Composite repairing
The method uses a thermoplastic-impregnated heating element to bond and heat repair patches to thermoplastic composite parts, addressing the inefficiencies of existing thermosetting patch methods by reducing time and energy use while ensuring effective bonding.
Patent Information
- Application Number
- JP2024224384
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2024-02-16
- Filing Date
- 2024-12-19
- Publication Date
- 2025-08-28
AI Technical Summary
Current thermoplastic composite part repair methods using thermosetting patches are time-consuming, difficult to scale, and require energetic surface preparation methods that can be challenging to access, especially in complex environments like vehicles.
A method involving a heating element impregnated with thermoplastic material that bonds to the repair area using an electrical current, followed by applying a repair patch and heating it to a patching temperature with optional pressure, allowing for efficient bonding of both thermoplastic and thermosetting patches.
This method reduces repair time and energy consumption while enabling effective bonding of repair patches to thermoplastic composite parts, even in hard-to-reach areas, without the need for high-energy surface preparation.
Smart Images
Figure 2025126124000001_ABST
Abstract
Description
[Technical Field]
[0001] The present disclosure relates generally to composite repair, and more particularly to repairing thermoplastic composite parts using heating elements that include thermoplastic materials. [Background technology]
[0002] Currently, repair techniques for thermoplastic composite parts are being planned and researched. Several thermosetting patches may be applied using adhesives to bond the thermosetting patch to the thermoplastic part. A heating blanket may be used to cure the thermosetting patch. Current thermosetting bonding methods use energetic surface preparation methods, such as plasma treatment of the thermoplastic part. Energetic surface treatments have time limitations on their usefulness. Furthermore, the energetic surface preparation method must be able to reach the area where the thermoplastic composite part will be treated. Access may be difficult on some vehicles and other platforms. Bonding a thermosetting patch to a thermoplastic part can be undesirably time consuming and difficult to scale to large area parts. Summary of the Invention [Problem to be solved by the invention]
[0003] It would therefore be desirable to have a method and apparatus that takes into account at least some of the problems discussed above, as well as other possible problems. It would be desirable to have a thermoplastic repair method that uses at least one of less time or less energy. [Means for solving the problem]
[0004] One embodiment of the present disclosure provides a method for repairing a thermoplastic composite component. A heating element impregnated with a thermoplastic material is placed over a repair area of the thermoplastic composite component. The thermoplastic material of the heating element is bonded to the repair area by generating heat within the heating element through an electrical current applied to the heating element. After bonding the heating element to the repair area, a repair patch is placed over the heating element. An electrical current is applied to the heating element to heat the repair patch to a patching temperature.
[0005] Another embodiment of the present disclosure provides a method for repairing a thermoplastic composite component. A heating element impregnated with a thermoplastic material is placed over a repair area of the thermoplastic composite component. The thermoplastic material of the heating element is bonded to the repair area by generating heat within the heating element via an electrical current applied to the heating element. A thermoplastic repair patch is placed over the heating element after bonding the heating element to the repair area. The thermoplastic repair patch is heated to a patching temperature using the heating element. Pressure is applied to the thermoplastic repair patch while the repair patch is heated.
[0006] Yet another embodiment of the present disclosure provides a method for repairing a thermoplastic composite component. A heating element impregnated with a thermoplastic material is placed over a repair area of the thermoplastic composite component. The thermoplastic material of the heating element is bonded to the repair area by generating heat within the heating element via an electrical current applied to the heating element. A thermosetting repair patch is placed over the heating element after bonding the heating element to the repair area. The thermosetting repair patch is heated to a patching temperature using the heating element. Pressure is applied to the repair patch while the thermosetting repair patch is being heated.
[0007] The above features and functions may be realized independently in various embodiments of the present disclosure or may be combined in other embodiments, further details of which can be seen with reference to the following description and drawings.
[0008] The novel features believed characteristic of the exemplary embodiments are set forth in the appended claims. However, the exemplary embodiments, as well as their preferred modes of use, further objects and features thereof, will best be understood by reference to the following detailed description of exemplary embodiments of the present disclosure, when considered in conjunction with the accompanying drawings. [Brief explanation of the drawings]
[0009] [Figure 1] 1 is an illustration of an aircraft in accordance with an illustrative embodiment; [Figure 2] FIG. 1 is a block diagram of a manufacturing environment in accordance with an illustrative embodiment. [Figure 3] 1 is a cross-sectional view of a thermoplastic composite component repair in accordance with an exemplary embodiment; [Figure 4] 1 is a cross-sectional view of a thermoplastic composite component repair in accordance with an exemplary embodiment; [Figure 5] 1 is a cross-sectional view of a thermoplastic composite component repair in accordance with an exemplary embodiment; [Figure 6] 1 is a cross-sectional view of a thermoplastic composite component repair in accordance with an exemplary embodiment; [Figure 7A] 1 illustrates a flowchart of a method for repairing a thermoplastic composite component in accordance with an illustrative embodiment. [Figure 7B] 1 illustrates a flowchart of a method for repairing a thermoplastic composite component in accordance with an illustrative embodiment. [Figure 8] 1 illustrates a flowchart of a method for repairing a thermoplastic composite component in accordance with an illustrative embodiment. [Figure 9] 1 illustrates a flowchart of a method for repairing a thermoplastic composite component in accordance with an illustrative embodiment. [Figure 10] 1 illustrates a flowchart of a method for repairing a thermoplastic composite component in accordance with an illustrative embodiment. [Figure 11] FIG. 1 is a block diagram of an aircraft manufacturing and service method in accordance with an illustrative embodiment; [Figure 12] FIG. 1 is a block diagram of an aircraft in which an illustrative embodiment may be implemented; DETAILED DESCRIPTION OF THE INVENTION
[0010] Referring now to Figure 1, an illustration of an aircraft is shown in accordance with an illustrative embodiment. Aircraft 100 has wing 102 and wing 104 attached to body 106. Aircraft 100 includes engine 108 attached to wing 102 and engine 110 attached to wing 104.
[0011] Body 106 has tail section 112. Horizontal stabilizer 114, horizontal stabilizer 116, and vertical stabilizer 118 are attached to tail section 112 of body 106.
[0012] Aircraft 100 is an example of an aircraft that may have a thermoplastic composite part to be repaired. At least one of wing 102, wing 104, body 106, horizontal stabilizer 114, horizontal stabilizer 116, or vertical stabilizer 118 of aircraft 100 may be repaired using the illustrative examples.
