QUICK REPAIR PATCH FOR REPAIRING EXTERNAL DAMAGE AND QUICK REPAIR PROCEDURES

Description

[0001] The invention relates to a rapid repair patch, preferably for aircraft, and a rapid repair method. Furthermore, the invention relates to a repair arrangement and uses of a rapid repair patch.

[0002] Civil and military aircraft, helicopters, drones, motor vehicles, ships, and wind turbines (or their rotor blades) are usually made of metal or composite materials. In the event of a lightning strike, repairs may be necessary. The most common type of damage from a lightning strike is merely superficial, meaning damage to the paint and possibly a few deeper layers. This usually does not result in significant material damage that could compromise the structure.

[0003] Following such an incident, localized and structurally insignificant damage (scratches, paint chips, tufting, and the like) is currently repaired temporarily using a so-called high-speed tape (HST, self-adhesive aluminum foil) due to time constraints and limited repair options. HST is inexpensive and available at many airports.

[0004] The purpose of the invention is to improve rapid repairs of local and structurally irrelevant damage, so that in particular not only operability but also functionality can be restored.

[0005] The problem is solved by the subject matter of the independent claims. Preferred further developments are the subject matter of the dependent claims.

[0006] The invention provides a quick repair patch for repairing local and structurally insignificant damage to a component, preferably an aircraft component, which includes a top layer and an underlying lightning protection surface, wherein the quick repair patch has a layered structure and comprises the layered structure: a plastic film layer that can be bonded to the top layer and that, when the quick repair patch is attached to the component, faces away from the damage; an electrically conductive lightning protection layer adapted for a lightning protection function or an electromagnetic interference protection function, which is arranged on the plastic film layer and which, when the quick repair patch is attached to the component, makes electrically conductive contact with the lightning surface protection; a bonding layer adapted for bonding the quick repair patch to the component and which is arranged at least on the plastic film layer on the same side as the electrically conductive lightning protection layer.

[0007] It is preferred that the plastic film layer contains reinforcing fibers. It is preferred that the plastic film layer contains a radar-attenuating, preferably a radar-absorbing, material. It is preferred that the plastic film layer contains an electrically conductive material. It is preferred that the plastic film layer contains a material that attenuates, preferably absorbs, UV light or ionizing radiation.

[0008] It is preferred that the plastic film layer is electrically insulated from the lightning protection layer.

[0009] It is preferred that the plastic film layer has a larger area than the lightning protection layer, wherein the plastic film layer has an edge region that is arranged between the outer contour of the plastic film layer and the outer contour of the lightning protection layer.

[0010] It is preferred that the bonding layer is applied to or arranged on the edge area.

[0011] It is preferred that the layer structure includes a functional layer. It is preferred that the functional layer is arranged on the side of the plastic film layer facing away from the lightning protection layer. It is preferred that the functional layer has a reinforcing function, a camouflage function, a static discharge protection function, and / or a protection function against radiation, in particular against UV radiation and / or ionizing radiation.

[0012] It is preferred that the layer structure comprises a reinforcing layer containing reinforcing fibers and arranged on the plastic film layer. It is preferred that the layer structure comprises a camouflage layer containing a radar-attenuating, preferably a radar-absorbing, material. It is preferred that the layer structure comprises an electrostatic discharge protection layer containing an electrically conductive material. The layer structure has a reinforcing layer arranged between the plastic film layer and the lightning protection layer, bonding them together. It is preferred that the layer structure has a radiation protection layer containing a material that attenuates, preferably absorbs, UV light or ionizing radiation.

[0013] It is preferred that the reinforcing layer, the camouflage layer, the discharge protection layer, and / or the radiation protection layer are combined in a common functional layer. It is preferred that the reinforcing layer, the camouflage layer, the discharge protection layer, the radiation protection layer, and / or the functional layer are arranged on the side of the plastic film layer facing away from the lightning protection layer.

[0014] It is preferred that the layer structure be formed in the sequence: plastic film layer, lightning protection layer, fastening layer. It is preferred that the layer structure be formed in the sequence: plastic film layer, bonding layer, lightning protection layer, fastening layer.

[0015] It is preferred that the layer structure be formed in the following order: reinforcing layer or camouflage layer or discharge protection layer or radiation protection layer, plastic film layer, lightning protection layer, bonding layer.

