Thermoplastic repair patch and method of use

Abstract

The present application relates to thermoplastic repair patches and methods of use. Thermoplastic components having thermoplastic repair patches and methods of repairing thermoplastic components are provided. A thermoplastic component having a thermoplastic repair patch includes a composite material having a cutout forming a repair area and a thermoplastic repair patch in the cutout. The composite material has a first melting temperature. The thermoplastic repair patch includes a plurality of consolidated thermoplastic plies, each consolidated thermoplastic ply including a thermoplastic composite ply between low-melt thermoplastic surfaces having a second melting temperature that is lower than the first melting temperature.

Description

Technical Field

[0001] This disclosure relates generally to thermoplastic materials, and more specifically to thermoplastic repairs. Background Technology

[0002] For aerospace structural repair, the repair of large thermoplastic components presents unexpected challenges. Existing thermoplastic repair methods involve secondary bonding of dissimilar materials or bolting to the thermoplastic substructure. This inhibits flush or near-flush repairs of aerodynamic surfaces.

[0003] One repair method utilizes a thermosetting repair patch, which is secondary-bonded to a thermoplastic structure after a large-scale surface preparation. Large-scale surface preparation can include grinding and plasma heating. Large-scale surface preparation is undesirably difficult and time-consuming. Process control during surface preparation is difficult to implement in the field. Curing the thermosetting repair patch requires an undesirable amount of time and skilled operation. The final repair depends on the surface preparation and curing of the thermosetting patch.

[0004] Another existing solution is area bolt-fixed repair. However, bolt-fixed repair typically does not produce an aerodynamic surface suitable for external surface repair.

[0005] Therefore, it is desirable to have a method and apparatus that take into account at least some of the problems discussed above, as well as other possible problems. Summary of the Invention

[0006] Embodiments of this disclosure provide a thermoplastic component with a thermoplastic repair patch. The thermoplastic component with the thermoplastic repair patch includes a composite material having a notch forming a repair area, and a thermoplastic repair patch within the notch. The composite material has a first melting temperature. The thermoplastic repair patch includes a plurality of bonded thermoplastic stacks, each bonded thermoplastic stack including a thermoplastic composite layer between low-melting-point thermoplastic surfaces having a second melting temperature below the first melting temperature.

[0007] Embodiments of this disclosure provide a method for repairing a thermoplastic part. A low-melting-point thermoplastic film is placed on the repair area of ​​the thermoplastic part. A plurality of bonded thermoplastic laminates are placed on top of the low-melting-point thermoplastic film to form a thermoplastic repair patch. The thermoplastic repair patch is heated to a processing temperature below the melting temperature of the thermoplastic part.

[0008] Another embodiment of this disclosure provides a method for repairing a thermoplastic part. A low-melting-point thermoplastic film is placed on the repair area of ​​the thermoplastic part. A first bonded thermoplastic laminate is placed on top of the low-melting-point thermoplastic film. The first bonded thermoplastic laminate is heated to a processing temperature below the melting temperature of the thermoplastic part. A second bonded thermoplastic laminate is placed on top of the low-melting-point thermoplastic film. The second bonded thermoplastic laminate is heated to the processing temperature to form a thermoplastic repair patch in the repair area.

[0009] Features and functions may be implemented independently in various embodiments of this disclosure, or may be combined in other embodiments, wherein further details can be seen with reference to the following description and accompanying drawings. Attached Figure Description

[0010] The appended claims set forth novel features considered to be characteristic of the illustrative embodiments. However, the illustrative embodiments, their preferred modes of use, additional objects and features will be best understood by referring to the following detailed description of the illustrative embodiments of this disclosure, when read in conjunction with the accompanying drawings, wherein:

[0011] Figure 1 This is an illustration of an aircraft according to an illustrative embodiment;

[0012] Figure 2 This is an illustration of a block diagram of a manufacturing environment according to an illustrative embodiment;

[0013] Figure 3 This is an illustration of a cross-sectional view of a thermoplastic repair patch being applied to a thermoplastic component according to an illustrative embodiment;

[0014] Figure 4 This is an illustration of a cross-sectional view of a bonded thermoplastic laminate for a thermoplastic repair patch according to an illustrative embodiment;

[0015] Figure 5 This is a flowchart of a method for repairing thermoplastic parts according to an illustrative embodiment;

[0016] Figure 6 This is a flowchart of a method for repairing thermoplastic parts according to an illustrative embodiment;

[0017] Figure 7 These are illustrations of a method for manufacturing and maintaining an aircraft in block diagram form according to illustrative embodiments; and

[0018] Figure 8 This is an illustration of an aircraft in the form of a block diagram that can implement illustrative embodiments. Detailed Implementation

[0019] Now go to Figure 1The illustration depicts an aircraft according to an illustrative embodiment. The aircraft 100 has wings 102 and 104 attached to a main body 106. The aircraft 100 includes an engine 108 attached to the wing 102 and an engine 110 attached to the wing 104.

[0020] The main body 106 has a tail 112. Horizontal stabilizers 114, 116 and vertical stabilizers 118 are attached to the tail 112 of the main body 106.

[0021] Aircraft 100 is an example of an aircraft whose thermoplastic parts can be repaired using a thermoplastic repair patch, which is an illustrative example. The thermoplastic repair patch can be used to repair the thermoplastic parts of aircraft 100 during maintenance.

