A is applied directly onto the release film 136 and assumes the same shape as the release film 136, thereby assuming the same shape as the surface 132. The coverage of the release film 136 on the surface 132 is at least as large as the coverage of the first metal layer 122A on the release film 136 to ensure that the release film 136 is inserted between the entire first metal layer 122A and the surface 132. The first metal layer 122A is deformable or flexible, which enables the first metal layer 122A to assume the same shape as the surface 132. The relatively small thickness of the first metal layer 122A enables the first metal layer 122A to deform. In some examples, the thickness of the first metal layer 122A is between 0.01 inches and 0.04 inches, inclusive. In one example, the first metal layer 122A is made of an aluminum alloy or a titanium alloy, and has a thickness between 0.01 inches and 0.03 inches, inclusive (eg, 0.02 inches).

[0056] The method 200 also includes (block 206) applying the curable adhesive layer 124 directly onto the first metal layer 122A such that the curable adhesive layer 124 conforms to the shape of the surface 132. Figure 3C In some examples, the curable adhesive layer 124 is applied directly to the first metal layer 122A and takes on the same shape as the first metal layer 122A, thereby taking on the same shape as the surface 132. The curable adhesive layer 124 is deformable or flexible before curing, which enables the curable adhesive layer 124 to take on the same shape as the surface 132. In some examples, the thickness of the curable adhesive layer 124 is less than the thickness of the first metal layer 122A. In one example, the curable adhesive layer 124 is made of a curable adhesive material (e.g., an adhesive, a resin, an epoxy resin, etc.). The curable adhesive material is capable of curing at any of a variety of temperatures, such as room temperature (e.g., between 68°F and 76°F) or an elevated temperature above room temperature. As explained in more detail below, the curable adhesive layer 124 is, in some examples, a non-fibrous adhesive layer 146 (e.g., see Figure 6 ), in other examples a fiber reinforced polymer layer 148 (e.g., Figure 7 ), or a combination of a non-fibrous binder layer 146 and a fiber-reinforced polymer layer 148 (see, for example, Figure 8).

[0057] When the curable adhesive layer 124 is or consists of a non-fibrous adhesive layer 146, the non-fibrous adhesive layer 146 may be applied to the first metal layer 122A using any of a variety of application techniques. When applied, the material of the non-fibrous adhesive layer 146 may be in a viscous or flowable state and applied by dispensing the non-fibrous adhesive layer 146 onto the first metal layer 122A. In other examples, the non-fibrous adhesive layer 146 may be a solid, non-flowable sheet material placed on the first metal layer 122A.

[0058] When the curable bonding layer 124 is a fiber reinforced polymer layer 148 made of a prepreg material, the prepreg material (which may be a prepreg material sheet) is placed or laid on the first metal layer 122A. The prepreg material may be a glass fiber prepreg material or a carbon fiber prepreg material. Figure 8 When the curable adhesive layer 124 has a laminated construction made of a combination of a non-fiber adhesive layer 146 and a fiber-reinforced polymer layer 148, the curable adhesive layer 124 is applied to the first metal layer 122A by applying the non-fiber adhesive layer 146 (e.g., a first non-fiber adhesive layer) on the first metal layer 122A, applying the fiber-reinforced polymer layer 148 on the non-fiber adhesive layer 146, and applying the non-fiber adhesive layer 146 (e.g., a second non-fiber adhesive layer) on the fiber-reinforced polymer layer 148. In some examples, when the fiber-reinforced polymer layer 148 is formed using a dry fiber sheet 154 infused with a liquid resin (as described below), the curable adhesive layer 124 may have a laminated construction made of a dry fiber sheet 154 infused with a resin (i.e., a resin-infused dry fiber sheet) inserted or sandwiched between two non-fiber adhesive layers 146.

[0059] The method 200 also includes (block 208) applying the second metal layer 122B directly onto the curable adhesive layer 124 such that the second metal layer 122B conforms to the shape of the surface 132. Figure 3D In some examples, the second metal layer 122B is directly applied on the curable adhesive layer 124 and takes on the same shape as the curable adhesive layer 124, thereby taking on the same shape as the surface 132. In some examples, the second metal layer 122B is configured the same as the first metal layer 122A and is made of the same material as the first metal layer 122A. Therefore, the second metal layer 122B is deformable or flexible, which enables the release film 136 to take on the same shape as the surface 132.