[0016] It is preferred that the layer structure be formed in the following order: functional layer, plastic film layer, lightning protection layer, bonding layer. It is preferred that the layer structure be formed in the following order: functional layer, plastic film layer, bonding layer, lightning protection layer, bonding layer.

[0017] It is preferred that the layered structure consists only of the aforementioned layers.

[0018] Preferably, the quick repair patch includes an information medium, preferably a QR code and / or an RFID tag, through which information about the quick repair performed using the quick repair patch can be stored or retrieved. It is preferred that the information is stored in or retrievable from the RFID tag. It is also preferred that the information can be stored or retrieved using a computer via the QR code.

[0019] It is preferred that the information medium is contained in or attached to the plastic film layer.

[0020] The invention provides a quick repair patch for repairing local and structurally insignificant damage to a component, preferably an aircraft component, which includes a top layer and an underlying lightning protection surface, wherein the quick repair patch has a layered structure and the layered structure consists of: a plastic film layer that can be bonded to the top layer and that, when the quick-repair patch is attached to the component, faces away from the damage; an electrically conductive lightning protection layer adapted for a lightning protection function or an electromagnetic interference protection function, which is arranged on the plastic film layer and which, when the quick-repair patch is attached to the component, makes electrically conductive contact with the lightning surface protection; a bonding layer adapted for bonding the quick-repair patch to the component and which is arranged at least on the plastic film layer on the same side as the electrically conductive lightning protection layer; optionally, a bonding layer arranged between the plastic film layer and the lightning protection layer, bonding them together;Optionally, a functional layer is arranged on the side of the plastic film layer facing away from the lightning protection layer.

[0021] It is preferred that the functional layer consists of a reinforcing layer containing reinforcing fibers; and / or a camouflage layer containing a radar-attenuating, preferably a radar-absorbing, material; and / or an electrostatic discharge protection layer containing an electrically conductive material.

[0022] It is preferred that the plastic film layer contains reinforcing fibers. It is preferred that the plastic film layer contains a radar-attenuating, preferably a radar-absorbing, material. It is preferred that the plastic film layer contains an electrically conductive material.

[0023] It is preferred that the plastic film layer is electrically insulated from the lightning protection layer.

[0024] The invention provides a repair arrangement comprising a component, preferably an aircraft component, and a previously described quick-repair patch, wherein the component has a top layer and an underlying lightning protection surface, as well as local and structurally insignificant damage, wherein the quick-repair patch covers the damage and is bonded to the component by means of the bonding layer, wherein the plastic film layer is bonded to the top layer and faces away from the damage, and wherein the electrically conductive lightning protection layer is arranged between the plastic film layer and the lightning protection surface.

[0025] It is preferred that the lightning protection layer is electrically connected to the lightning strike surface protection.

[0026] The invention provides an aircraft comprising a previously described quick repair patch and / or a previously described repair arrangement, wherein the component is preferably selected from among lift-enhancing devices, flaps, leading-edge slats, control surfaces, elevators, rudders, ailerons, fuselage parts, rotor blades, wings, engine nacelles, horizontal stabilizers and / or vertical stabilizers.

[0027] The invention provides a rapid repair method for repairing local and structurally irrelevant damage to a component, preferably an aircraft component, which includes a top layer and an underlying lightning protection surface, wherein the method comprises: 1. Create a bonding surface on the component for a quick repair patch and, if necessary, expose the lightning protection surface; 2. Position a previously described quick repair patch on the damage; and 3. Attach the quick repair patch to the bonding surfaces created in step 1 by pressing it on, thereby bonding the plastic film layer to the top layer.

[0028] It is preferred that in step 1 the creation of the connecting surfaces and / or the exposure of the lightning protection surface is carried out, e.g. by grinding.

[0029] It is preferred that in step 1 the manufacturing process includes cleaning, drying and / or degreasing a surface area of ​​the component to create the joining surface.

[0030] It is preferred that in step 2 the quick repair patch is positioned in such a way that the lightning protection layer can contact the lightning surface protection.

[0031] It is preferred that in step 3 the lightning protection layer is electrically contacted with the lightning surface protection.