[0013] Referring now to Figure 2, a block diagram of a manufacturing environment is shown in accordance with an illustrative embodiment. Manufacturing environment 200 is an environment in which repairs to thermoplastic composite part 202 may be performed. In this illustrative example, a heating element 206 is applied to repair area 204 to adhere repair patch 208 onto thermoplastic composite part 202. Repair patch 208 may comprise either a thermoplastic repair patch 210 or a thermoset repair patch 212.
[0014] The thermoplastic composite part 202 includes a composite material 214 having a melting temperature 216. The heating element 206 is impregnated 226 with a thermoplastic material 218. The thermoplastic material 218 is sometimes referred to as a low melting point 220 thermoplastic material 218. The thermoplastic material 218 is sometimes referred to as a low melting point 220 thermoplastic material 218 because the melting temperature 222 of the thermoplastic material 218 is lower than the melting temperature 216 of the thermoplastic composite part 202. The heating element 206 can heat from room temperature to the desired joining temperature at an extremely fast rate (approximately 150°C / min).
[0015] The carbon conductive material 224 resides within the heating element 206 and melts the thermoplastic material 218, bonding the heating element 206 to the thermoplastic composite part 202. When an electric current 223 is applied to the carbon conductive material 224, the carbon conductive material 224 generates heat. In some illustrative examples, the carbon conductive material 224 is a fiber, mesh, coil, or unidirectional tape. In some illustrative examples, the carbon conductive material 224 generates heat to melt the thermoplastic material 218. In some illustrative examples, the carbon conductive material 224 has a thickness in the range of 0.005 inches to 0.02 inches. When an electric current 223 is applied to the carbon conductive material 224, the carbon conductive material 224 generates heat.
[0016] A control system 225 is present to control the application of the electrical current 223. In some illustrative examples, the electrical current 223 is controlled based on a feedback control loop. A temperature sensor may be present to monitor the temperature of the heating element 206. The control system 225 is configured to control the electrical current 223 applied to the carbon conductive material 224 based on the temperature of at least one of the thermoplastic composite part 202, the heating element 206, or the repair patch 208.
[0017] The thermoplastic material 218 can take any desired form that has a melting temperature 222 that is lower than the melting temperature 216 of the thermoplastic composite part 202 .
[0018] In some illustrative examples, thermoplastic material 218 is polyaryletherketone. In some illustrative examples, polyaryletherketone has a melting temperature 222 in the range of 260-350 degrees Celsius. In some illustrative examples, thermoplastic material 218 is polyetherketoneketone. In some illustrative examples, thermoplastic material 218 is polyetheretherketone. In some illustrative examples, thermoplastic material 218 is a blend of two thermoplastic materials.
[0019] In some illustrative examples, the blend of two thermoplastic materials has a melting temperature 222 in the range of 260-350 degrees Celsius and a glass transition temperature in the range of 180-200 degrees Celsius. The glass transition temperature can be used to bond the heating element 206 to the thermosetting material, such as when the repair patch 208 takes the form of the thermosetting repair patch 212. In some illustrative examples, the thermoplastic material 218 is a blend when the repair patch 208 takes the form of the thermosetting repair patch 212.
[0020] In some illustrative examples, the thermoplastic material 218 joining the thermoset repair patch 212 and the thermoplastic composite part 202 is a blend of two thermoplastic materials. In some illustrative examples, the thermoplastic material 218 joining two thermoplastic composite components, such as the thermoplastic composite part 202 and the thermoplastic repair patch 210, is a single thermoplastic material having a melting temperature 222.
[0021] A heating element 206 impregnated (226) with a thermoplastic material 218 is applied over the repair area 204 of the thermoplastic composite part 202. The repair area 204 may take any desired form. In some illustrative examples, the repair area 204 is a surface 228 over a mismatch 232. In these illustrative examples, the mismatch 232 may remain in the thermoplastic composite part 202.
[0022] In some illustrative examples, the repair region is created by removing a mismatch from the thermoplastic composite component. In some illustrative examples, the repair region 204 includes the surface 228 of the thermoplastic composite component 202 within the cutout 234 formed by removing the mismatch 232 from the thermoplastic composite component 202.
[0023] In some illustrative examples, repair area 204 includes portion 230 of thermoplastic composite component 202 after mismatch 232 has been removed from thermoplastic composite component 202. In some illustrative examples, a series of layers of composite material have been cut from thermoplastic composite component 202 to create repair area 204.
[0024] The repair area 204 can have any desired size or shape. In some illustrative examples, the repair area 204 is scarred (236).
[0025] The thermoplastic material 218 of the heating element 206 is bonded to the repair area 204 by generating heat within the heating element 206 via an electrical current 223 applied to the heating element 206. After bonding the heating element 206 to the repair area 204, a repair patch 208 is placed over the heating element 206. An electrical current 223 is applied to the heating element 206 to heat the repair patch 208 to a patching temperature.
[0026] In some illustrative examples, the thermoplastic repair patch 210 is already solidified and is the same material as the thermoplastic composite part 202. When the repair patch is in the form of the thermoplastic repair patch 210, an electric current 223 is applied to the heating element 206 to heat the thermoplastic repair patch 210 to a patching temperature 238. The patching temperature 238 is selected to solidify the thermoplastic repair patch 210. In some illustrative examples, the patching temperature 238 is between about 280°C and 340°C. In some illustrative examples, the patching temperature 238 is about 310°C.
[0027] While the thermoplastic repair patch 210 is being heated, pressure 240 is applied to the thermoplastic repair patch 210 to compress the thermoplastic repair patch 210. In some illustrative examples, a pressure 240 of approximately 15-45 psi is applied to the thermoplastic repair patch 210 while the thermoplastic repair patch 210 is being heated to bond the thermoplastic repair patch 210 to the thermoplastic composite component 202. In some illustrative examples, a pressure 240 of approximately 30 psi is applied to the thermoplastic repair patch 210 while the thermoplastic repair patch 210 is being heated to bond the thermoplastic repair patch 210 to the thermoplastic composite component 202. In some illustrative examples, pressure 240 is removed from the thermoplastic repair patch 210 after the thermoplastic repair patch 210 is allowed to cool to 150°C. When the repair patch takes the form of a thermosetting repair patch 212, an electric current 223 is applied to the heating element 206 to heat the thermosetting repair patch 212 to a patching temperature 242. The patching temperature 242 is selected to cure the thermosetting repair patch 212. In some illustrative examples, the patching temperature 242 is between about 170°C and 190°C. In some illustrative examples, the patching temperature 242 is about 180°C.