[0022] Now go to Figure 2 The illustration depicts a block diagram of a manufacturing environment according to an illustrative embodiment. A thermoplastic component 202 having a thermoplastic repair patch 204 is present in the manufacturing environment 200. The thermoplastic component 202 includes a composite material 206 having a cutout 214 forming a repair area 210. The composite material 206 has a first melting temperature, namely a melting temperature 208. In some illustrative examples, the melting temperature 208 is greater than 340 degrees Celsius.

[0023] The thermoplastic repair patch 204 in the cut 214 includes a plurality of bonded thermoplastic stacks 222. Each of the plurality of bonded thermoplastic stacks 222 includes a thermoplastic composite layer between low-melting-point thermoplastic surfaces having a second melting temperature below the first melting temperature.

[0024] The plurality of consolidated thermoplastic stacks 222 may include any desired number of consolidated thermoplastic stacks. In this illustrative example, the plurality of consolidated thermoplastic stacks 222 may include two consolidated thermoplastic stacks. The plurality of consolidated thermoplastic stacks 222 may include a first consolidated thermoplastic stack 224 and a second consolidated thermoplastic stack 226.

[0025] The first consolidated thermoplastic laminate 224 includes a thermoplastic composite sheet 232 between a low-melting-point thermoplastic surface, a low-melting-point thermoplastic surface 238, and a low-melting-point thermoplastic surface 240, having a second melting temperature below the first melting temperature. In this illustrative example, the low-melting-point thermoplastic surfaces 238 and 240 are formed of a low-melting-point thermoplastic material 241 having a melting temperature 230. The melting temperature 230 may be referred to as the second melting temperature. In some illustrative examples, the melting temperature 230 is between 260 degrees Celsius and 335 degrees Celsius.

[0026] The second consolidated thermoplastic laminate 226 includes a thermoplastic composite sheet 244 located between a low-melting-point thermoplastic surface, a low-melting-point thermoplastic surface 250, and a low-melting-point thermoplastic surface 252, having a second melting temperature lower than the first melting temperature. In this illustrative example, the low-melting-point thermoplastic surfaces 250 and 252 are formed of a low-melting-point thermoplastic material 241 having a melting temperature 230.

[0027] A second bonded thermoplastic stack 226 is placed on top of a first bonded thermoplastic stack 224, such that the first bonded thermoplastic stack 224 and the second bonded thermoplastic stack 226 are continuous in the direction of thickness through the thermoplastic component 202. In this illustrative example, the first bonded thermoplastic stack 224 is first placed in the repair region 210.

[0028] In some illustrative examples, a low-melting-point thermoplastic film 228 is placed in the repair area 210 and heated to a processing temperature 256 to bond the low-melting-point thermoplastic film 228 to the thermoplastic part 202.

[0029] In some illustrative examples, the repair area 210 is created by removing the inconsistency 220 from the thermoplastic part 202. In some illustrative examples, the repair area 210 includes the surface 212 of the thermoplastic part 202 in a cut 214 formed by removing the inconsistency 220 from the thermoplastic part 202.

[0030] In some illustrative examples, after the inconsistency 220 has been removed from the thermoplastic component 202, the repair region 210 includes a portion 218 of the thermoplastic component 202. In some illustrative examples, a series of composite material layers have been cut away from the thermoplastic component 202 to create the repair region 210.

[0031] The repair area 210 can have any desired size or shape. In some illustrative examples, the repair area 210 is interposed with 216.

[0032] The thermoplastic composite layer of the thermoplastic repair patch 204 has been solidified. In some illustrative examples, the thermoplastic composite layer of the thermoplastic repair patch 204 is made of the same material as the thermoplastic part 202. Heating blanket 260 is applied to heat the thermoplastic repair patch 204 to a processing temperature 256. The processing temperature 256 is selected to be below the melting temperature 208 of the thermoplastic part 202. The processing temperature 256 is selected such that the thermoplastic composite layer of the thermoplastic repair patch 204 remains solidified. The processing temperature 256 is selected to melt the low-melting-point thermoplastic material 241. In some illustrative examples, the processing temperature 256 is approximately 280°C to 340°C.

[0033] In some illustrative examples, the heating blanket 260 is sufficiently conformable 262 to conform to the thermoplastic repair patch 204 on the thermoplastic component 202. In some illustrative examples, the heating blanket 260 is sufficiently conformable 262 to conform to the cut 214. In some illustrative examples, the heating blanket 260 is sufficiently conformable 262 to conform to the first consolidated thermoplastic laminate 224 in the cut 214.

[0034] During heating of the thermoplastic repair patch 204, pressure 258 is applied to the thermoplastic repair patch 204 to adhere it. In some illustrative examples, a pressure 258 of less than 15 psi is applied to the thermoplastic repair patch 204 while heating it to bond the thermoplastic repair patch 204 to the thermoplastic part 202.

[0035] A low-melting-point thermoplastic film 228 is located between the thermoplastic repair patch 204 and the repair area 210. The low-melting-point thermoplastic film 228 comprises a low-melting-point thermoplastic material 241 having a melting temperature 230°C.

