Thermoplastic repair patch and method of use thereof
The thermoplastic repair patch with integrated stacks and low-melting-point layers addresses the challenges of forming a flush aerodynamic surface in thermoplastic repairs by using low-temperature and low-pressure bonding, reducing complexity and time.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- THE BOEING CO
- Filing Date
- 2025-11-19
- Publication Date
- 2026-07-02
Smart Images
Figure 2026110512000001_ABST
Abstract
Description
Technical Field
[0006] ,
[0001] The present disclosure generally relates to thermoplastic materials, and more specifically to the repair of thermoplastic resins.
Background Art
[0002] In the repair of aerospace structures, the repair of large thermoplastic parts is very difficult. Existing thermoplastic resin repair processes involve secondary bonding or bolting different types of materials to the thermoplastic structure. As a result, it is prevented from making the aerodynamic surface and the repair location flush or nearly flush.
[0003] One of the repair processes involves secondarily bonding a thermosetting repair patch to the thermoplastic structure, and prior to bonding, surface treatment is performed over a wide area. This surface treatment may include polishing and plasma heating. Performing surface treatment over a wide area is very difficult and time-consuming. Also, it is very difficult to perform process control of the surface treatment on-site. The curing of the thermosetting repair patch requires a lot of time and skilled operation. The result of the repair depends on the surface treatment and the curing of the thermosetting patch.
[0004] Another existing solution involves bolting the repair area. However, using bolts for the repair of the outer surface usually cannot form an aerodynamic surface.
[0005] Therefore, there is a desire to provide a method and apparatus that take into account at least some of the above-described matters and other potential matters.
Summary of the Invention
[0006] Embodiments of the present disclosure provide a thermoplastic component with a thermoplastic repair patch. The thermoplastic component with a thermoplastic repair patch comprises a composite material including a notch forming a repair area, and the thermoplastic repair patch disposed in the notch. The composite material has a first melting temperature. The thermoplastic repair patch comprises a plurality of integrated thermoplastic stacks, each integrated thermoplastic stack comprising a thermoplastic composite ply disposed between a plurality of low-melting-point thermoplastic surface layers having a second melting temperature lower than the first melting temperature.
[0007] According to embodiments of the present disclosure, a method for repairing a thermoplastic component is provided. A low-melting-point thermoplastic film is placed in the repair area of the thermoplastic component. A plurality of integrated thermoplastic stacks are placed on the low-melting-point thermoplastic film, thereby forming a thermoplastic repair patch. The thermoplastic repair patch is heated to a processing temperature lower than the melting temperature of the thermoplastic component.
[0008] Another embodiment of the present disclosure provides a method for repairing a thermoplastic component. A low-melting-point thermoplastic film is placed in a repair area of the thermoplastic component. A first integrated thermoplastic stack is placed on the low-melting-point thermoplastic film. The first integrated thermoplastic stack is heated to a processing temperature lower than the melting temperature of the thermoplastic component. A second integrated thermoplastic stack is placed on the low-melting-point thermoplastic film. The second integrated thermoplastic stack is heated to the processing temperature, thereby forming a thermoplastic repair patch in the repair area.
[0009] These features and functions can be achieved individually or in combination with other embodiments of this disclosure. Further details will become apparent with reference to the following description and drawings. [Brief explanation of the drawing]
[0010] Novel features that are considered to characterize exemplary embodiments are defined in the appended claims. However, exemplary embodiments, as well as preferred uses, other purposes and features, will be best understood by reading the detailed description of exemplary embodiments of this disclosure, which is set forth below, with reference to the accompanying drawings.
[0011] [Figure 1] This figure shows an aircraft according to an exemplary embodiment. [Figure 2] This block diagram shows a manufacturing environment according to an exemplary embodiment. [Figure 3] This is a cross-sectional view of a thermoplastic repair patch placed on a thermoplastic component, according to an exemplary embodiment. [Figure 4] This is a cross-sectional view showing an integrated thermoplastic stack for a thermoplastic repair patch according to an exemplary embodiment. [Figure 5] This is a flowchart illustrating a method for repairing thermoplastic components according to an exemplary embodiment. [Figure 6] This is a flowchart illustrating a method for repairing thermoplastic components according to an exemplary embodiment. [Figure 7] This is a block diagram showing a method for manufacturing and maintaining an aircraft according to an exemplary embodiment. [Figure 8] This is a block diagram showing an aircraft capable of carrying out an exemplary embodiment. [Modes for carrying out the invention]
[0012] Referring to Figure 1, an aircraft according to an exemplary embodiment is shown. The aircraft 100 includes wings 102 and 104 attached to a fuselage 106. The aircraft 100 also includes an engine 108 attached to wing 102 and an engine 110 attached to wing 104.