[0060] Method 200 additionally includes (block 210) applying pressure to first metal layer 122A, curable adhesive layer 124, and second metal layer 122B such that first metal layer 122A, curable adhesive layer 124, and second metal layer 122B are pressed against surface 132. Figure 3E In one example, pressure is applied to the layer via a negative pressure created within a vacuum bag 138, which is sealed to the surface 132 over the layer. The vacuum bag 138 can be sealed to the surface 132 via any of a variety of sealing techniques (e.g., tape, adhesive, etc.). An inner cavity is defined between the vacuum bag 138 and the layer. The vacuum bag 138 includes an outlet that fluidly couples the inner cavity (e.g., via a conduit or hose) to a vacuum source 140. When the vacuum source 140, which may include a vacuum device, is activated, the pressure within the inner cavity decreases until the vacuum bag 138 applies a uniform pressure to the first metal layer 122A, the curable adhesive layer 124, and the second metal layer 122B, which presses the layers against the surface 132. Although the application of negative pressure is shown herein, in alternative examples, the pressure applied to the layer may be a positive pressure, such as pressure applied via a pressurized cylinder or actuator.

[0061] The method 200 also includes (block 212) curing the curable adhesive layer 124 while applying pressure to the curable adhesive layer 124 (and the first metal layer 122A and the second metal layer 122B). In some examples, the curable adhesive layer 124 is cured at room temperature based on the type of curable material of the curable adhesive layer 124. For example, the curable adhesive layer 124 can be a liquid resin that cures when left at room temperature for a predetermined period of time. However, in other examples, based on the type of curable material of the curable adhesive layer 124, the curable adhesive layer 124 is cured by heating the curable material. For example, the curable material can be a solid resin of a prepreg sheet that cures when heated to a curing temperature of the solid resin for a predetermined period of time. Reference Figure 3F In some examples of curing the curable material of curable adhesive layer 124 by heating the curable material, the curable material is heated by applying a heating blanket 142 over first metal layer 122A, curable adhesive layer 124, and second metal layer 122B and activating heating blanket 142 (by supplying power from power source 144) to generate heat. The heat from heating blanket 142 is transferred to the layers including curable adhesive layer 124 to cure curable adhesive layer 124. Figure 3F As shown, in some examples, after applying the heating blanket 142 to the first metal layer 122A, the curable adhesive layer 124, and the second metal layer 122B, the vacuum bag 138 is applied over the heating blanket 142. Thus, in these examples, the heating blanket 142 is located within the inner cavity defined by the vacuum bag 138, and when the pressure within the inner cavity is reduced, the heating blanket 142 is compressed along with the layers.

[0062] The method 200 also includes (block 214) removing the first metal layer 122A, the curable adhesive layer 124, and the second metal layer 122B from the surface 132 after the curable adhesive layer 124 is cured. After the curable adhesive layer 124 is cured, the first metal layer 122A, the curable adhesive layer 124, and the second metal layer 122B form the reinforcement portion 120. Therefore, removing the first metal layer 122A, the curable adhesive layer 124 (after being cured), and the second metal layer 122B means removing the reinforcement portion 120 from the surface 132. In other words, the reinforcement portion 120 is formed in situ on the surface 132 of the portion 130 of the vehicle before being removed from the surface 132. Figure 3G An example of a finished reinforcement portion 120 is shown in FIG. It should be appreciated that removing the reinforcement portion 120 from the surface 132 means that the reinforcement portion 120 is removed from the release film 136. Subsequently, the release film 136 can also be removed from the surface 132 and reused or discarded. An additional step of the method can include trimming the reinforcement portion 120 to an appropriate size to facilitate attachment back to the surface 132 over the damage 134.