[0028] While the thermosetting repair patch 212 is being heated, pressure 244 is applied to the thermosetting repair patch 212 to compress the thermosetting repair patch 212. In some illustrative examples, a pressure 244 of approximately 60 psi to 90 psi is applied to the thermosetting repair patch 212 while the thermosetting repair patch 212 is being heated to bond the thermosetting repair patch 212 to the thermoplastic composite component 202. In some illustrative examples, a pressure 244 of approximately 85 psi is applied to the thermosetting repair patch 212 while the thermosetting repair patch 212 is being heated to bond the thermosetting repair patch 212 to the thermoplastic composite component 202. In some illustrative examples, pressure 244 is removed from the thermosetting repair patch 212 after the thermosetting repair patch 212 is allowed to cool to ambient temperature.
[0029] In some illustrative examples, after the repair patch 208 is adhered to the thermoplastic composite component 202, the end of the heating element 206 can extend outside of the repair patch 208. In some illustrative examples, after the repair patch 208 is adhered to the thermoplastic composite component 202, the end of the heating element 206 extends from the thermoplastic composite component 202. As shown, end 246 and end 248 of the heating element 206 extend from between the repair patch 208 and the thermoplastic composite component 202. As shown, the trimming end of the heating element 206 can comprise trimming end 246 and end 248.
[0030] The illustration of manufacturing environment 200 in FIG. 2 is not meant to imply physical or architectural limitations to the manner in which an illustrative embodiment may be implemented. Other components in addition to or in place of the illustrated components may be used. Some components may be unnecessary. Also, the blocks are shown to represent some functional components. One or more of these blocks may be combined, divided, or combined and then divided into different blocks when implemented in an illustrative embodiment.
[0031] For example, in some illustrative examples, there may be additional heating elements and additional repair patches, hi some illustrative examples, one each on either side of mismatch 232 in thermoplastic composite part 202 through the thickness.
[0032] Referring now to FIG. 3, an illustration shows a cross-sectional view of a thermoplastic composite part repair in accordance with an illustrative embodiment. Thermoplastic composite part 302 is a physical implementation of thermoplastic composite part 202 of FIG. 2. In view 300, a heating element 306 is positioned over a repair area 304 of thermoplastic composite part 302. In this illustrative example, repair area 304 includes a portion of thermoplastic composite part 302 after a mismatch has been removed from thermoplastic composite part 302. In this illustrative example, a series of layers of composite material have been cut from thermoplastic composite part 302 to create repair area 304.
[0033] In this illustrative example, heating element 306 is placed over repair area 304 and heated to bond heating element 306 to thermoplastic composite component 302. After heating element 306 is bonded to thermoplastic composite component 302, repair patch 308 is placed over heating element 306. Heating element 306 is used to heat repair patch 308 to a patching temperature. The patching temperature is selected based on the material type of repair patch 308.
[0034] The repair patch 308 was pre-laid up adjacent to the layer of thermoplastic composite part 302 that was removed to create the repair area 304. In some illustrative examples, the repair patch 308 may be referred to as a scarf patch. Once the repair patch 308 is placed in contact with the thermoplastic material 312 of the heating element 306, the repair patch 308 enters a solidified state.
[0035] The heating element 306 is impregnated with a thermoplastic material 312. The heating element 306 includes a carbon conductive material 310 and a thermoplastic material 312. The thermoplastic material 312 is the portion of the heating element 306 that is bonded to the repair area 304 of the thermoplastic composite part 302. The carbon conductive material 310 is the portion of the heating element 306 that generates heat in response to passing an electric current through the heating element 306.
[0036] Referring now to FIG. 4, an illustration shows a cross-sectional view of a thermoplastic composite part repair in accordance with an illustrative embodiment. Thermoplastic composite part 402 is a physical implementation of thermoplastic composite part 202 from FIG. 2. In view 400, a heating element 406 is positioned over a repair area 405 of thermoplastic composite part 402. In this illustrative example, repair area 405 includes a portion of a surface 407 of composite part 402. In this illustrative example, a mismatch 404 exists in thermoplastic composite part 402. Repair area 405 is a portion of surface 407 of thermoplastic composite part 402 above mismatch 404.
[0037] In this illustrative example, heating element 406 is placed over repair area 405 and heated to bond heating element 406 to repair area 405 of thermoplastic composite part 402. After bonding heating element 406 to thermoplastic composite part 402, repair patch 408 is placed over heating element 406. Heating element 406 is used to heat repair patch 408 to a patching temperature. The patching temperature is selected based on the material type of repair patch 408.
[0038] The repair patch 408 is laid up over the mismatch 404 without removing the mismatch 404 from the thermoplastic composite part 402. In some illustrative examples, the repair patch 408 may be referred to as an external doubler. The repair patch 408 may be used to repair mismatches that do not penetrate the thickness of the thermoplastic composite part 402.
[0039] The heating element 406 is impregnated with a thermoplastic material 412. The heating element 406 includes a carbon conductive material 410 and a thermoplastic material 412. The thermoplastic material 412 is the portion of the heating element 406 that is bonded to the thermoplastic composite part 402. The carbon conductive material 410 is the portion of the heating element 406 that generates heat in response to passing an electric current through the heating element 406.
[0040] Referring now to FIG. 5, a cross-sectional view of a thermoplastic composite part repair is shown in accordance with an illustrative embodiment. Thermoplastic composite part 502 is a physical implementation of thermoplastic composite part 202 from FIG. 2. In view 500, heating element 506 is positioned over repair area 505 of thermoplastic composite part 502. In view 500, heating element 516 is positioned over repair area 514 of thermoplastic composite part 502. In this illustrative example, repair area 505 and repair area 514 are on a surface of composite part 502. In this illustrative example, repair area 505 includes a portion of surface 507 of composite part 502. In this illustrative example, mismatch 504 exists in thermoplastic composite part 502. Repair area 505 is a portion of surface 507 of thermoplastic composite part 502 above mismatch 504.
[0041] In this illustrative example, repair area 514 includes a portion of surface 515 of composite part 502. In this illustrative example, repair area 514 is a portion of surface 515 on mismatch 504 of thermoplastic composite part 502.
[0042] In this illustrative example, heating element 506 is placed over repair area 505 and heated to bond heating element 506 to repair area 505 of thermoplastic composite part 502. After bonding heating element 506 to thermoplastic composite part 502, repair patch 508 is placed over heating element 506. Heating element 506 is used to heat repair patch 508 to a patching temperature. The patching temperature is selected based on the material type of repair patch 508.