[0013] The fuselage 106 has a tail section 112. A horizontal stabilizer 114, a horizontal stabilizer 116, and a vertical stabilizer 118 are attached to the tail section 112 of the fuselage 106.
[0014] Aircraft 100 is an example of an aircraft that may include thermoplastic components repaired using the thermoplastic repair patch of the exemplary embodiment. The thermoplastic repair patch can be used to repair thermoplastic components during maintenance of aircraft 100.
[0015] Referring to Figure 2, a block diagram of a manufacturing environment according to an exemplary embodiment is shown. The manufacturing environment 200 includes a thermoplastic part 202 with a thermoplastic repair patch 204. The thermoplastic part 202 is made of a composite material 206 and includes a cut-out 214 that forms a repair area 210. The composite material 206 has a first melting temperature, as a melting temperature 208. In some exemplary embodiments, the melting temperature 208 is higher than 340 degrees Celsius.
[0016] The thermoplastic repair patch 204 positioned in the notch 214 comprises a plurality of consolidated thermoplastic stacks 222. Each of the consolidated thermoplastic stacks 222 comprises a thermoplastic composite ply positioned between a plurality of low-melt thermoplastic surfaces having a second melting temperature lower than a first melting temperature.
[0017] The multiple integrated thermoplastic stacks 222 include any number of integrated thermoplastic stacks. In this exemplary embodiment, the multiple integrated thermoplastic stacks 222 include two integrated thermoplastic stacks. The multiple integrated thermoplastic stacks 222 include a first integrated thermoplastic stack 224 and a second integrated thermoplastic stack 226.
[0018] The first integrated thermoplastic stack 224 includes a thermoplastic composite ply 232 between a low melting point thermoplastic surface layer 238 and a low melting point thermoplastic surface layer 240, which are a plurality of low melting point thermoplastic surface layers having a second melting temperature lower than the first melting temperature. In this exemplary embodiment, the low melting point thermoplastic surface layer 238 and the low melting point thermoplastic surface layer 240 are formed of a low melting point thermoplastic material 241 having a melting temperature 230. The melting temperature 230 may also be referred to as the second melting temperature. In some exemplary embodiments, the melting temperature 230 is between 260 degrees Celsius and 335 degrees Celsius.
[0019] The second integrated thermoplastic stack 226 includes a thermoplastic composite ply 244 between a low melting point thermoplastic surface layer 250 and a low melting point thermoplastic surface layer 252, which are low melting point thermoplastic surface layers having a second melting temperature lower than the first melting temperature. In this exemplary embodiment, the low melting point thermoplastic surface layer 250 and the low melting point thermoplastic surface layer 252 are formed of a low melting point thermoplastic material 241 having a melting temperature 230.
[0020] The second integrated thermoplastic stack 226 is disposed over the first integrated thermoplastic stack 224, and thus, the first integrated thermoplastic stack 224 and the second integrated thermoplastic stack 226 are continuous in the thickness direction of the thermoplastic part 202. In this exemplary embodiment, the first integrated thermoplastic stack 224 is first disposed in the repair region 210.
[0021] In some exemplary embodiments, a low melting point thermoplastic film 228 is disposed in the repair region 210 and heated to a processing temperature 256, whereby the low melting point thermoplastic film 228 is bonded to the thermoplastic part 202.
[0022] In some exemplary embodiments, the repair region 210 is formed by removing an inconsistency 220 from the thermoplastic part 202. In some exemplary embodiments, the repair region 210 includes the surface 212 of the thermoplastic part 202 disposed in a notch 214 formed by removing the irregularity 220 from the thermoplastic part 202.
[0023] In some exemplary embodiments, the repair region 210 includes a portion 218 of the thermoplastic part 202 after removing the irregularity 220. In some exemplary embodiments, the repair region 210 is formed by cutting a series of composite material layers from the thermoplastic part 202.
[0024] The repair region 210 can be formed in any size and shape. In some exemplary embodiments, the repair region 210 is a scarfed shape 216 that is obliquely trimmed.