[0063] although Figure 3G The reinforcement portion 120 shown includes only two metal layers and a curable adhesive layer between the two metal layers, but in other examples, the reinforcement portion 120 may include one or more additional curable adhesive layers and metal layers. In other words, the reinforcement portion 120 may have any number of alternating metal layers and curable adhesive layers. For example, Figure 4 As shown, the second reinforcing portion 120A includes a second curable adhesive layer 124A and a third metal layer 122C, wherein the second curable adhesive layer 124A is inserted between the second metal layer 122B and the third metal layer 122C. As another example, Figure 5 As shown, the third reinforcing portion 120B includes a third curable adhesive layer 124B and a fourth metal layer 122D, wherein the third curable adhesive layer 124B is inserted between the third metal layer 122C and the fourth metal layer 122D. In addition, the size and / or shape of one or more metal layers and curable adhesive layers can be different from another one or more metal layers and curable adhesive layers. For example, the reinforcing portion can be a repeating pattern of metal layers and curable adhesive layers, wherein at least one of the metal layers and at least one of the curable adhesive layers has a smaller size relative to the underlying layers. For example, as Figure 5 As shown, the first metal layer 122A, the curable adhesive layer 124 and the second metal layer 122B have a first width W1, and the second curable adhesive layer 124A, the third metal layer 122C, the third curable adhesive layer 124B and the fourth metal layer 122D have a second width W2 which is smaller than the first width W1.

[0064] refer to Figure 9A-9D In some examples, the curable adhesive layer 124 includes a dry fiber sheet 154 infused with a liquid resin. In such examples, the step of applying the curable adhesive layer 124 includes applying the dry fiber sheet 154 directly to the first metal layer 122A and infusing the liquid resin into the dry fiber sheet 54 after applying it to the first metal layer 122A. In some examples, such as Fig. 9A As shown, the substrate or second curable adhesive layer 124A is directly applied to the release film 136, and the first metal layer 122A is directly applied to the second curable adhesive layer 124A, thereby indirectly applying the first metal layer 122A to the release film 136. The second curable adhesive layer 124A can include a dry fiber sheet 154 injected with a liquid resin and can be applied in the same manner as described above. The liquid resin is supplied from a resin source 158 and can be injected into the dry fiber sheet 154 manually or automatically.

[0065] refer to Fig. 9C In order to promote uniform infusion of the resin throughout the dry fiber sheet 154, in some examples, the step of infusing the liquid resin includes applying a vacuum bag 160 over the first metal layer 122A, the fiber-reinforced polymer layer 148 (e.g., a dry fiber sheet infused with liquid resin), the second metal layer 122B, and the optional second curable adhesive layer 124A, and sealing the vacuum bag 160 to the surface 132. When sealed, the vacuum bag 160 and the surface 132 define a cavity that accommodates the first metal layer 122A, the fiber-reinforced polymer layer, the second metal layer 122B, and the optional substrate or second curable adhesive layer 124A. The pressure in the cavity is reduced (e.g., via the second vacuum source 141), thereby creating a vacuum condition in the cavity, and the vacuum bag 160 applies uniform pressure to the first metal layer 122A, the fiber-reinforced polymer layer 148, the second metal layer 122B, and the optional second curable adhesive layer 124A. The uniform pressure helps to evenly distribute the resin within the dry fiber sheet 154 of the fiber-reinforced polymer layer 148 and the optional second curable bonding layer 124A.

[0066] refer to Fig.9D In some examples where the curable adhesive layer 124 includes a dry fiber sheet 154 infused with a liquid resin, the liquid resin is cured by heating the curable material with a heating blanket 142 applied over a vacuum bag 160. In addition, another vacuum bag 138 is applied over the heating blanket 142, and thus over the vacuum bag 160. Thus, in such an example, the heating blanket 142 and the vacuum bag 160 are located within the inner cavity defined by the vacuum bag 138, and are compressed together with the layer when the pressure within the inner cavity of the vacuum bag 138 is reduced. In this way, a double vacuum bag solution can be used to infuse resin into a dry fiber sheet and promote the curing of the resin.

[0067] In some examples where the curable adhesive layer 124 includes a curable material capable of curing at room temperature, the curing at room temperature is an initial cure, and the method further includes additionally or finally curing the curable adhesive layer 124 after removing the reinforcement portion 120 from the surface 132. The final curing of the curable adhesive layer 124 may include raising the temperature of the curable adhesive layer 124 to a certain predetermined temperature associated with an increase in the strength of the curable adhesive layer 124.