[0036] Multiple bonded thermoplastic laminates 222 are bonded via low-melting-point thermoplastic surfaces. A first bonded thermoplastic laminate 224 is bonded to the thermoplastic component 202 via a low-melting-point thermoplastic film 228 and a low-melting-point thermoplastic surface 240. The low-melting-point thermoplastic surface 240 and the low-melting-point thermoplastic film 228 are bonded by heating the low-melting-point thermoplastic material 241 to a processing temperature 256 and applying pressure 258.

[0037] The second consolidated thermoplastic laminate 226 is bonded to the first consolidated thermoplastic laminate 224 via low-melting-point thermoplastic surface 238 and low-melting-point thermoplastic surface 252. The low-melting-point thermoplastic surface 238 and low-melting-point thermoplastic surface 252 are bonded by heating the low-melting-point thermoplastic material 241 to the processing temperature 256 and applying pressure 258.

[0038] The thermoplastic composite sheet 232 of the first consolidated thermoplastic laminate 224 includes a sheet number 234 and a sheet orientation 236. The sheet orientation 236 includes any desired fiber angle. In some illustrative examples, the sheet orientation 236 may be selected from at least one of 0 degrees, 90 degrees, + / - 45 degrees, + / - 30 degrees, or + / - 60 degrees. In some illustrative examples, the sheet orientation 236 is selected to approximate the sheet orientation of the sheets of the thermoplastic part 202 removed from the cut 214. The sheet number 234 may include any desired number of sheets. In some illustrative examples, the sheet number 234 includes two to six sheets.

[0039] The first consolidated thermoplastic laminate 224 has a shape 242. The shape 242 is selected to fill a portion of the cutout 214. When the cutout 214 is fitted 216, the shape 242 of the first consolidated thermoplastic laminate 224 is different from the shape 254 of the second consolidated thermoplastic laminate 226.

[0040] In some illustrative examples, the shape 242 of the first consolidated thermoplastic laminate 224 can be cut from a consolidated sheet (such as consolidated sheet 264). The consolidated sheet 264 comprises multiple thermoplastic composite layers between two low-melting-point thermoplastic surfaces. Multiple different shapes can be cut from the consolidated sheet 264 to form consolidated thermoplastic laminates for repair. In some other illustrative examples, the shape 242 of the first consolidated thermoplastic laminate 224 can be laid out individually.

[0041] The thermoplastic composite sheet 244 of the second consolidated thermoplastic laminate 226 includes a sheet number 246 and a sheet orientation 248. The sheet orientation 248 includes any desired fiber angle. In some illustrative examples, the sheet orientation 248 may be selected from at least one of 0 degrees, 90 degrees, + / - 45 degrees, + / - 30 degrees, or + / - 60 degrees. In some illustrative examples, the sheet orientation 248 is selected to approximate the sheet orientation of the sheets of the thermoplastic part 202 removed from the cut 214. The sheet number 246 may include any desired number of sheets. In some illustrative examples, the sheet number 246 includes sheets between two and six sheets.

[0042] In some illustrative examples, the shape 254 of the second bonded thermoplastic laminate 226 can be cut from a bonded sheet (such as bonded sheet 264). In some illustrative examples, the lamination orientation 248 is the same as the lamination orientation 236, and the number of laminations 246 is the same as the number of laminations 234. In these illustrative examples, both the second bonded thermoplastic laminate 226 and the first bonded thermoplastic laminate 224 can be cut from the bonded sheet 264. In other illustrative examples, the first bonded thermoplastic laminate 224 and the second bonded thermoplastic laminate 226 are cut from two different bonded sheets. In some other illustrative examples, the shape 254 of the second bonded thermoplastic laminate 226 can be laid separately.

[0043] In some illustrative examples, a low-melting-point thermoplastic film 228 and a plurality of bonded thermoplastic laminates 222 are simultaneously bonded to a thermoplastic component 202. In some illustrative examples, the low-melting-point thermoplastic film 228 and the plurality of bonded thermoplastic laminates 222 are all placed in a notch 214 before applying a processing temperature 256 and a pressure 258. In some illustrative examples, the processing temperature 256 and a pressure 258 are applied to the low-melting-point thermoplastic film 228 in the notch 214 before any one of the plurality of bonded thermoplastic laminates 222 is applied to the notch 214.

[0044] In some illustrative examples, a processing temperature 256 and a pressure 258 are applied to the low-melting-point thermoplastic film 228 in the cut 214 before the first consolidated thermoplastic laminate 224 is applied to the cut 214. In some illustrative examples, a processing temperature 256 and a pressure 258 are applied to the first consolidated thermoplastic laminate 224 in the cut 214 before the second consolidated thermoplastic laminate 226 is applied to the first consolidated thermoplastic laminate 224. In some illustrative examples, the processing temperature 256 and the pressure 258 are repeatedly applied to the material in the repair area 210 until all portions of the thermoplastic repair patch 204 have been applied and treated.

[0045] Figure 2 The illustration of manufacturing environment 200 does not imply any physical or architectural limitations on the ways in which the illustrative embodiments can be implemented. Other components may be used in addition to or in place of the illustrated components. Some components may be unnecessary. Furthermore, boxes are presented to indicate some functional components. When implemented in the illustrative embodiments, one or more of these boxes may be combined, divided, or combined and divided into different boxes.