[0025] The thermoplastic composite plies constituting the thermoplastic repair patch 204 are already integrated. In some exemplary embodiments, the thermoplastic composite plies of the thermoplastic repair patch 204 are of the same material as the thermoplastic part 202. By heating the heating blanket 260, the thermoplastic repair patch 204 is heated to a processing temperature 256. The processing temperature 256 is selected to be lower than the melting temperature 208 of the thermoplastic part 202. The processing temperature 256 is selected such that the integration of the thermoplastic composite plies constituting the thermoplastic repair patch 204 is maintained. The processing temperature 256 is selected to melt the low melting point thermoplastic material 241. In some exemplary embodiments, the processing temperature 256 is about 280°C to 340°C.
[0026] In some exemplary embodiments, the heating blanket 260 has high shape conformability 262 and can conform to the shape of a thermoplastic repair patch 204 placed on a thermoplastic component 202. In some exemplary embodiments, the heating blanket 260 has high shape conformability 262 and can conform to the shape of a notch 214. In some exemplary embodiments, the heating blanket 260 has high shape conformability 262 and can conform to the shape of a first integrated thermoplastic stack 224 placed in the notch 214.
[0027] During the heating of the thermoplastic repair patch 204, a pressure 258 is applied to the thermoplastic repair patch 204, thereby bonding the thermoplastic repair patch 204. In some exemplary embodiments, while the thermoplastic repair patch 204 is heating, a pressure 258 of less than 15 psi is applied to the thermoplastic repair patch 204, thereby bonding the thermoplastic repair patch 204 to the thermoplastic component 202.
[0028] The low-melting-point thermoplastic film 228 is placed between the thermoplastic repair patch 204 and the repair area 210. The low-melting-point thermoplastic film 228 is composed of a low-melting-point thermoplastic material 241 having a melting temperature of 230.
[0029] Multiple integrated thermoplastic stacks 222 are joined by a low-melting-point thermoplastic surface layer. The first integrated thermoplastic stack 224 is joined to the thermoplastic component 202 by a low-melting-point thermoplastic film 228 and a low-melting-point thermoplastic surface layer 240. By heating the low-melting-point thermoplastic material 241 to a processing temperature 256 and applying a pressure 258, the low-melting-point thermoplastic surface layer 240 and the low-melting-point thermoplastic film 228 are joined.
[0030] The second integrated thermoplastic stack 226 is joined to the first integrated thermoplastic stack 224 by a low-melting-point thermoplastic surface layer 238 and a low-melting-point thermoplastic surface layer 252. The low-melting-point thermoplastic material 241 is heated to a processing temperature 256 and pressure 258 is applied to join the low-melting-point thermoplastic surface layer 238 and the low-melting-point thermoplastic surface layer 252.
[0031] The thermoplastic composite plies 232 of the first integrated thermoplastic stack 224 have a predetermined number of plies 234 and a ply orientation 236. The ply orientation 236 has any desired fiber angle. In some exemplary embodiments, the ply orientation 236 is selected from at least one of 0 degrees, 90 degrees, ±45 degrees, ±30 degrees, or ±60 degrees. In some exemplary embodiments, the ply orientation 236 is selected to approximate the orientation of the plies removed from the notch 214 of the thermoplastic component 202. The predetermined number of plies 234 can include any desired number of plies. In some exemplary embodiments, the predetermined number of plies 234 includes 2 to 6 plies.
[0032] The first integrated thermoplastic stack 224 has a given shape 242. The shape 242 is selected to fill a portion of the notch 214. If the notch 214 is a scarf-shaped portion 216, the shape 242 of the first integrated thermoplastic stack 224 is different from the shape 254 of the second integrated thermoplastic stack 226.
[0033] In some exemplary embodiments, the shape 242 of the first integrated thermoplastic stack 224 can be cut from an integrated sheet such as an integrated sheet 264. The integrated sheet 264 includes multiple thermoplastic composite plies between two low-melting-point thermoplastic surface layers. Repair integrated thermoplastic stacks can be formed by cutting out multiple different shapes from the integrated sheet 264. In some other exemplary embodiments, the shape 242 of the first integrated thermoplastic stack 224 can be laid up individually.
[0034] The thermoplastic composite plies 244 of the second integrated thermoplastic stack 226 have a predetermined number of plies 246 and a ply orientation 248. The ply orientation 248 has any desired fiber angle. In some exemplary embodiments, the ply orientation 248 is selected from at least one of 0 degrees, 90 degrees, ±45 degrees, ±30 degrees, or ±60 degrees. In some exemplary embodiments, the ply orientation 248 is selected to approximate the orientation of the plies removed from the notch 214 of the thermoplastic component 202. The predetermined number of plies 246 can include any desired number of plies. In some exemplary embodiments, the predetermined number of plies 246 includes 2 to 6 plies.