[0068] Reference again Fig.15 The method 200 additionally includes (block 216) removing the reinforcing portion 120 from the surface 132 after forming the reinforcing portion 120 on the surface 132, and then attaching the reinforcing portion 120 to the surface 132. Figure 11-13 In some examples, reinforcing portion 120 is attached to surface 132 over (e.g., covering) damage 134 to help strengthen (e.g., reduce the spread of damage 134 to) surface 132. However, in other examples, such as Fig.14 As shown, the reinforcing portion 120 is attached to the surface 132 adjacent to a feature 166 (or damage) of the surface 132 to help strengthen the feature 166 by building a thickness / gauge around the feature or damage. The feature 166 can be any of a variety of features, such as a hole, a build-up around a hole, etc. In these examples, the reinforcing portion 120 can be formed with an opening 168 corresponding to the feature 166, so that the feature 166 can be accessible through the reinforcing portion 120.

[0069] The reinforcement portion 120 may be attached to the surface 132 of the portion 130 in a variety of ways. In a first example, Fig.11 and Fig.14 As shown, the reinforcement portion 120 is secondarily bonded directly to the surface 132 by the adhesive 150 without any fasteners. Fig.12 In the second example shown, the reinforcing portion 120 is secondarily bonded directly to the surface 132 via an adhesive 150, and the reinforcing portion 120 is fastened to the surface 132, for example, via bolts or fasteners 152. The fasteners 152 can help carry the load in the event that the bond created by the adhesive 150 weakens or fails. In a third example, as shown in FIG. Fig.13 As shown, the reinforcement portion 120 is secured to the surface 132 without an adhesive.

[0070] As described above, the reinforcing portion 120 is formed on the surface 132 using the surface 132 as a tooling surface, the reinforcing portion 120 is removed from the surface 132, and then the reinforcing portion 120 is attached to the surface 132. The location on the surface 132 or the portion of the surface 132 to which the reinforcing portion 120 is attached is associated with the damaged portion of the surface 132 (i.e., the location or portion of the surface 132 having the damage 134). In other words, the reinforcing portion 120 is attached to the damaged portion of the surface 132 such that the reinforcing portion 120 is either directly adjacent to (e.g., surrounding) the damage 134 or on top of (e.g., covering) the damage 134.

[0071] However, the portion of the surface 132 used as the tooling surface for forming the reinforcing portion 120 may be a damaged portion or an undamaged portion of the surface 132 (i.e., a location or portion on the surface 132 that is not damaged, but whose profile is the same as the profile of the damaged portion of the surface 132). In one example, the reinforcing portion 120 is formed on an undamaged portion of the surface 132 that shares similar profile features with the damaged portion. For example, the undamaged portion may be a portion that is connected to or adjacent to the damaged portion (e.g., above, below, or to the side of the damaged portion). According to some embodiments, the undamaged portion of the surface 132 (on which the reinforcing portion 120 is formed) is a portion of the surface 132 above or below the damaged portion at the same axial position along the vehicle body, because the surface profile at the same axial position may be the same along the entire circumference of the vehicle. Since the profile features of the undamaged portion and the damaged portion are similar or identical, when the profile of the reinforcing portion 120 is formed on the undamaged portion, it facilitates mating engagement with the damaged portion when attached to the damaged portion.

[0072] According to another example, the reinforcing portion 120 is formed on the damaged portion of the surface 132. In these examples, the reinforcing portion 120 is removed from the damaged portion to allow the release film 136 to be removed and then attached to the same damaged portion. Forming the reinforcing portion 120 on the same surface to which the reinforcing portion 120 will be attached ensures a mating engagement with the damaged portion of the surface 132.

[0073] In the above description, certain terms may be used, such as "upward", "downward", "upper", "lower", "horizontal", "vertical", "left", "right", "above", "below", etc. Where applicable, these terms are used to provide some clear description when dealing with relative relationships. However, these terms do not mean absolute relationships, positioning and / or orientations. For example, for an object, the "upper" surface can become the "lower" surface by simply flipping the object. However, it is still the same object. In addition, unless otherwise expressly provided, the terms "including", "comprising", "having" and their variations all mean "including but not limited to". Unless otherwise expressly provided, the list of enumerated items does not mean that any or all items are mutually exclusive and / or mutually inclusive. Unless otherwise expressly provided, the terms "a", "an" and "the" also mean "one or more". In addition, the term "multiple" can be limited to "at least two". In addition, unless otherwise stated, as defined herein, multiple specific features do not necessarily mean each specific feature in the entire specific feature set or category.