[0032] The invention provides for the use of a previously described quick repair patch to repair local and structurally irrelevant damage to an aircraft component.

[0033] The idea described here can extend the typical lifespan of quick repairs, which is usually around two months. This allows for a longer time until a full repair, as specified in the repair manual, is completed. By adjusting the plastic film, the patch can be fitted to the area being repaired, making the quick repair less noticeable overall.

[0034] Military aircraft typically have a coating that reduces their radar signature. The quick repair patch can prevent so-called hotspots that impair the radar signature.

[0035] The smart quick surface repair patch (SQSR patch) presented here is a multi-layered patch of predefined size and usually has three to four layers.

[0036] Layer 1 is a plastic film layer. This layer can be colored. The plastic film layer is, for example, a polyurethane film. The plastic film can contain a marking for information purposes, such as a QR code or an RFID tag. This can store various details about the patch and the quick repair process (e.g., type, manufacturing date, installation date, and individual number). Optionally, the plastic film layer can contain reinforcement made of reinforcing fibers (e.g., glass fibers, Kevlar). These are particularly suitable for repairing fuel tanks or combat damage. Optionally, the plastic film can also be provided with camouflage-enhancing properties (e.g., through suitable radar-absorbing or attenuating substances). A colorless top layer can also be applied.

[0037] Layer 2 contains electrically conductive material. Examples of electrically conductive materials include expanded metal foil, perforated metal foil, expanded metal mesh, graphene, or similar materials. This layer serves as lightning strike surface protection (LSSP) or shielding against electromagnetic interference (EMI). Depending on the material, an additional adhesive layer may be provided as a bonding layer between Layer 1 and Layer 2.

[0038] Layer 3 is a bonding layer, for example made of adhesive film. This layer can be applied only to layer 1. It can also be applied to layer 2, in which case conductive adhesive is preferably used.

[0039] Furthermore, a layer designated as Layer 1 +< can be arranged on top of Layer 1. This layer can optionally be designed as a reinforcing layer with reinforcing fibers, as a camouflage layer with camouflage-enhancing materials, or as electrostatic discharge protection. This layer can also be referred to as a functional layer.

[0040] The order of the layers can be adapted to the specific application. Likewise, the shape of the patch can be adapted to different situations. For example, the patch can be square, rectangular, circular, or elliptical. The same applies to the shape of layer 2. The shape of layer 2 can differ from the overall shape.

[0041] The quick repair patch can be applied using a method similar to that of the HST (High Pressure Repair) patch. Its design helps prevent peeling. Unlike the HST, this patch is also waterproof, thus increasing corrosion resistance. Even damaged logos or markings on the aircraft can be repaired with minimal effort.

[0042] Compared to HST, the patch allows maintenance for minor damage to be postponed until the regular D-check. In certain cases, the patch may even be acceptable as a permanent repair.

[0043] Accordingly, the ideas presented here allow for a simpler, more durable, and safer repair of surface damage for the operator. The repair patch provides long-lasting protection that reduces, minimizes, or even prevents lightning-related surface damage.

[0044] Examples of implementation are explained in more detail with reference to the attached schematic drawings. These show: Fig. 1 an embodiment of an aircraft; Fig. 2 an embodiment of a quick repair patch; Fig. 3 a top view of a quick repair patch; Fig. 4 an embodiment of a repair arrangement with a quick repair patch made of Fig. 2 ; and Fig. 5 shows an embodiment of a patch strip.

[0045] First, attention will be paid to the Fig. 1 Reference is made to the figure showing an aircraft 10. The aircraft 10 comprises, in a manner known per se, a fuselage 12 to which a pair of wings 14 are arranged. At the rear end of the fuselage 12, a vertical stabilizer 16 and a horizontal stabilizer 18 are arranged. Each wing 14 comprises airfoils 20 and lift-enhancing devices 22. The wing 14, the vertical stabilizer 16, and the horizontal stabilizer 18 also have control surfaces 24.

[0046] The aforementioned components 26 may exhibit local damage 28, caused, for example, by a lightning strike, which is not structurally relevant. Component 26 comprises a base body 30. The base body 30 may be made of metal or a fiber-reinforced plastic. Component 26 also comprises a lightning strike surface protection 32. The lightning strike surface protection 32 may also be formed by the base body 30 itself. Furthermore, component 26 comprises a cover layer 34, which is arranged on the lightning strike surface protection 32.