[0046] For example, although only two bonded thermoplastic stacks are depicted in thermoplastic repair patch 204, more than two bonded thermoplastic stacks may be present in a thermoplastic repair patch. Although each of the low-melting-point thermoplastic surface and the low-melting-point thermoplastic film 228 includes a low-melting-point thermoplastic material 241, in some examples not depicted, more than one type of thermoplastic material may be present in the thermoplastic repair patch and the low-melting-point thermoplastic film. Additionally, in some illustrative examples, at least one of the number of sheets 246 or the number of sheets 234 includes a single sheet.

[0047] Now go to Figure 3 This illustration depicts a cross-sectional view of a thermoplastic repair patch being applied to a thermoplastic part according to an illustrative embodiment. View 300 may be a repair Figure 1 View 300 is a view of the thermoplastic components of the aircraft 100. View 300 may be constructed using... Figure 2 A view of thermoplastic repair patch 204 repairing thermoplastic part 202.

[0048] In view 300, a thermoplastic repair patch 304 is present in a cutout 305 in the repair area 303 of the thermoplastic component 302. A low-melting-point thermoplastic film 306 is present between the thermoplastic repair patch 304 and the repair area 303. The thermoplastic repair patch 304 in the cutout 305 includes a plurality of bonded thermoplastic stacks 308. Each bonded thermoplastic stack includes a thermoplastic composite layer between low-melting-point thermoplastic surfaces.

[0049] In this illustrative example, the plurality of consolidated thermoplastic stacks 308 include consolidated thermoplastic stacks 310, 312, and 314. Consolidated thermoplastic stack 310 includes a thermoplastic composite sheet 322 between low-melting-point thermoplastic surfaces. Consolidated thermoplastic stack 310 includes a low-melting-point thermoplastic surface in contact with a low-melting-point thermoplastic film 306. Consolidated thermoplastic stack 310 includes a low-melting-point thermoplastic surface forming part of a low-melting-point thermoplastic material 316.

[0050] The consolidated thermoplastic laminate 312 includes a thermoplastic composite sheet 324 between low-melting-point thermoplastic surfaces. The consolidated thermoplastic laminate 312 includes a low-melting-point thermoplastic surface forming part of a low-melting-point thermoplastic material 316. The consolidated thermoplastic laminate 312 includes a low-melting-point thermoplastic surface forming part of a low-melting-point thermoplastic material 318.

[0051] The consolidated thermoplastic laminate 314 includes a thermoplastic composite sheet 326 between low-melting-point thermoplastic surfaces. The consolidated thermoplastic laminate 314 includes a low-melting-point thermoplastic surface forming part of a low-melting-point thermoplastic material 318. The consolidated thermoplastic laminate 314 includes a low-melting-point thermoplastic surface forming a low-melting-point thermoplastic material 320.

[0052] In view 300, processing temperature and pressure have been applied to the thermoplastic repair patch 304. By applying the processing temperature, the low-melting-point thermoplastic surface has been melted to bond multiple solidified thermoplastic laminates 308. By applying the processing temperature, the low-melting-point thermoplastic surface has been melted to form low-melting-point thermoplastic material 316, low-melting-point thermoplastic material 318, and low-melting-point thermoplastic material 320.

[0053] Processing temperature is applied to the thermoplastic repair patch 304 via a heating blanket 330. A release film 328 is positioned between the thermoplastic repair patch 304 and the heating blanket 330. In this illustrative example, a vacuum bag 332 is sealed around the repair area 303 for repair processing.

[0054] Figure 3 The illustration of the application of thermoplastic repair patch 304 does not imply any physical or architectural limitation on the manner in which the illustrative embodiments can be implemented. Other components may be used in addition to or in place of the illustrated components. Some components may be unnecessary. For example, thermoplastic repair patch 304 may have any desired number of bonded thermoplastic stacks. Although three bonded thermoplastic stacks are depicted, thermoplastic repair patch 304 may have more than three or fewer bonded thermoplastic stacks. Figure 3 The image depicts a single heating blanket, but in some illustrative examples, the heating blanket can be applied to both outer surfaces of the repair area to allow the desired heat distribution to enter the region of interest for membrane melting and consolidation.

[0055] Now go to Figure 4 This illustration depicts a cross-sectional view of a bonded thermoplastic laminate for a thermoplastic repair patch according to an illustrative embodiment. The bonded thermoplastic laminate 400 can be used for repair... Figure 1 The thermoplastic component of the aircraft 100. The bonded thermoplastic laminate 400 is... Figure 2 One of the physical embodiments of a plurality of consolidated thermoplastic laminates 222. The consolidated thermoplastic laminate 400 may be... Figure 3 A portion of the thermoplastic repair patch 304.

[0056] The consolidated thermoplastic laminate 400 includes a thermoplastic composite sheet 406 between low-melting-point thermoplastic surfaces. The thermoplastic composite sheet 406 is located between low-melting-point thermoplastic surfaces 402 and 404. The low-melting-point thermoplastic surfaces 402 and 404 are formed of low-melting-point thermoplastic films with melting temperatures lower than the melting temperature of the thermoplastic composite sheet 406. The low-melting-point thermoplastic surfaces 402 and 404 can be used to bond the consolidated thermoplastic laminate 400 to other consolidated thermoplastic laminates.