[0074] In addition, examples of an element being "coupled" to another element in this specification may include direct and indirect coupling. Direct coupling may be defined as one element being coupled to another element and maintaining a certain contact. Indirect coupling may be defined as a coupling between two elements that are not in direct contact with each other, but there are one or more additional elements between the coupled elements. In addition, as used herein, fixing an element to another element may include direct fixing and indirect fixing. In addition, as used herein, "adjacent" does not necessarily mean contact. For example, an element may be adjacent to another element without being in contact with the element.

[0075] As used herein, when used with a list of items, the phrase "at least one of..." means that different combinations of one or more of the listed items may be used, and only one of the items in the list may be required. The item may be a specific object, thing, or category. In other words, "at least one of..." means that any combination of items or number of items from the list may be used, but not all items in the list are required. For example, "at least one of item A, item B, and item C" may refer to item A; item A and item B; item B; item A, item B, and item C; or item B and item C. In some cases, "at least one of item A, item B, and item C" may mean, for example, but not limited to, two of item A, one of item B, and ten of item C; four of item B and seven of item C; or some other suitable combination.

[0076] Unless otherwise indicated, the terms "first," "second," etc. are used herein merely as labels and are not intended to impose order, position, or hierarchy requirements on the items to which these terms refer. Furthermore, reference to, for example, a "second" item does not require or preclude the existence of, for example, a "first" or lower-numbered item and / or a "third" or higher-numbered item.

[0077] As used herein, a system, device, structure, article, element, component, or hardware that is "configured to" perform a specified function is actually capable of performing the specified function without any changes, rather than merely having the potential to perform the specified function after further modification. In other words, a system, device, structure, article, element, component, or hardware that is "configured to" perform a specified function is selected, created, implemented, used, programmed, and / or designed specifically for the purpose of performing the specified function. As used herein, "configured to" means existing characteristics of a system, device, structure, article, element, component, or hardware that enable the system, device, structure, article, element, component, or hardware to perform the specified function without further modification. For the purposes of this disclosure, a system, device, structure, article, element, component, or hardware that is described as "configured to" perform a particular function may additionally or alternatively be described as being "suitable for" and / or "operable to" perform that function.

[0078] The schematic flow charts included herein are generally presented as logical flow charts. Therefore, the depicted order and the marked steps indicate an example of the presented method. Other steps and methods that are equivalent to one or more steps or parts thereof of the illustrated method in function, logic or effect can be envisioned. In addition, the format and symbols adopted are provided to explain the logical steps of the method and should not be understood as limiting the scope of the method. Although various arrow types and line types can be adopted in the flow chart, it should be understood that they do not limit the scope of the corresponding method. In fact, some arrows or other connectors can be used to indicate only the logical flow of the method. For example, an arrow can indicate a waiting or monitoring period of unspecified duration between the enumerated steps of the depicted method. In addition, the order in which a particular method occurs may strictly comply with or not strictly comply with the order of the corresponding steps shown.

[0079] The present invention also includes embodiments according to the following examples.

[0080] Example 1. A method of manufacturing a reinforcement portion (120) of a vehicle (100), the method comprising:

[0081] applying a release film (136) directly onto the surface (132) of the vehicle (100) such that the release film (136) conforms to the shape of the surface (132);

[0082] Applying a first metal layer (122A) directly or indirectly to the release film (136) such that the first metal layer (122A) conforms to the shape of the surface (132);

[0083] applying a curable adhesive layer (124) directly onto the first metal layer (122A) such that the curable adhesive layer (124) conforms to the shape of the surface (132);

[0084] applying a second metal layer (122B) directly onto the curable adhesive layer (124) such that the curable adhesive layer (124) is interposed between the first metal layer (122A) and the second metal layer (122B) and such that the second metal layer (122B) conforms to the shape of the surface (132);

[0085] applying pressure to the first metal layer (122A), the curable adhesive layer (124), and the second metal layer (122B) so that the first metal layer (122A), the curable adhesive layer (124), and the second metal layer (122B) are pressed against the surface (132);

[0086] curing the curable adhesive layer (124) while applying pressure to the curable adhesive layer (124) to form the reinforcing portion (120); and

[0087] After curing the curable adhesive layer (124), the reinforcing portion (120) is removed from the surface (132).