[0047] The Figs. 2 to 4 schematically show a quick repair patch 36, which is used to repair the damage 28 in a repair arrangement 37 ( Fig. 4 ) can be used. The quick repair patch has a thickness of approximately 0.1 mm to 0.2 mm.

[0048] The quick repair patch 36 comprises a layer structure 38. The layer structure 38 includes a plastic film layer 40. The plastic film layer 40 is preferably made of a polyurethane film. The plastic film layer 40 may be colored. In this case, the plastic film layer 40 is rectangular. However, the plastic film layer 40 can also have other shapes, for example, circular, elliptical, or square.

[0049] The layer structure 38 comprises an electrically conductive lightning protection layer 42 arranged on a surface of the plastic film layer 40. The lightning protection layer 42 contains an electrically conductive material made of metal or graphene. Accordingly, the lightning protection layer 42 can contain expanded metal, perforated metal foil, and the like. In this case, the lightning protection layer 42 has an elliptical shape. However, the lightning protection layer 42 can also have other shapes, for example, a circle, a rectangle, or a square. The lightning protection layer 42 has a smaller surface area than the plastic film layer 40. Viewed from above ( Fig. 3 ) the plastic film layer 40 has an edge area 44 which is arranged between the contour of the plastic film layer 40 and the lightning protection layer 42.

[0050] Between the plastic film layer 40 and the lightning protection layer 42, a thin bonding layer 46 is arranged in the thickness direction, which connects the two layers in a materially bonded manner.

[0051] The layer structure 38 further comprises a bonding layer 48 arranged on the plastic film layer 40. The bonding layer 48 contains an adhesive to bond the quick-repair patch 36 to the component 26. In one variant, the bonding layer 48 can be bonded to the component 26 by welding. The bonding layer 48 is applied only to or arranged on the edge region 44. The bonding layer 48 can also be applied to the lightning protection layer 42. In the area of ​​the lightning protection layer 42, the adhesive is preferably conductive. Alternatively, an area of ​​the lightning protection layer 42 is left uncovered to allow electrical contact between the lightning protection layer 42 and the lightning strike surface protection 32.

[0052] The layer structure 38 can also include a functional layer 50. The functional layer 50 is arranged on the surface of the plastic film layer 40 facing away from the lightning protection layer 42.

[0053] The functional layer 50 can have a reinforcing layer 52 containing reinforcing fibers. Glass fibers or Kevlar are used as reinforcing fibers.

[0054] The functional layer 50 may have a camouflage layer 54 containing a radar-absorbing or -attenuating additive or additives.

[0055] The functional layer 50 can contain an electrostatic discharge protection layer 56 containing conductive material.

[0056] The functional layer 50 is preferably designed as a single layer in which the reinforcement layer 52, the camouflage layer 54 and the discharge protection layer 56 are integrated.

[0057] Alternatively, the functions of the reinforcement layer 52, the camouflage layer 54 or the discharge protection layer 56 can be implemented in any combination in the plastic film layer.

[0058] The quick repair patch 36 may also include information means 58 by means of which details about the quick repair patch 36 and / or the quick repair performed with it can be stored or retrieved. These details include the type and date of manufacture of the quick repair patch 36, the date and location of the repair, and any other information, particularly technical information, that is relevant to the quick repair patch 36 or the repair itself. Information means 58 may, for example, be a QR code or an RFID tag. The QR code and the RFID tag may each serve as a reference to the corresponding details stored in a computer system or network. The RFID tag may also be designed to contain the details directly.

[0059] A quick repair is described below with reference to Fig. 4This is explained in more detail below. The damage 28 is first treated, for example by grinding, to create a smooth, clean, dry and grease-free bonding surface 60 for the quick repair patch 36.

[0060] A suitable quick repair patch 36 is then selected and placed over the damage 28 so that it is completely covered. The quick repair patch 36 is then pressed onto the component 26. In doing so, the plastic film layer 40, particularly the edge area 44, is pressed against the cover layer 34 and bonded to it by the bonding layer 48. Furthermore, the lightning protection layer 42 is pressed against the lightning surface protection 32, creating an electrical contact. If the lightning protection layer 42 is also coated with adhesive, it is also bonded to the lightning surface protection 32.