[0057] Now go to Figure 5 A flowchart of a method for repairing a thermoplastic part is depicted according to an illustrative embodiment. Method 500 can be implemented to repair... Figure 1 Thermoplastic components of aircraft 100. Method 500 can be implemented to use... Figure 2 Thermoplastic repair patch 204 is used to repair thermoplastic part 202. Method 500 can be used with... Figure 3 Thermoplastic repair patch 304 is used to repair thermoplastic component 302. Figure 4 The consolidated thermoplastic laminate 400 can be one of the multiple consolidated thermoplastic laminates of method 500.

[0058] Method 500 involves placing a low-melting-point thermoplastic film on the repair area of ​​the thermoplastic part (operation 502). Method 500 involves placing multiple bonded thermoplastic laminates over the low-melting-point thermoplastic film to form a thermoplastic repair patch (operation 504). Method 500 involves heating the thermoplastic repair patch to a processing temperature below the melting temperature of the thermoplastic part (operation 506). Method 500 then terminates.

[0059] In some illustrative examples, method 500 removes a portion of the thermoplastic part to form a repair area (operation 508). In some illustrative examples, the removed portion of the thermoplastic part includes inconsistencies. In some illustrative examples, removing inconsistencies from the thermoplastic part includes removing material to form a wedged cut.

[0060] In some illustrative examples, method 500 treats the surface of the repair area before placing the low-melting-point thermoplastic film on the repair area of ​​the thermoplastic part, wherein the treatment includes cleaning and sanding the repair area (operation 510). In some illustrative examples, treating the surface of the thermoplastic part takes considerably less time, requires less energy, or is less complex than treating a thermoplastic surface to bond to a thermosetting repair patch.

[0061] In some illustrative examples, each of the multiple bonded thermoplastic stacks includes a thermoplastic composite sheet between low-melting-point thermoplastic surfaces, and wherein heating the thermoplastic repair patch to a processing temperature includes melting the low-melting-point thermoplastic surfaces (operation 512). In these illustrative examples, melting the low-melting-point thermoplastic surfaces bonds the low-melting-point thermoplastic surfaces together.

[0062] In some illustrative examples, the processing temperature is approximately 280 to 340 degrees Celsius (Operation 514). In some illustrative examples, the processing temperature is less than 345 degrees Celsius (Operation 516). The processing temperature is selected such that the thermoplastic part remains solidified as the low-melting-point thermoplastic material melts. The processing temperature is selected such that the solidified thermoplastic composite sheets remain solidified.

[0063] In some illustrative examples, method 500 applies a pressure of less than 15 psi to the thermoplastic repair patch while heating the thermoplastic repair patch to bond the thermoplastic repair patch to the thermoplastic part (operation 518). In some illustrative examples, method 500 applies compression to the thermoplastic repair patch while heating the thermoplastic repair patch to a processing temperature to bond the thermoplastic repair patch to the thermoplastic part (operation 520).

[0064] In some illustrative examples, method 500 heats the low-melting-point thermoplastic film to a processing temperature (operation 522) before placing the plurality of consolidated thermoplastic layers over the low-melting-point thermoplastic film. In some illustrative examples, the low-melting-point thermoplastic film and the plurality of consolidated thermoplastic layers are placed in the repair area before heating the low-melting-point thermoplastic film to the processing temperature.

[0065] Now go to Figure 6 A flowchart of a method for repairing a thermoplastic component is depicted according to an illustrative embodiment. Method 600 can be implemented to repair... Figure 1 Thermoplastic components of aircraft 100. Method 600 can be implemented to use... Figure 2 Thermoplastic repair patch 204 is used to repair thermoplastic part 202. Method 600 can be used with... Figure 3 Thermoplastic repair patch 304 is used to repair thermoplastic component 302. Figure 4 The consolidated thermoplastic laminate 400 can be one of the multiple consolidated thermoplastic laminates of method 600.

[0066] Method 600 involves placing a low-melting-point thermoplastic film on the repair area of ​​the thermoplastic component (operation 602). Method 600 involves placing a first consolidated thermoplastic laminate over the low-melting-point thermoplastic film (operation 604). Method 600 involves heating the first consolidated thermoplastic laminate to a processing temperature below the melting temperature of the thermoplastic component (operation 606). Method 600 involves placing a second consolidated thermoplastic laminate over the low-melting-point thermoplastic film (operation 608). Method 600 involves heating the second consolidated thermoplastic laminate to the processing temperature to form a thermoplastic repair patch in the repair area (operation 610). Method 600 then terminates.

[0067] In some illustrative examples, method 600 further includes: removing a portion of the thermoplastic part to form a repair area (operation 612). In some illustrative examples, method 600 further includes: treating the surface of the repair area before placing a low-melting-point thermoplastic film on the repair area of ​​the thermoplastic part, wherein the treatment includes: cleaning and abrading the repair area (operation 614).

[0068] In some illustrative examples, method 600 further includes heating the low-melting-point thermoplastic film to a processing temperature (operation 616) before placing the first consolidated thermoplastic laminate over the low-melting-point thermoplastic film. The processing temperature is selected such that the thermoplastic part remains consolidated as the low-melting-point thermoplastic material melts.