[0088] Example 2. The method of Example 1, wherein the curable adhesive layer (124) comprises a fiber reinforced polymer layer (148).

[0089] Example 3. The method of Example 2, wherein:

[0090] The fiber reinforced polymer layer (148) comprises a prepreg material; and

[0091] Curing the curable adhesive layer (124) includes heating the prepreg material.

[0092] Example 4. A method according to Example 3, wherein heating the prepreg material includes applying a heating blanket (142) over the first metal layer (122A), the fiber reinforced polymer layer (148) and the second metal layer (122B), and activating the heating blanket (142).

[0093] Example 5. The method of Example 2, wherein:

[0094] The curable adhesive layer (124) comprises a dry fiber sheet (154) impregnated with a liquid resin; and

[0095] Applying the curable adhesive layer (124) includes applying the dry fiber sheet (154) directly to the first metal layer (122A) and infusing liquid resin into the dry fiber sheet (154) when applying the dry fiber sheet (154) to the first metal layer (122A).

[0096] Example 6. The method of Example 5, wherein the liquid resin cures at room temperature.

[0097] Example 7. The method of Example 6 further comprising curing the fiber reinforced polymer layer (148) at a temperature above room temperature after removing the reinforcing portion (120) from the surface (132).

[0098] Example 8. The method of Example 5, wherein injecting the liquid resin into the dry fiber sheet (154) comprises:

[0099] applying a vacuum bag (160) over the first metal layer (122A), the fiber reinforced polymer layer (148), and the second metal layer (122B);

[0100] sealing the vacuum bag (160) to the surface (132) such that the first metal layer (122A), the fiber reinforced polymer layer (148), and the second metal layer (122B) are sealed within a cavity defined between the vacuum bag (138) and the surface (132); and

[0101] The pressure within the cavity is reduced.

[0102] Example 9. The method of Example 8, wherein:

[0103] Curing the curable adhesive layer (124) includes applying a heating blanket over the vacuum bag (160), the first metal layer (122A), the fiber reinforced polymer layer (148), and the second metal layer (122B); and

[0104] Applying pressure to the first metal layer (122A), the fiber reinforced polymer layer (148), and the second metal layer (122B) includes:

[0105] applying a second vacuum bag (138) over the heating blanket (142), the vacuum bag (160), the first metal layer (122A), the fiber reinforced polymer layer (148), and the second metal layer (122B);

[0106] The second vacuum bag (138) is sealed to the surface (132) so that the heating blanket (142), the vacuum bag (160), the first metal layer (122A), the fiber reinforced polymer layer (148)

[0107] and the second metal layer is sealed between the second vacuum bag (138) and the surface (132)

[0108] within a second cavity defined by the space between the two chambers; and

[0109] The pressure in the second chamber is reduced.

[0110] Example 10. The method of Example 1, wherein applying pressure to the first metal layer (122A), the curable adhesive layer (124), and the second metal layer (122B) comprises:

[0111] applying a vacuum bag (138) over the first metal layer (122A), the curable adhesive layer (124), and the second metal layer (122B);

[0112] sealing the vacuum bag (138) to the surface (132) such that the first metal layer (122A), the curable adhesive layer (124), and the second metal layer (122B) are sealed within a cavity defined between the vacuum bag (138) and the surface (132); and

[0113] The pressure within the cavity is reduced.

[0114] Example 11. The method of example 1, wherein the curable adhesive layer (124) is comprised of a non-fibrous adhesive layer (146).

[0115] Example 12. The method of Example 1, wherein the curable adhesive layer (124) comprises:

[0116] a first non-fibrous adhesive layer (146);

[0117] a second non-fibrous adhesive layer (146); and

[0118] A fiber reinforced polymer layer (148) is interposed between the first non-fibrous binder layer (146) and the second non-fibrous binder layer (146).