[0035] In some exemplary embodiments, the shape 254 of the second integrated thermoplastic stack 226 can be cut from an integrated sheet such as an integrated sheet 264. In some exemplary embodiments, the ply orientation 248 is the same orientation as the ply orientation 236, and a predetermined number of plies 246 is the same number as a predetermined number of plies 234. In these exemplary embodiments, the second integrated thermoplastic stack 226 and the first integrated thermoplastic stack 224 can be cut from the same integrated sheet 264. In other exemplary embodiments, the first integrated thermoplastic stack 224 and the second integrated thermoplastic stack 226 can be cut from two different integrated sheets. In some other exemplary embodiments, the shape 254 of the second integrated thermoplastic stack 226 can be laid up individually.
[0036] In some exemplary embodiments, the low-melting-point thermoplastic film 228 and multiple integrated thermoplastic stacks 222 are simultaneously bonded to the thermoplastic component 202. In some exemplary embodiments, the low-melting-point thermoplastic film 228 and multiple integrated thermoplastic stacks 222 are both placed in the notch 214 before being subjected to a processing temperature 256 and pressure 258. In some exemplary embodiments, the low-melting-point thermoplastic film 228 placed in the notch 214 is subjected to a processing temperature 256 and pressure 258 before being placed in the notch 214.
[0037] In some exemplary embodiments, a processing temperature 256 and pressure 258 are applied to the low-melting-point thermoplastic film 228 placed in the notch 214 before the first integrated thermoplastic stack 224 is placed in the notch 214. In some exemplary embodiments, a processing temperature 256 and pressure 258 are applied to the first integrated thermoplastic stack 224 placed in the notch 214 before the second integrated thermoplastic stack 226 is placed on top of the first integrated thermoplastic stack 224. In some exemplary embodiments, a processing temperature 256 and pressure 258 are repeatedly applied to the material placed in the repair area 210 until the entire area of the thermoplastic repair patch 204 is placed and processed.
[0038] The manufacturing environment 200 shown in Figure 2 does not impose any physical or structural limitations on the manner in which the exemplary embodiment can be carried out. Additional or alternative components may be used for the illustrated components. Some components may be unnecessary. Also, the illustrated blocks may represent some functional components. In carrying out the exemplary embodiment, these blocks may be combined, separated, or combined and then separated into different blocks.
[0039] For example, although the thermoplastic repair patch 204 is shown with only two integrated thermoplastic stacks, a thermoplastic repair patch may have more than two integrated thermoplastic stacks. While the low-melting-point thermoplastic surface layer and the low-melting-point thermoplastic film 228 are all composed of the low-melting-point thermoplastic material 241, in other embodiments not shown, the thermoplastic repair patch and the low-melting-point thermoplastic film may contain multiple types of thermoplastic materials. In addition, in some exemplary embodiments, at least one of a predetermined number of plies 246 or a predetermined number of plies 234 may be a single ply.
[0040] Next, referring to Figure 3, a cross-sectional view of a thermoplastic repair patch placed on a thermoplastic component according to an exemplary embodiment is shown. View 300 shows, for example, the process of repairing a thermoplastic component of aircraft 100 in Figure 1. View 300 also shows, for example, the process of repairing a thermoplastic component 202 using thermoplastic repair patch 204 in Figure 2.
[0041] In view 300, the thermoplastic repair patch 304 is positioned in a notch 305 of a repair area 303 in the thermoplastic component 302. A low-melting-point thermoplastic film 306 is positioned between the thermoplastic repair patch 304 and the repair area 303. The thermoplastic repair patch 304 positioned in the notch 305 includes a plurality of integrated thermoplastic stacks 308. Each integrated thermoplastic stack includes a thermoplastic composite ply positioned between a plurality of low-melting-point thermoplastic surface layers.
[0042] In this exemplary embodiment, the plurality of integrated thermoplastic stacks 308 include an integrated thermoplastic stack 310, an integrated thermoplastic stack 312, and an integrated thermoplastic stack 314. The integrated thermoplastic stack 310 includes a plurality of thermoplastic composite plies 322 disposed between a plurality of low-melting-point thermoplastic surface layers. The integrated thermoplastic stack 310 includes a low-melting-point thermoplastic surface layer in contact with a low-melting-point thermoplastic film 306. The integrated thermoplastic stack 310 includes a low-melting-point thermoplastic surface layer that constitutes part of the low-melting-point thermoplastic material 316.