[0043] The heating element 506 is impregnated with a thermoplastic material 512. The heating element 506 includes a carbon conductive material 510 and a thermoplastic material 512. The thermoplastic material 512 is the portion of the heating element 506 that is bonded to the thermoplastic composite part 502. The carbon conductive material 510 is the portion of the heating element 506 that generates heat in response to passing an electric current through the heating element 506.
[0044] In this illustrative example, heating element 516 is placed over repair area 514 and heated to bond heating element 516 to repair area 514 of thermoplastic composite part 502. After bonding heating element 516 to thermoplastic composite part 502, repair patch 518 is placed over heating element 516. Heating element 516 is used to heat repair patch 518 to a patching temperature. The patching temperature is selected based on the material type of repair patch 518.
[0045] The heating element 516 is impregnated with a thermoplastic material 522. The heating element 516 includes a carbon conductive material 520 and a thermoplastic material 522. The thermoplastic material 522 is the portion of the heating element 516 that is bonded to the thermoplastic composite part 502. The carbon conductive material 520 is the portion of the heating element 516 that generates heat in response to the passage of an electrical current through the heating element 516.
[0046] Referring now to Figure 6, an illustration of a cross-sectional view of a thermoplastic composite part repair is shown in accordance with an illustrative embodiment. Thermoplastic composite part 602 is a physical implementation of thermoplastic composite part 202 from Figure 2. In view 600, a heating element 608 is positioned over a repair area 606 of thermoplastic composite part 602. In this illustrative example, thermoplastic composite part 602 is a stiffener. Thermoplastic composite part 602 is a stiffener bonded to a thermoplastic composite skin 601.
[0047] In this illustrative example, repair area 606 includes a portion of surface 605 of composite part 602. In this illustrative example, mismatch 604 exists in thermoplastic composite part 602. Repair area 606 is a portion of surface 605 of thermoplastic composite part 602 above mismatch 604.
[0048] In this illustrative example, heating element 608 is placed over repair area 606 and heated to bond heating element 608 to repair area 606 of thermoplastic composite part 602. After bonding heating element 608 to thermoplastic composite part 602, repair patch 610 is placed over heating element 608. Heating element 608 is used to heat repair patch 610 to a patching temperature. The patching temperature is selected based on the material type of repair patch 610.
[0049] The repair patch 610 is laid up over the mismatch 604 without removing the mismatch 604 from the thermoplastic composite part 602. In some illustrative examples, the repair patch 610 may be referred to as an external doubler. The repair patch 610 may be used to repair mismatches that do not penetrate the thickness of the thermoplastic composite part 602.
[0050] The heating element 608 is impregnated with a thermoplastic material 614. The heating element 608 includes a carbon conductive material 612 and a thermoplastic material 614. The thermoplastic material 614 is the portion of the heating element 608 that is bonded to the thermoplastic composite part 602. The carbon conductive material 612 is the portion of the heating element 608 that generates heat in response to passing an electrical current through the heating element 608.
[0051] 7A and 7B , a flowchart of a method for repairing a thermoplastic composite component is shown in accordance with an illustrative embodiment. Method 700 may be implemented to repair a thermoplastic composite component of aircraft 100 in FIG. 1 . Method 700 may be implemented to repair thermoplastic composite component 202 in FIG. 2 . Method 700 may be implemented to repair thermoplastic composite component 302 in FIG. 3 . Method 700 may be implemented to repair thermoplastic composite component 402 in FIG. 4 . Method 700 may be implemented to repair thermoplastic composite component 502 in FIG. 5 . Method 700 may be implemented to repair thermoplastic composite component 602 in FIG. 6 .
[0052] The method 700 positions a heating element impregnated with a thermoplastic material over a repair area of the thermoplastic composite part (operation 702). The repair area can take any desired form. In some illustrative examples, the repair area is a surface over a mismatch. In some illustrative examples, the repair area is created by removing the mismatch from the thermoplastic composite part. The repair area can have any desired size or shape.
[0053] The method 700 bonds the thermoplastic material of the heating element to the repair area by generating heat within the heating element via an electrical current applied to the heating element (operation 704). After bonding the heating element to the repair area, the method 700 places a repair patch over the heating element (operation 706). The method 700 applies an electrical current to the heating element to heat the repair patch to a patching temperature (operation 708). The method 700 then ends.
[0054] In some illustrative examples, the method 700 removes a portion of the thermoplastic composite component to form a repair region (operation 710). In some illustrative examples, the removed portion of the thermoplastic composite component comprises a mismatch. In some illustrative examples, removing the portion of the thermoplastic composite component includes iteratively removing layers of the thermoplastic composite component. In some illustrative examples, removing the portion of the thermoplastic composite component includes removing a scar from the thermoplastic composite component.
[0055] In some illustrative examples, method 700 treats the surface of the repair area prior to applying the heating element, where treating includes cleaning and polishing the repair area (operation 712). In these illustrative examples, treating the surface includes treating the surface without using a high-energy preparation. In these illustrative examples, treating the surface includes treating the surface without plasma treatment.
[0056] In some illustrative examples, the method 700 applies compression to the repair patch while heating the repair patch to a patch processing temperature to bond the repair patch to the thermoplastic composite part (operation 714), the compression being sufficient to process the material of the repair patch during heating.
[0057] In some illustrative examples, the repair patch comprises a thermoplastic repair patch (Operation 716). In some illustrative examples, the patch processing temperature is between about 280°C and 340°C (Operation 718). In some illustrative examples, the patch processing temperature is about 310°C. In some illustrative examples, the method 700 applies a pressure of between about 15 and 45 psi to the repair patch while heating the repair patch to bond the repair patch to the thermoplastic composite component (Operation 720). In some illustrative examples, the method 700 applies a pressure of about 30 psi to the repair patch while heating the repair patch to bond the repair patch to the thermoplastic composite component. In some illustrative examples, the method 700 removes pressure from the repair patch after allowing the repair patch to cool to 150°C (Operation 722).
[0058] In some illustrative examples, the method 700 trims the end of the heating element that extends from the thermoplastic composite part (operation 724). In some illustrative examples, the end of the heating element that extends beyond the repair patch is trimmed. In some illustrative examples, the trimmed end is exposed.
[0059] In some illustrative examples, the repair patch comprises a thermosetting repair patch (Operation 726). In some illustrative examples, the patch processing temperature is about 170°C to 190°C (Operation 728). In some illustrative examples, the patch processing temperature is about 180°C. In some illustrative examples, the method 700 applies a pressure of about 60 to 90 psi to the repair patch while heating the repair patch to bond the repair patch to the thermoplastic composite component (Operation 730). In some illustrative examples, the method 700 applies a pressure of about 85 psi to the repair patch while heating the repair patch to bond the repair patch to the thermoplastic composite component. In some illustrative examples, the method 700 removes pressure from the repair patch after allowing the repair patch to cool to ambient temperature (Operation 732).