[0119] Example 13. The method of Example 1, wherein the thickness of each of the first metal layer (122A) and the second metal layer (122B) is between 0.01 inches and 0.04 inches, inclusive.

[0120] Example 14. A method according to Example 1, wherein the shape of the surface (132) to which the release film (136), the first metal layer (122A), the curable adhesive layer (124) and the second metal layer (122B) conform is non-planar.

[0121] Example 15. The method of Example 1, wherein:

[0122] The vehicle (100) is an aircraft; and

[0123] The surface (132) is an outer surface of the skin of the aircraft.

[0124] Example 16. The method of Example 1, wherein one of the following:

[0125] The first metal layer (122A) is applied directly onto the release film (136); or

[0126] The method also includes applying a second curable adhesive layer (124) directly onto the release film (136) such that the second curable adhesive layer (126) conforms to the shape of the surface (132), and the first metal layer (122A) is directly applied onto the second curable adhesive layer (124).

[0127] Example 17. A method of reinforcing a vehicle (100), the method comprising:

[0128] applying a release film (136) directly onto the surface (132) of the vehicle (100) such that the release film (136) conforms to the shape of the surface (132);

[0129] Applying a first metal layer (122A) directly or indirectly to the release film (136) such that the first metal layer (122A) conforms to the shape of the surface (132);

[0130] applying a curable adhesive layer (124) directly onto the first metal layer (122A) such that the curable adhesive layer (124) conforms to the shape of the surface (132);

[0131] applying a second metal layer (122B) directly onto the curable adhesive layer (124) such that the curable adhesive layer (124) is interposed between the first metal layer (122A) and the second metal layer (122B) and such that the second metal layer (122B) conforms to the shape of the surface (132);

[0132] applying pressure to the first metal layer (122A), the curable adhesive layer (124), and the second metal layer (122B) so that the first metal layer (122A), the curable adhesive layer (124), and the second metal layer (122B) are pressed against the surface (132);

[0133] curing the curable adhesive layer (124) while applying pressure to the curable adhesive layer (124) to form a reinforcing portion (120) including the first metal layer (122A), the curable adhesive layer (124) and the second metal layer (122B);

[0134] After curing the curable adhesive layer (124), removing the reinforcing portion (120) from the surface (132), and removing the release film (136) from the surface (132); and

[0135] After removing the reinforcing portion (120) and the release film (136) from the surface (132), the reinforcing portion (120) is attached to the surface (132).

[0136] Example 18. The method of Example 17, wherein:

[0137] The release film (136) is applied directly to the first portion of the surface (132) over or adjacent to the damage to the feature of the first portion of the surface (132);

[0138] The first metal layer (122A), the curable adhesive layer (124), and the second metal layer (122B) conform to the shape of the first portion of the surface (132); and

[0139] The reinforcing portion (120) is attached to the first portion of the surface (132) over or adjacent to the damage to the feature of the first portion of the surface (132).

[0140] Example 19. The method of Example 17, wherein:

[0141] The release film (136) is applied directly to a first portion of the surface (132);

[0142] The first metal layer (122A), the curable adhesive layer (124), and the second metal layer (122B) conform to the shape of the first portion of the surface (132);

[0143] The reinforcing portion (120) is attached to a second portion of the surface (132) over or adjacent to a damage to a feature of the second portion of the surface (132), the second portion being spaced apart from the first portion of the surface (132); and

[0144] The first portion of the surface (132) has a profile that matches a profile of the second portion of the surface (132).

[0145] Example 20. The method of Example 17, wherein attaching the reinforcing portion (120) to the surface (132) comprises bonding the reinforcing portion (120) to the surface (132).

[0146] Example 21. The method of Example 20, wherein attaching the reinforcing portion (120) to the surface (132) further comprises bolting the reinforcing portion (120) to the surface (132).

[0147] Example 22. The method of Example 17, wherein attaching the reinforcing portion (120) to the surface (132) includes bolting the reinforcing portion (120) to the surface (132).

[0148] The subject matter may be embodied in other specific forms without departing from its spirit or essential characteristics. The described examples are to be considered in all respects as illustrative only and not restrictive. All changes within the meaning and range of equivalence of the claims should be included within their scope.