[0069] In some illustrative examples, the first consolidated thermoplastic laminate includes a thermoplastic composite sheet between low-melting-point thermoplastic surfaces, and wherein heating the first consolidated thermoplastic laminate to a processing temperature includes melting the low-melting-point thermoplastic surfaces (operation 618). The processing temperature is selected such that the consolidated thermoplastic composite sheet remains consolidated.

[0070] In some illustrative examples, the processing temperature is approximately 280°C to 340°C (operation 620). In some illustrative examples, method 600 further includes applying a pressure of less than 15 psi to the first consolidated thermoplastic laminate while heating the first consolidated thermoplastic laminate to bond the first consolidated thermoplastic laminate to the thermoplastic part (operation 622). In some illustrative examples, method 600 further includes applying compression to the first consolidated thermoplastic laminate while heating the first consolidated thermoplastic laminate to the processing temperature to bond the first consolidated thermoplastic laminate to the thermoplastic part (operation 624).

[0071] 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 can be used, and it may be necessary to use only one of each item in the list. For example, “at least one of item A, item B, or item C” can be, but is not limited to, item A, item B, or item C. This example could also include item A, item B, and item C, or item B and item C. Of course, any combination of these items can exist. In other examples, “at least one of” can be, 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 other suitable combinations. Items can be specific objects, things, or categories. In other words, at least one of any combination and quantity of items can be used from the list, but not all items in the list are required.

[0072] As used in this article, when referring to items, "multiple" means one or more items.

[0073] The flowcharts and block diagrams in the different depicted embodiments illustrate the architecture, functionality, and operation of some possible implementations of the apparatus and methods in the illustrative embodiments. In this regard, each block in the flowchart or block diagram may represent at least one of a module, segment, function, or part of an operation or step.

[0074] In some alternative implementations of the illustrative embodiments, one or more functions mentioned in the boxes may not occur in the order shown in the drawings. For example, in some cases, depending on the functions involved, two boxes shown consecutively may be executed substantially simultaneously, or these boxes may sometimes be executed in reverse order. Furthermore, in addition to the boxes shown in the flowchart or block diagram, other boxes may be added. Some blocks may be optional. For example, operations 508 to 522 may be optional. As another example, operations 612 to 624 may be optional.

[0075] It can be like Figure 7 The aircraft manufacturing and maintenance methods 700 shown and such Figure 8 Illustrative embodiments of this disclosure are described in the context of the aircraft 800 shown. First, turn to... Figure 7 The illustration depicts an aircraft manufacturing and maintenance method in block diagram form according to an illustrative embodiment. During pre-production, the aircraft manufacturing and maintenance method 700 may include... Figure 8 Specifications and design of the aircraft 800 702 and material procurement 704.

[0076] During production, the manufacturing of components and sub-assemblies of aircraft 800 (706) and system integration (708) occur. Afterward, aircraft 800 may undergo certification and delivery (710) for entry into service (712). When put into service by the customer (712), aircraft 800 is scheduled for routine maintenance and repairs (714), which may include modifications, reconfigurations, refurbishments, or other maintenance and repairs.

[0077] Each process in the aircraft manufacturing and maintenance method 700 can be performed or carried out by a systems integrator, a third party, and / or an operator. In these examples, the operator can be a customer. For the purposes of this description, a systems integrator can include, but is not limited to, any number of aircraft manufacturers and major systems subcontractors; a third party can include, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator can be an airline, leasing company, military entity, service organization, etc.

[0078] Now for reference Figure 8 The diagram illustrates the aircraft in block form, showcasing illustrative embodiments that can be implemented. In this example, the aircraft 800 consists of... Figure 7 The aircraft manufacturing and maintenance method 700 produces an aircraft that may include a fuselage 802 with multiple systems 804 and an interior 806. Examples of systems 804 include one or more of a propulsion system 808, an electrical system 810, a hydraulic system 812, and an environmental system 814. Any number of other systems may be included.

[0079] The apparatus and methods embodied herein may be used during at least one stage of the aircraft manufacturing and maintenance method 700. Figure 7 One or more illustrative embodiments are manufactured or used during at least one of the following periods: manufacturing of components and sub-assemblies 706, system integration 708, commissioning 712, or maintenance and repair 714.

[0080] The illustrative example provides a thermoplastic repair patch with a low-melting-point thermoplastic film. The use of the low-melting-point thermoplastic film allows the thermoplastic to eutecticly fuse into the structure to be repaired. The illustrative example enables the patch to be processed onto the material at lower temperatures and lower pressures. Compared to repairs using thermoplastic materials at higher temperatures, the illustrative example allows for the application of fewer tools and less heat.

[0081] When compared to thermosetting repair materials, the illustrative examples demonstrate greater structural and processing robustness in repair. The illustrative examples utilize surface preparation that is less complex than that for thermosetting patches to repair thermoplastic parts. Thermoplastic processing and joining are far less sensitive to surface treatments and other boundary conditions than thermosetting repair methods.

[0082] The illustrative examples demonstrate the repair of thermoplastic parts with significantly reduced repair time compared to using thermosetting patches. The time required for thermoplastic treatment is a fraction of the time required for thermosetting treatment.

[0083] The formulation of the low-melting-point thermoplastic film is chosen to be compatible with the thermoplastic material of the underlying structure. The low-melting-point thermoplastic film in the illustrative example is capable of structurally and chemically eutectic bonding at temperatures and pressures lower than those used to treat the underlying structural material. In the illustrative example, the structural material does not soften or solidify during the repair treatment.