[0061] The following will be discussed Fig. 5Reference is made to a dosage form of quick repair patches 36 as patch strips 62. A plurality of quick repair patches 36 are connected to one another at a separable edge area 64, for example by means of perforation. The patch strip 62 can be wound onto a roll. The desired quick repair patch 36 is detached from the patch strip 62 before use.

[0062] To improve rapid repairs of local and structurally insignificant damage (28) in aircraft components (26), a rapid repair patch (36) is proposed. The rapid repair patch (36) has a layered structure (38) comprising a plastic film (40) on which a lightning protection element (42) is applied, and an adhesive layer (48) that is located at least on the plastic film (40). The rapid repair patch (36) can be applied to the damage (28) so that the lightning protection element (42) is in electrical contact with the lightning protection element of the component (26). The rapid repair patch (36) can include a QR code or an RFID tag through which information about the rapid repair patch (36) or the rapid repair (36) can be stored or retrieved. Reference symbol list:

[0063] 10 Aircraft 12 Fuselage 14 Wing 16 Vertical stabilizer 18 Horizontal stabilizer 20 Wing 22 Lift aid 24 Control surface 26 Component 28 Damage 30 Base body 32 Lightning surface protection 34 Top layer 36 Quick repair patch 37 Repair arrangement 38 Layer structure 40 Plastic film layer 42 Lightning protection layer 44 Edge area 46 Bonding layer 48 Fastening layer 50 Functional layer 52 Reinforcement layer 54 Camouflage layer 56 Discharge protection layer 58 Information medium 60 Bonding surface 62 Patch strip 64 Edge area

Claims

1. Quick repair patch (36) for repairing local damage (28) to a component (26) that is not relevant in terms of structural mechanics, preferably an aircraft component (12, 14, 16, 18, 20, 22, 24), which contains a top layer (34) and a lightning strike surface protection (32) located underneath, wherein the quick repair patch (36) has a layer structure (38) and the layer structure (38) comprises: - A plastic film layer (40) that can be bonded to the top layer (34) and which, when the quick repair patch (36) is attached to the component, faces away from the damage (28); - An electrically conductive lightning protection layer (42) adapted for a lightning protection function or an electromagnetic interference protection function, which is arranged on the plastic film layer (40) and which, when the quick repair patch (36) is attached to the component (26), is in electrically conductive contact with the lightning strike surface protection (32) when the quick repair patch (36) is attached to the component (26); wherein the lightning protection layer (42) has a smaller area than the plastic film layer (40) and the plastic film layer (40) has an edge area (44) which is arranged between the contour of the plastic film layer (40) and the lightning protection layer (42); - A connecting layer (46) between the plastic layer (40) and the lightning protection layer (42), which connects the two layers (40, 42) to each other in a material-locking manner; and - A fastening layer (48) that is adapted to fasten the quick repair patch (36) to the component in a material-locking manner and that is arranged only on the edge area (44) of the plastic film layer (40) on the same side as the electrically conductive lightning protection layer (42).

2. Quick repair patch (36) according to claim 1, characterized in that the plastic film layer (40) contains reinforcing fibers, a radar radiation attenuating, preferably a radar radiation absorbing, material, and / or an electrically conductive material, wherein the plastic film layer (40) is electrically insulated from the lightning protection layer (42), and / or wherein the plastic film layer (40) contains a material that attenuates, preferably absorbs, UV light or ionizing radiation.

3. Quick repair patch (36) according to one of the preceding claims, characterized in that the layer structure (38) comprises - A reinforcement layer (52) containing reinforcement fibers and arranged on the plastic film layer (40); and / or - A camouflage layer (54) containing a radar radiation attenuating, preferably radar radiation absorbing, material; and / or - An electrostatic discharge protection layer (56) containing an electrically conductive material; - A radiation protection layer containing a material that attenuates, preferably absorbs, UV light or ionizing radiation; and - The connecting layer (46).

4. Quick repair patch (36) according to claim 3, characterized in that the reinforcement layer (52), the camouflage layer (54), the discharge protection layer (56), and / or the radiation protection layer are combined in a common functional layer (50); and / or that the reinforcement layer (52), the camouflage layer (54), the discharge protection layer (56), the radiation protection layer and / or the functional layer (50) are arranged on the side of the plastic film layer (40) facing away from the lightning protection layer (42).