[0060] Referring now to Figure 8, a flowchart of a method for repairing a thermoplastic composite component is shown in accordance with an illustrative embodiment. Method 800 may be implemented to repair a thermoplastic composite component of aircraft 100 in Figure 1. Method 800 may be implemented to repair thermoplastic composite component 202 in Figure 2. Method 800 may be implemented to repair thermoplastic composite component 302 in Figure 3. Method 800 may be implemented to repair thermoplastic composite component 402 in Figure 4. Method 800 may be implemented to repair thermoplastic composite component 502 in Figure 5. Method 800 may be implemented to repair thermoplastic composite component 602 in Figure 6.
[0061] The method 800 positions a heating element impregnated with thermoplastic material over a repair area of a thermoplastic composite component (operation 802). The method 800 bonds the thermoplastic material of the heating element to the repair area by generating heat within the heating element via an electrical current applied to the heating element (operation 804). After bonding the heating element to the repair area, the method 800 positions a thermoplastic repair patch over the heating element (operation 806). The method 800 heats the thermoplastic repair patch to a patching temperature using the heating element (operation 808). The method 800 applies pressure to the thermoplastic repair patch while heating the repair patch (operation 810). The method 800 then ends.
[0062] In some illustrative examples, method 800 treats the surface of the repair area prior to applying the heating element, where treating includes cleaning and polishing the repair area (operation 812). In these illustrative examples, treating the surface includes treating the surface without using a high-energy preparation. In these illustrative examples, treating the surface includes treating the surface without plasma treatment.
[0063] In some illustrative examples, the patch processing temperature is between 280°C and 340°C (OPERATION 814). In some illustrative examples, the patch processing temperature is about 310°C. In some illustrative examples, the pressure is between 15 and 45 psi (OPERATION 816). In some illustrative examples, the pressure is about 30 psi. In some illustrative examples, the method 800 removes pressure from the repair patch after allowing the repair patch to cool to 150°C (OPERATION 818).
[0064] In some illustrative examples, the method 800 trims an end of the heating element that extends from the thermoplastic composite part (operation 820). The heating element remains within the thermoplastic composite part after application of the repair patch. The heating element remains within the thermoplastic composite part during operation of a platform, such as an aircraft, that includes the thermoplastic composite part. In some illustrative examples, the end of the heating element that extends beyond the repair patch is trimmed. In some illustrative examples, the trimmed end is exposed after bonding the repair patch to the thermoplastic composite part.
[0065] Referring now to Figure 9, a flowchart of a method for repairing a thermoplastic composite component is shown in accordance with an illustrative embodiment. Method 900 may be implemented to repair a thermoplastic composite component of aircraft 100 in Figure 1. Method 900 may be implemented to repair thermoplastic composite component 202 in Figure 2. Method 900 may be implemented to repair thermoplastic composite component 302 in Figure 3. Method 900 may be implemented to repair thermoplastic composite component 402 in Figure 4. Method 900 may be implemented to repair thermoplastic composite component 502 in Figure 5. Method 900 may be implemented to repair thermoplastic composite component 602 in Figure 6.
[0066] The method 900 positions a heating element impregnated with a thermoplastic material over a repair area of a thermoplastic composite component (operation 902). The method 900 bonds the thermoplastic material of the heating element to the repair area by generating heat within the heating element via an electrical current applied to the heating element (operation 904). After bonding the heating element to the repair area, the method 900 positions a thermosetting repair patch over the heating element (operation 906). The method 900 heats the thermosetting repair patch to a patching temperature using the heating element (operation 908). The method 900 applies pressure to the repair patch while heating the thermosetting repair patch (operation 910). The method 900 then ends.
[0067] In some illustrative examples, the method 900 treats the surface of the repair area prior to applying the heating element, where treating includes cleaning and polishing the repair area (operation 912). In these illustrative examples, treating the surface includes treating the surface without using a high-energy preparation. In these illustrative examples, treating the surface includes treating the surface without plasma treatment.
[0068] In some illustrative examples, the patch processing temperature is about 170°C to 190°C (Operation 914). In some illustrative examples, the patch processing temperature is about 180°C. In some illustrative examples, the method 900 applies a pressure of about 60 to 90 psi to the repair patch while heating the repair patch to bond the repair patch to the thermoplastic composite component (Operation 916). In some illustrative examples, the method 900 applies a pressure of about 85 psi to the repair patch while heating the repair patch to bond the repair patch to the thermoplastic composite component. In some illustrative examples, the method 900 removes the pressure from the repair patch after allowing the repair patch to cool to ambient temperature (Operation 918).
[0069] In some illustrative examples, the method 900 trims an end of the heating element that extends from the thermoplastic composite part (operation 920). The heating element remains within the thermoplastic composite part after application of the repair patch. The heating element remains within the thermoplastic composite part during operation of a platform, such as an aircraft, that includes the thermoplastic composite part. In some illustrative examples, the end of the heating element that extends beyond the repair patch is trimmed. In some illustrative examples, the trimmed end is exposed.
[0070] Referring now to Figure 10 , a flowchart of a method for repairing a thermoplastic composite component is shown in accordance with an illustrative embodiment. Method 1000 may be implemented to repair a thermoplastic composite component of aircraft 100 in Figure 1 . Method 1000 may be implemented to repair thermoplastic composite component 202 in Figure 2 . Method 1000 may be implemented to repair thermoplastic composite component 302 in Figure 3 . Method 1000 may be implemented to repair thermoplastic composite component 402 in Figure 4 . Method 1000 may be implemented to repair thermoplastic composite component 502 in Figure 5 . Method 1000 may be implemented to repair thermoplastic composite component 602 in Figure 6 .
[0071] The method 1000 bonds the low melting point thermoplastic material of the heating element to the repair area of the thermoplastic composite part (operation 1002). The method 1000 bonds the low melting point thermoplastic material to the repair patch (operation 1004). The method 1000 then ends.
[0072] In some illustrative examples, the method 1000 removes a portion of the thermoplastic composite component to form a repair region (operation 1006). In some illustrative examples, the removed portion of the thermoplastic composite component comprises a mismatch. In some illustrative examples, removing the portion of the thermoplastic composite component includes iteratively removing layers of the thermoplastic composite component. In some illustrative examples, removing the portion of the thermoplastic composite component includes removing a scar from the thermoplastic composite component.