[0084] In the illustrative examples, the base thermoplastic material melts / solidifies at a high temperature. In some illustrative examples, the base thermoplastic material melts / solidifies at 380 degrees Celsius or higher. The illustrative examples provide thermoplastic films with melting temperatures from 260 degrees Celsius to 335 degrees Celsius for bonding base high-temperature thermoplastics.

[0085] The illustrative examples present a method comprising performing a heat / pressure treatment to create a co-cured / co-melted structure between a substrate and a low-melting-point thermoplastic material. In some illustrative examples, the heat / pressure treatment involves applying a temperature below 345 degrees Celsius. In some illustrative examples, the heat / pressure treatment involves applying a pressure less than 15 psi.

[0086] Illustrative examples utilize an external heat source. In some illustrative examples, the external heat source is a heating blanket that conforms to the surface of the structure to be repaired (including the repair interlocking profile).

[0087] A first low-temperature thermoplastic film layer is bonded to the substructure / substrate thermoplastic material. The interlocking voids can be filled with thermoplastic material. The filler material is made of unique sheets pre-fabricated for this purpose. Each unique repair filler sheet is a sandwich of the low-temperature film, the base thermoplastic material, and the low-temperature film. The thermoplastic substrate forming the center of the sandwich sheet can be a single unidirectional sheet or can consist of 2 to 6 sheets with different orientations. An example of a thermoplastic composite sheet could be three thermoplastic layers with a 45 / 0 / -45 orientation. The thermoplastic composite sheet can include any desired number of sheets. A lower number of sheets allows for easier conformation to the interlocking profile to be filled at room temperature.

[0088] In some illustrative examples, the filler material is made into large sheets, and filler layers for interlocking gaps are cut from the sheets to fit the interlocking pattern. The cut thermoplastic consolidation laminates are then applied to the gaps, and vacuum bag pressure is applied. A heating blanket is then applied, and the patch is treated according to the consolidation temperature distribution of the low-melting-point thermoplastic film.

[0089] In some illustrative examples, depending on the heat transfer characteristics of the applied environment, the patch can be heated / applied sequentially. In some illustrative examples, if the thermoplastic repair patch is too thick to transfer heat from the external heating blanket across the entire repair area to reach the melting temperature, the consolidated thermoplastic laminate can be applied and heated individually or in groups. In some illustrative examples, a smaller amount of filler material and heat can be applied to groups of consolidated thermoplastic laminates, and this laminate construction can be repeated until the repair is complete. After the thermal cycling is complete, the repair area can be inspected.

[0090] This application involves the following provisions:

[0091] 1. A thermoplastic component having a thermoplastic repair patch, the thermoplastic component comprising:

[0092] Composite material having a cut forming a repair area, the composite material having a first melting temperature; and

[0093] The thermoplastic repair patch, located in the cut, comprises a plurality of bonded thermoplastic stacks, each of which includes a thermoplastic composite layer between thermoplastic surfaces having a second melting temperature lower than the first melting temperature.

[0094] 2. The thermoplastic component according to Clause 1, further comprising: a low-melting-point thermoplastic film between the thermoplastic repair patch and the repair area.

[0095] 3. The thermoplastic part according to Clause 1, wherein the first melting temperature is greater than 340 degrees Celsius.

[0096] 4. The thermoplastic part according to Clause 1, wherein the second melting temperature is between 260 degrees Celsius and 335 degrees Celsius.

[0097] 5. The thermoplastic component according to Clause 1, wherein the plurality of bonded thermoplastic stacks are joined through the low-melting-point thermoplastic surface.

[0098] 6. A method for repairing a thermoplastic component, the method comprising:

[0099] A low-melting-point thermoplastic film is placed on the repair area of ​​the thermoplastic component;

[0100] Multiple consolidated thermoplastic layers are placed on top of the low-melting-point thermoplastic film to form a thermoplastic repair patch; and

[0101] The thermoplastic repair patch is heated to a processing temperature below the melting temperature of the thermoplastic component.

[0102] 7. The method according to Clause 6, wherein each of the plurality of consolidated thermoplastic stacks comprises a thermoplastic composite sheet between low-melting-point thermoplastic surfaces, and wherein heating the thermoplastic repair patch to the processing temperature comprises melting the low-melting-point thermoplastic surfaces.

[0103] 8. The method according to Clause 6, wherein the processing temperature is 280 degrees Celsius to 340 degrees Celsius.

[0104] 9. The method according to Clause 6, further comprising:

[0105] Apply a pressure of less than 15 psi to the thermoplastic repair patch while heating it to bond the thermoplastic repair patch to the thermoplastic part.

[0106] 10. The method according to Clause 6, further comprising:

[0107] Compression is applied to the thermoplastic repair patch while the thermoplastic repair patch is heated to the processing temperature to bond the thermoplastic repair patch to the thermoplastic component.

[0108] 11. The method according to Clause 6, further comprising:

[0109] Before placing the plurality of consolidated thermoplastic layers on top of the low-melting-point thermoplastic film, the low-melting-point thermoplastic film is heated to the processing temperature.

[0110] 12. The method according to Clause 6, further comprising:

[0111] A portion of the thermoplastic component is removed to form the repair area.