5. Quick repair patch (36) according to one of the preceding claims, characterized in that the layer structure (38) is formed in one of the following sequences: - Plastic film layer (40), lightning protection layer (42), fastening layer (48); or - Plastic film layer (40), bonding layer (46), lightning protection layer (42), fastening layer (48); or - Reinforcement layer (52) or camouflage layer (54) or discharge protection layer (56) or radiation protection layer, plastic film layer (40), lightning protection layer (42), fastening layer (48); or - Reinforcement layer (52) or camouflage layer (54) or discharge protection layer (56) or radiation protection layer, plastic film layer (40), bonding layer (46), lightning protection layer (42), fastening layer (48); or - Functional layer (50), plastic film layer (40), lightning protection layer (42), fastening layer (48); or - Functional layer (50), plastic film layer (40), connecting layer (46), lightning protection layer (42), fastening layer (48).

6. Quick repair patch (36) according to one of the preceding claims, characterized in that the layer structure (38) comprises solely of the layers mentioned.

7. Quick repair patch (36) according to one of the preceding claims, characterized in that the quick repair patch (36) comprises information means (58), preferably a QR code and / or an RFID tag, by means of which information about the quick repair patch (36) and / or the quick repair carried out using the quick repair patch (36) can be stored or retrieved.

8. Patch strip (62) comprising a plurality of quick repair patches (36) according to one of the preceding claims, wherein the quick repair patches (36) are connected to each other at an edge area (64) in a manner that allows them to be separated from each other individually.

9. Patch strip (62) according to claim 8, characterized in that the edge area (64) is perforated for separation.

10. Patch strip (62) according to claim 8 or 9, characterized in that the patch strip (62) is designed in the form of a roll.

11. Repair assembly (37) comprising a component (26), preferably an aircraft component (12, 14, 16, 18, 20, 22, 24), and a quick repair patch (36) according to one of claims 1 to 6, wherein the component (26) has a top layer (34) and an underlying lightning strike surface protection (32) as well as local damage (28) that is not relevant in terms of structural mechanics, wherein the quick repair patch (36) covers the damage (28) and is bonded to the component (26) by means of the fastening layer (48), wherein the plastic film layer (40) is bonded to the cover layer (34) and faces away from the damage (28), wherein the electrically conductive lightning protection layer (42) is arranged between the plastic film layer (40) and the lightning strike surface protection (32).

12. Aircraft (10) comprising a quick repair patch (36) and / or a repair assembly (37) according to any of the preceding claims, wherein preferably the component (26) is located among lift aids (22), flaps, slats, control surfaces (24), elevators, rudders, ailerons, fuselage parts (12), rotor blades, wings (20), engine nacelles, horizontal stabilizers (18), and / or vertical stabilizers (16).

13. Quick repair method for repairing local damage (28) to a component (26), preferably an aircraft component (12, 14, 16, 18, 20, 22, 24), which includes a top coat (34) and an underlying lightning strike surface protection (32), wherein the method comprises: 13.1 Creating bonding surfaces (60) on the component (26) for a quick repair patch (36) and, if necessary, exposing the lightning strike surface protection (32); 13.2 Positioning a quick repair patch (36) according to one of the preceding claims on the damage (28); 13.3 Applying a fastening layer (48) only to an edge area (44) of a plastic film layer (40) of the quick repair patch (36); and 13.4 Fastening the quick repair patch (36) to the connecting surfaces (60) created in step 13.1 by pressing down on the plastic film layer (40), particularly in the edge area (44), whereby the plastic film layer (40) is connected to the cover layer (34) in a material-locking manner and a lightning protection layer (42) of the quick repair patch (36) is preferably electrically conductively contacted with the lightning strike surface protection (32).

14. Quick repair method according to claim 13, characterized in that in step 13.1, the connecting surfaces (60) are produced and / or the lightning strike surface protection (32) is exposed by grinding.

15. Use of a quick repair patch (36) according to one of claims 1 to 6 for repairing local damage (28) to an aircraft component (12, 14, 16, 18, 20, 22, 24) that is not relevant in terms of structural mechanics.