[0073] In some illustrative examples, adhering the low melting point thermoplastic material to the repair area includes heating the heating element by applying an electric current to the heating element (OPERATION 1008). In some illustrative examples, the electric current applied to the heating element heats a carbon conductive material within the heating element. In some illustrative examples, adhering the low melting point thermoplastic material to the repair patch includes heating the heating element by applying an electric current to the heating element (OPERATION 1010).
[0074] In some illustrative examples, the method 1000 applies compression to the repair patch while heating the repair patch to a patch processing temperature to bond the repair patch to the thermoplastic composite part (operation 1012). The amount of compression is selected based on the type of material of the repair patch.
[0075] In some illustrative examples, the repair patch comprises a thermoplastic repair patch (OPERATION 1014). In some other illustrative examples, the repair patch comprises a thermosetting repair patch (OPERATION 1016). The thermoplastic material in the heating element is different for the thermoplastic repair patch than for the thermosetting repair patch. Furthermore, the processing temperature and pressure of the repair patch are different for the thermoplastic patch and the thermosetting repair patch.
[0076] In some illustrative examples, the method 1000 trims any ends of the heating element that extend from the thermoplastic composite part (operation 1018). The heating element remains in the thermoplastic composite part after application of the repair patch. The heating element remains in the thermoplastic composite part during operation of a platform, such as an aircraft, that includes the thermoplastic composite part. Any ends of the heating element that extend from the thermoplastic composite part are trimmed.
[0077] As used herein, the phrase "at least one of," when used in conjunction with a list of items, means that various combinations of one or more of the listed items may be used, and that only one of each item in the list may be required. For example, "at least one of item A, item B, or item C" may include, but is not limited to, item A, item A and item B, or item B. This example may also include item A, item B, and item C, or item B and item C. Of course, any combination of these items is possible. In other examples, "at least one of" may be, for example, but is not limited to, two items A, one item B, and ten items C, four items B, and seven items C, or other suitable combinations. An item may be a particular object, thing, or category. In other words, "at least one of" means that any combination and number of items may be used from the list, but not all of the items in the list are required.
[0078] As used herein, "a number of," when used in reference to items, means one or more of the items.
[0079] The flowcharts and block diagrams in the various depicted embodiments illustrate the architecture, functionality, and operation of some possible implementations of apparatuses and methods in the illustrative embodiments. In this regard, each block in the flowcharts or block diagrams may represent at least one module, segment, function, or portion of an operation or step.
[0080] In some alternative implementations of the exemplary embodiments, one or more functions noted in the blocks may occur out of the order noted in the figures. For example, in some cases, two blocks shown in succession may be executed substantially concurrently or may even be executed in the reverse order, depending on the functionality involved. Also, other blocks may be added in addition to the illustrated blocks in a flowchart or block diagram. Some blocks may be optional. For example, operations 710 through 732 may be optional. For example, operations 812 through 820 may be optional. For example, operations 912 through 920 may be optional.
[0081] An exemplary embodiment of the present disclosure will be described with reference to aircraft manufacturing and service method 1100 shown in Figure 11 and aircraft 1200 shown in Figure 12. Turning initially to Figure 11, an illustration of the aircraft manufacturing and service method is shown in block diagram form, in accordance with an exemplary embodiment. During pre-production, aircraft manufacturing and service method 1100 may include specification and design 1102 and material procurement 1104 of aircraft 1200 in Figure 12.
[0082] During production, component and subassembly manufacturing 1106 and systems integration 1108 of the aircraft 1200 occurs. The aircraft 1200 may then go through certification and delivery 1110 to place it in service 1112. While in service 1112 with a customer, the aircraft 1200 is scheduled for routine maintenance and service 1114, which may include modification, reconfiguration, refurbishment, or other maintenance and service.
[0083] Each of the processes of aircraft manufacturing and service method 1100 may be performed or carried out by a system integrator, a third party, and / or an operator. In these examples, the operator may be a customer. For purposes of this description, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors; a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, a leasing company, the military, a service provider, etc.
[0084] Referring now to Figure 12, an illustration of an aircraft in block diagram form is shown in which an illustrative embodiment may be implemented. In this example, aircraft 1200 may be produced by aircraft manufacturing and service method 1100 in Figure 11 and may include an airframe 1202 having a number of systems 1204 and an interior 1206. Example systems 1204 include one or more of propulsion system 1208, electrical system 1210, hydraulic system 1212, and environmental system 1214. Any number of other systems may also be included.
[0085] Apparatus and methods embodied herein may be used during at least one of the stages of aircraft manufacturing and service method 1100. One or more illustrative embodiments may be produced or used during at least one of component and subassembly manufacturing 1106, system integration 1108, in-service 1112, or maintenance and service 1114 in Figure 11 .
[0086] An illustrative example uses a heating element containing a thermoplastic material to bond a repair patch to a thermoplastic part having a mismatch. The illustrative example allows for the use of either a thermoplastic or a thermosetting repair patch without a surface preparation step for the thermoplastic part. The heating element within the bond line provides localized heating to the bond area. The heating element can heat from room temperature to the desired bond temperature at a very fast rate (approximately 150°C / min).
[0087] The illustrative example provides a method for performing structural repairs to thermoplastic components during manufacturing and in service. The illustrative example uses a low melting temperature thermoplastic material in a heating element to bond a repair patch to the thermoplastic composite component. The repair patch can be a thermoplastic composite patch or a thermoset composite patch. Depending on the material of the repair patch, different thermoplastic films are used.
[0088] An illustrative example eliminates the need for surface preparation other than cleaning or polishing to use the repair patch. An illustrative example eliminates the need for surface preparation including high-energy preparations, such as plasma treatment, to use the repair patch. An illustrative example eliminates the need for traditional structural adhesives to bond the repair patch to the thermoplastic composite component. An illustrative example utilizes a heating element between the repair patch and the thermoplastic composite component to provide localized heating to bond them. The use of a heating element increases efficiency and allows for in-service aircraft repair. Different thermoplastic formulations for the heating element allow for repair with either a thermoplastic patch or a thermoset patch.