Claims

1. A method for manufacturing a reinforcement portion (120) of a vehicle (100), the method comprising: applying a release film (136) directly onto the surface (132) of the vehicle (100) such that the release film (136) conforms to the shape of the surface (132); Applying a first metal layer (122A) directly or indirectly to the release film (136) such that the first metal layer (122A) conforms to the shape of the surface (132); applying a curable adhesive layer (124) directly onto the first metal layer (122A) such that the curable adhesive layer (124) conforms to the shape of the surface (132); applying a second metal layer (122B) directly onto the curable adhesive layer (124) such that the curable adhesive layer (124) is interposed between the first metal layer (122A) and the second metal layer (122B) and such that the second metal layer (122B) conforms to the shape of the surface (132); applying pressure to the first metal layer (122A), the curable adhesive layer (124), and the second metal layer (122B) so that the first metal layer (122A), the curable adhesive layer (124), and the second metal layer (122B) are pressed against the surface (132); curing the curable adhesive layer (124) while applying pressure to the curable adhesive layer (124) to form the reinforcing portion (120); and After curing the curable adhesive layer (124), the reinforcing portion (120) is removed from the surface (132).

2. The method of claim 1, wherein the curable bonding layer (124) comprises a fiber reinforced polymer layer (148).

3. The method according to claim 2, wherein: The fiber reinforced polymer layer (148) comprises a prepreg material; and Curing the curable adhesive layer (124) includes heating the prepreg material.

4. The method of claim 3, wherein heating the prepreg material comprises applying a heating blanket (142) over the first metal layer (122A), the fiber reinforced polymer layer (148), and the second metal layer (122B), and activating the heating blanket (142).

5. The method according to claim 2, wherein: The curable adhesive layer (124) comprises a dry fiber sheet (154) impregnated with a liquid resin; and Applying the curable adhesive layer (124) includes applying the dry fiber sheet (154) directly to the first metal layer (122A) and infusing liquid resin into the dry fiber sheet (154) when applying the dry fiber sheet (154) to the first metal layer (122A). The method according to claim 5 , wherein the liquid resin is cured at room temperature.

7. The method of claim 6, further comprising curing the fiber reinforced polymer layer (148) at a temperature above room temperature after removing the reinforcement portion (120) from the surface (132).

8. The method of claim 5, wherein injecting the liquid resin into the dry fiber sheet (154) comprises: applying a vacuum bag (160) over the first metal layer (122A), the fiber reinforced polymer layer (148), and the second metal layer (122B); sealing the vacuum bag (160) to the surface (132) such that the first metal layer (122A), the fiber reinforced polymer layer (148), and the second metal layer (122B) are sealed within a cavity defined between the vacuum bag (138) and the surface (132); and The pressure within the cavity is reduced.

9. The method according to claim 8, wherein: Curing the curable adhesive layer (124) includes applying a heating blanket over the vacuum bag (160), the first metal layer (122A), the fiber reinforced polymer layer (148), and the second metal layer (122B); and Applying pressure to the first metal layer (122A), the fiber reinforced polymer layer (148), and the second metal layer (122B) includes: applying a second vacuum bag (138) over the heating blanket (142), the vacuum bag (160), the first metal layer (122A), the fiber reinforced polymer layer (148), and the second metal layer (122B); sealing the second vacuum bag (138) to the surface (132) such that the heating blanket (142), the vacuum bag (160), the first metal layer (122A), the fiber reinforced polymer layer (148), and the second metal layer are sealed within a second cavity defined between the second vacuum bag (138) and the surface (132); and The pressure in the second chamber is reduced.

10. The method of claim 1, wherein applying pressure to the first metal layer (122A), the curable adhesive layer (124), and the second metal layer (122B) comprises: applying a vacuum bag (138) over the first metal layer (122A), the curable adhesive layer (124), and the second metal layer (122B); sealing the vacuum bag (138) to the surface (132) such that the first metal layer (122A), the curable adhesive layer (124), and the second metal layer (122B) are sealed within a cavity defined between the vacuum bag (138) and the surface (132); and The pressure within the cavity is reduced.

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