[0112] 13. The method according to Clause 12, further comprising:

[0113] Before placing the low-melting-point thermoplastic film on the repair area of ​​the thermoplastic component, the surface of the repair area is treated, wherein the treatment includes cleaning and polishing the repair area.

[0114] 14. A method for repairing a thermoplastic component, the method comprising:

[0115] A low-melting-point thermoplastic film is placed on the repair area of ​​the thermoplastic component;

[0116] The first consolidated thermoplastic laminate is placed on top of the low-melting-point thermoplastic film;

[0117] The first consolidated thermoplastic laminate is heated to a processing temperature lower than the melting temperature of the thermoplastic component;

[0118] The second consolidated thermoplastic laminate is placed on top of the low-melting-point thermoplastic film; and

[0119] The second consolidated thermoplastic laminate is heated to the processing temperature to form a thermoplastic repair patch in the repair area.

[0120] 15. The method according to Clause 14, wherein the first consolidated thermoplastic laminate comprises a thermoplastic composite sheet between low-melting-point thermoplastic surfaces, and wherein heating the first consolidated thermoplastic laminate to the processing temperature comprises: melting the low-melting-point thermoplastic surfaces.

[0121] 16. The method according to Clause 14, wherein the processing temperature is 280 degrees Celsius to 340 degrees Celsius.

[0122] 17. The method according to Clause 14, further comprising:

[0123] A pressure of less than 15 psi is applied to the first bonded thermoplastic laminate while the first bonded thermoplastic laminate is heated to bond the first bonded thermoplastic laminate to the thermoplastic part.

[0124] 18. The method according to Clause 14, further comprising:

[0125] Compression is applied to the first consolidated thermoplastic laminate while the first consolidated thermoplastic laminate is heated to the processing temperature to bond the first consolidated thermoplastic laminate to the thermoplastic component.

[0126] 19. The method according to Clause 14, further comprising:

[0127] Before placing the first consolidated thermoplastic laminate on top of the low-melting-point thermoplastic film, the low-melting-point thermoplastic film is heated to the processing temperature.

[0128] 20. The method according to Clause 14, further comprising:

[0129] A portion of the thermoplastic component is removed to form the repair area.

[0130] 21. The method according to Clause 20, further comprising:

[0131] Before placing the low-melting-point thermoplastic film on the repair area of ​​the thermoplastic component, the surface of the repair area is treated, wherein the treatment includes cleaning and polishing the repair area.

[0132] Various illustrative embodiments have been presented for purposes of illustration and description, and are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those skilled in the art. Furthermore, different illustrative embodiments may provide different features compared to other illustrative embodiments. The selection and description of one or more embodiments are intended to best explain the principles of the embodiments, their practical application, and to enable others skilled in the art to understand the disclosure of various embodiments with various modifications suitable for the particular intended use.

Claims

1. A thermoplastic component having a thermoplastic repair patch, the thermoplastic component comprising: A composite material having a cutout forming a repair area, the composite material having a first melting temperature; as well as The thermoplastic repair patch, located in the cut, comprises a plurality of bonded thermoplastic stacks, each of which includes a thermoplastic composite layer between thermoplastic surfaces having a second melting temperature lower than the first melting temperature.

2. The thermoplastic component according to claim 1, further comprising: A low-melting-point thermoplastic film is placed between the thermoplastic repair patch and the repair area.

3. The thermoplastic component according to claim 1, wherein, The first melting temperature is greater than 340 degrees Celsius.

4. The thermoplastic component according to claim 1, wherein, The second melting temperature is between 260 degrees Celsius and 335 degrees Celsius.

5. The thermoplastic part according to claim 1, wherein, The plurality of consolidated thermoplastic layers are bonded together through the low-melting-point thermoplastic surface.

6. A method for repairing a thermoplastic component, the method comprising: A low-melting-point thermoplastic film is placed on the repair area of ​​the thermoplastic component; Multiple bonded thermoplastic layers are placed on top of the low-melting-point thermoplastic film to form a thermoplastic repair patch; as well as The thermoplastic repair patch is heated to a processing temperature below the melting temperature of the thermoplastic component.

7. The method according to claim 6, wherein, Each of the plurality of consolidated thermoplastic laminates includes a thermoplastic composite sheet between low-melting-point thermoplastic surfaces, and wherein heating the thermoplastic repair patch to the processing temperature includes melting the low-melting-point thermoplastic surfaces.

8. The method according to claim 6, wherein, The processing temperature is between 280 degrees Celsius and 340 degrees Celsius.

9. The method according to claim 6, further comprising: Apply a pressure of less than 15 psi to the thermoplastic repair patch while heating it to bond the thermoplastic repair patch to the thermoplastic part.

10. A method for repairing a thermoplastic component, the method comprising: A low-melting-point thermoplastic film is placed on the repair area of ​​the thermoplastic component; The first consolidated thermoplastic laminate is placed on top of the low-melting-point thermoplastic film; The first consolidated thermoplastic laminate is heated to a processing temperature lower than the melting temperature of the thermoplastic component; The second consolidated thermoplastic laminate is placed on top of the low-melting-point thermoplastic film; as well as The second consolidated thermoplastic laminate is heated to the processing temperature to form a thermoplastic repair patch in the repair area.

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