[0089] The description of various exemplary embodiments has been presented for purposes of illustration and description and is not intended to be exhaustive or limited to the embodiments in the form disclosed. Many modifications and variations will be apparent to those skilled in the art. Furthermore, different exemplary embodiments may provide different features as compared to other exemplary embodiments. The selected embodiment or embodiments have been chosen and described in order to best explain the principles and practical applications of the embodiments and to enable others skilled in the art to understand the disclosure of the various embodiments with various modifications suitable for the particular use contemplated. [Explanation of symbols]
[0090] 100 aircraft, 102 wing, 104 wing, 106 body, 108 engine, 110 engine, 112 tail, 114 horizontal stabilizer, 116 horizontal stabilizer, 118 vertical stabilizer, 200 manufacturing environment, 202 thermoplastic composite part, 204 repair area, 206 heating element, 208 repair patch, 210 thermoplastic repair patch, 212 thermosetting repair patch, 214 composite material, 216 melting temperature, 218 thermoplastic material, 220 low melting point, 222 melting temperature, 223 electrical current, 224 carbon conductive material, 225 control system, 226 impregnation, 228 surface, 230 part, 232 inconsistency, 234 notch, 236 scarring, 238 patching temperature, 240 pressure, 242 Patching temperature, 244 pressure, 246 edge, 248 edge, 300 view, 302 thermoplastic composite part, 304 repair area, 306 heating element, 308 repair patch, 310 carbon conductive material, 312 thermoplastic material, 400 view, 402 thermoplastic composite part, 404 mismatch, 405 repair area, 406 heating element, 407 surface, 408 repair patch, 410 carbon conductive material, 412 thermoplastic material, 500 view, 502 thermoplastic composite part, 504 mismatch, 505 repair area, 506 heating element, 507 surface, 508 repair patch, 510 carbon conductive material, 512 thermoplastic material, 514 repair area, 516 heating element, 518 repair patch, 520 carbon conductive material, 522 thermoplastic material, 600 view, 601 Thermoplastic composite skin, 602 Thermoplastic composite parts, 604 Inconsistencies, 605 Surfaces, 606 Repair areas, 608 Heating elements, 610 Repair patches, 612 Carbon conductive materials, 614 Thermoplastic materials, 1100 Aircraft manufacturing and maintenance methods, 1102 Specifications and design, 1104 Materials procurement, 1106 Component and subassembly manufacturing, 1108 System integration, 1110 Certification and delivery, 1112 In-service, 1114 Maintenance and overhaul, 1200 Aircraft, 1202 Airframe, 1204 Systems, 1206 Interior, 1208 Propulsion systems, 1210 Electrical systems, 1212 Hydraulic systems, 1214 Environmental systems
Claims
1. A method (700) of repairing a thermoplastic composite component (202, 302, 402, 502, 602), comprising: placing (702) a heating element (206, 306, 406, 506, 516, 608) impregnated (226) with a thermoplastic material (218, 312, 412, 512, 522, 614) over a repair area (204, 304, 405, 505, 514, 606) of a thermoplastic composite part (202, 302, 402, 502, 602); bonding (704) the thermoplastic material (218, 312, 412, 512, 522, 614) of the heating element (206, 306, 406, 506, 516, 608) to the repair area (204, 304, 405, 505, 514, 606) by generating heat within the heating element (206, 306, 406, 506, 516, 608) via an electric current (223) applied to the heating element; placing (706) a repair patch (208, 308, 408, 508, 518, 610) over the heating element (206, 306, 406, 506, 516, 608) after adhering the heating element (206, 306, 406, 506, 516, 608) to the repair area (204, 304, 405, 505, 514, 606); applying (708) an electric current (223) to the heating element (206, 306, 406, 506, 516, 608) to heat the repair patch (208, 308, 408, 508, 518, 610) to a patch treatment temperature (238, 242); A method (700).
2. applying (714) compression to the repair patch (208, 308, 408, 508, 518, 610) while heating the repair patch (208, 308, 408, 508, 518, 610) to the patch processing temperature (238, 242) to bond the repair patch (208, 308, 408, 508, 518, 610) to the thermoplastic composite component (202, 302, 402, 502, 602); The method (700) of claim 1, further comprising:
3. removing (710) a portion (230) of the thermoplastic composite component (202, 302, 402, 502, 602) to form the repair area (204, 304, 405, 505, 514, 606); The method (700) of claim 1, further comprising:
4. The method (700) of claim 1, wherein the repair patch (208, 308, 408, 508, 518, 610) comprises a thermoplastic repair patch (210).
5. The method (700) of claim 4, wherein the patch treatment temperature (238) is between 280°C and 340°C (718).
6. applying (720) a pressure (240) of 15 psi to 45 psi to the repair patch (208, 308, 408, 508, 518, 610) while heating the repair patch (208, 308, 408, 508, 518, 610) to bond the repair patch to the thermoplastic composite component (202, 302, 402, 502, 602); The method (700) of claim 5, further comprising:
7. removing (722) the pressure (240) from the repair patch (208, 308, 408, 508, 518, 610) after allowing the repair patch (208, 308, 408, 508, 518, 610) to cool to 150°C. The method (700) of claim 6, further comprising:
8. The method (700) of claim 1, wherein the repair patch (208, 308, 408, 508, 518, 610) comprises a thermosetting repair patch (212).
9. 10. The method (700) of claim 8, wherein the patch treatment temperature (242) is between 170°C and 190°C (728).
10. applying (730) a pressure (244) of 60 psi to 90 psi to the repair patch (208, 308, 408, 508, 518, 610) while heating the repair patch (208, 308, 408, 508, 518, 610) to bond the repair patch to the thermoplastic composite component (202, 302, 402, 502, 602); 10. The method (700) of claim 9, further comprising:
11. removing (732) the pressure (244) from the repair patch (208, 308, 408, 508, 518, 610) after allowing the repair patch (208, 308, 408, 508, 518, 610) to cool to ambient temperature. The method (700) of claim 10, further comprising:
12. trimming (724) the ends (246, 248) of the heating elements (206, 306, 406, 506, 516, 608) extending from the thermoplastic composite part (202, 302, 402, 502, 602); The method (700) of claim 1, further comprising:
13. preparing (712) a surface (228, 407, 507, 515, 605) of the repair area (204, 304, 405, 505, 514, 606) before applying the heating element (206, 306, 406, 506, 516, 608), the preparing comprising cleaning and polishing the repair area (204, 304, 405, 505, 514, 606); The method (700) of claim 1, further comprising:
14. A method (800) of repairing a thermoplastic composite component (202, 302, 402, 502, 602), comprising: placing (802) a heating element (206, 306, 406, 506, 516, 608) impregnated (226) with a thermoplastic material (218, 312, 412, 512, 522, 614) over a repair area (204, 304, 405, 505, 514, 606) of a thermoplastic composite part (202, 302, 402, 502, 602); bonding (804) the thermoplastic material (218, 312, 412, 512, 522, 614) of the heating element (206, 306, 406, 506, 516, 608) to the repair area (204, 304, 405, 505, 514, 606) by generating heat within the heating element (206, 306, 406, 506, 516, 608) via an electric current (223) applied to the heating element; placing (806) a thermoplastic repair patch (210) over the heating element (206, 306, 406, 506, 516, 608) after adhering the heating element (206, 306, 406, 506, 516, 608) to the repair area (204, 304, 405, 505, 514, 606); heating (808) the thermoplastic repair patch (210) to a patch processing temperature (238, 242) using the heating element (206, 306, 406, 506, 516, 608); applying pressure (240) to the thermoplastic repair patch (210) while heating the thermoplastic repair patch (210); A method (800) comprising:
15. The method (800) of claim 14, wherein the patch treatment temperature (238) is between 280°C and 340°C (814).
16. The method (800) of claim 14, wherein the pressure (240) is between 15 psi and 45 psi (816).
17. removing (818) the pressure (240) from the thermoplastic repair patch (210) after allowing the thermoplastic repair patch (210) to cool to 150°C; 17. The method (800) of claim 16, further comprising:
18. preparing (812) a surface (228, 407, 507, 515, 605) of the repair area (204, 304, 405, 505, 514, 606) before applying the heating element (206, 306, 406, 506, 516, 608), the preparing comprising cleaning and polishing the repair area (204, 304, 405, 505, 514, 606); 15. The method (800) of claim 14, further comprising:
19. 15. The method (800) of claim 14, further comprising trimming (820) an end (246, 248) of the heating element (206, 306, 406, 506, 516, 608) extending from the thermoplastic composite part (202, 302, 402, 502, 602).
20. A method (900) of repairing a thermoplastic composite component (202, 302, 402, 502, 602), comprising: placing (902) a heating element (206, 306, 406, 506, 516, 608) impregnated (226) with a thermoplastic material (218, 312, 412, 512, 522, 614) over the repair area (204, 304, 405, 505, 514, 606) of the thermoplastic composite part (202, 302, 402, 502, 602); bonding (904) the thermoplastic material (218, 312, 412, 512, 522, 614) of the heating element (206, 306, 406, 506, 516, 608) to the repair area (204, 304, 405, 505, 514, 606) by generating heat within the heating element (206, 306, 406, 506, 516, 608) via an electric current (223) applied to the heating element; placing (906) a thermosetting repair patch (212) over the heating element (206, 306, 406, 506, 516, 608) after adhering the heating element (206, 306, 406, 506, 516, 608) to the repair area (204, 304, 405, 505, 514, 606); heating (908) the thermosetting repair patch (212) to a patch processing temperature (238, 242) using the heating element (206, 306, 406, 506, 516, 608); applying pressure (244) to the thermosetting repair patch (212) while heating the thermosetting repair patch (212); A method (900).
21. 21. The method (900) of claim 20, wherein the patch treatment temperature (238, 242) is between 170°C and 190°C.
22. applying (916) a pressure (244) of 60 psi to 90 psi to the thermoset repair patch (212) while heating the thermoset repair patch (212) to bond the thermoset repair patch (212) to the thermoplastic composite component (202, 302, 402, 502, 602); 21. The method (900) of claim 20, further comprising:
23. removing (918) the pressure (244) from the thermosetting repair patch (212) after allowing the thermosetting repair patch (212) to cool to ambient temperature; 23. The method (900) of claim 22, further comprising:
24. preparing (912) a surface (228, 407, 507, 515, 605) of the repair area (204, 304, 405, 505, 514, 606) before applying the heating element (206, 306, 406, 506, 516, 608), the preparing comprising cleaning and polishing the repair area (204, 304, 405, 505, 514, 606); 21. The method (900) of claim 20, further comprising:
25. trimming (920) the ends (246, 248) of the heating elements (206, 306, 406, 506, 516, 608) extending from the thermoplastic composite part (202, 302, 402, 502, 602); 21. The method (900) of claim 20, further comprising:
26. A method (1000) of repairing a thermoplastic composite component (202, 302, 402, 502, 602), comprising: bonding (1002) a low melting point (220) thermoplastic material (218, 312, 412, 512, 522, 614) of a heating element (206, 306, 406, 506, 516, 608) to a repair area (204, 304, 405, 505, 514, 606) of a thermoplastic composite part (202, 302, 402, 502, 602); bonding (1004) said low melting point (220) thermoplastic material (218, 312, 412, 512, 522, 614) to the repair patch (208, 308, 408, 508, 518, 610); A method (1000) comprising:
27. applying compression (1012) to the repair patch (208, 308, 408, 508, 518, 610) while heating the repair patch (208, 308, 408, 508, 518, 610) to a patch processing temperature (238, 242) to bond the repair patch (208, 308, 408, 508, 518, 610) to the thermoplastic composite component (202, 302, 402, 502, 602); 27. The method (1000) of claim 26, further comprising:
28. removing (1006) a portion (230) of the thermoplastic composite component (202, 302, 402, 502, 602) to form the repair area (204, 304, 405, 505, 514, 606); 27. The method (1000) of claim 26, further comprising:
29. 27. The method (1000) of claim 26, wherein the repair patch (208, 308, 408, 508, 518, 610) comprises a thermoplastic repair patch (210).
30. 27. The method (1000) of claim 26, wherein the repair patch (208, 308, 408, 508, 518, 610) comprises (1016) a thermosetting repair patch (212).
31. trimming (1018) the ends (246, 248) of the heating elements (206, 306, 406, 506, 516, 608) extending from the thermoplastic composite part (202, 302, 402, 502, 602); 27. The method (1000) of claim 26, further comprising:
32. 27. The method (1000) of claim 26, wherein the step (1010) of adhering the low melting point (220) thermoplastic material (218, 312, 412, 512, 522, 614) to the repair area (204, 304, 405, 505, 514, 606) comprises heating the heating element (206, 306, 406, 506, 516, 608) by applying an electric current (223) to the heating element (206, 306, 406, 506, 516, 608).
33. 27. The method (1000) of claim 26, wherein adhering (1008) the low melting point (220) thermoplastic material (218, 312, 412, 512, 522, 614) to the repair patch (208, 308, 408, 508, 518, 610) comprises heating the heating element (206, 306, 406, 506, 516, 608) by applying an electric current (223) to the heating element (206, 306, 406, 506, 516, 608).