[0043] The integrated thermoplastic stack 312 includes a thermoplastic composite ply 324 disposed between a plurality of low-melting-point thermoplastic surface layers. The integrated thermoplastic stack 312 includes a low-melting-point thermoplastic surface layer that constitutes part of the low-melting-point thermoplastic material 316. The integrated thermoplastic stack 312 includes a low-melting-point thermoplastic surface layer that constitutes part of the low-melting-point thermoplastic material 318.
[0044] The integrated thermoplastic stack 314 includes multiple thermoplastic composite plies 326 arranged between multiple low-melting-point thermoplastic surface layers. The integrated thermoplastic stack 314 includes a low-melting-point thermoplastic surface layer that constitutes part of the low-melting-point thermoplastic material 318. The integrated thermoplastic stack 314 includes a low-melting-point thermoplastic surface layer that constitutes part of the low-melting-point thermoplastic material 320.
[0045] In view 300, a processing temperature and pressure are applied to the thermoplastic repair patch 304. By applying the processing temperature, the low-melting-point thermoplastic surface layer melts, and multiple integrated thermoplastic stacks 308 are joined together. By applying the processing temperature, the low-melting-point thermoplastic surface layer melts, forming low-melting-point thermoplastic material 316, low-melting-point thermoplastic material 318, and low-melting-point thermoplastic material 320.
[0046] The thermoplastic repair patch 304 is heated to a processing temperature 2 by a heating blanket 330. A release film 328 is placed between the thermoplastic repair patch 304 and the heating blanket 330. In this exemplary embodiment, the area to be repaired 303 is sealed with a vacuum bag 332 for the repair process.
[0047] The arrangement of the thermoplastic repair patch 304 shown in Figure 3 does not impose any physical or structural limitations on the manner in which the exemplary embodiment can be implemented. Additional or alternative components may be used for the illustrated components. Some components may be omitted. For example, the thermoplastic repair patch 304 may contain any number of integrated thermoplastic stacks. Although three integrated thermoplastic stacks are shown in the illustration, the thermoplastic repair patch 304 may contain more or fewer than three integrated thermoplastic stacks. Also, although only one heating blanket is shown in Figure 3, in some exemplary embodiments, heating blankets may be placed on both outer surfaces of the repair area to form a desired thermal profile in the area to be melted and integrated with the film.
[0048] Referring to Figure 4, a cross-sectional view of an integrated thermoplastic stack for a thermoplastic repair patch according to an exemplary embodiment is shown. The integrated thermoplastic stack 400 can be used to repair thermoplastic components of aircraft 100 in Figure 1. The integrated thermoplastic stack 400 is a physical implementation of one of the integrated thermoplastic stacks 222 in Figure 2. The integrated thermoplastic stack 400 is, for example, part of the thermoplastic repair patch 304 in Figure 3.
[0049] The integrated thermoplastic stack 400 includes multiple thermoplastic composite plies 406 arranged between multiple low-melting-point thermoplastic surface layers. The thermoplastic composite plies 406 are located between a low-melting-point thermoplastic surface layer 402 and a low-melting-point thermoplastic surface layer 404. The low-melting-point thermoplastic surface layers 402 and 404 are formed from low-melting-point thermoplastic films having a melting temperature lower than that of the thermoplastic composite plies 406. The low-melting-point thermoplastic surface layers 402 and 404 can be used to bond the integrated thermoplastic stack 400 to other integrated thermoplastic stacks.
[0050] Referring next to Figure 5, a flowchart of a method for repairing thermoplastic components according to an exemplary embodiment is shown. Method 500 can be performed to repair thermoplastic components of aircraft 100 in Figure 1. Method 500 can be performed to repair thermoplastic component 202 using thermoplastic repair patch 204 in Figure 2. Method 500 can be used to repair thermoplastic component 302 using thermoplastic repair patch 304 in Figure 3. The integrated thermoplastic stack 400 shown in Figure 4 may be one of several integrated thermoplastic stacks in Method 500.
[0051] Method 500 involves placing a low-melting-point thermoplastic film on the repair area of the thermoplastic component (step 502). Method 500 then involves placing multiple integrated thermoplastic stacks on the low-melting-point thermoplastic film to form a thermoplastic repair patch (step 504). Method 500 then involves heating the thermoplastic repair patch to a processing temperature lower than the melting temperature of the thermoplastic component (step 506). After that, Method 500 is completed.
[0052] In some exemplary embodiments, Method 500 forms a repair area by removing a portion of the thermoplastic component (step 508). In some exemplary embodiments, the portion removed from the thermoplastic component includes an irregular portion. In some exemplary embodiments, removing the irregular portion from the thermoplastic component includes forming a scarf-shaped cutout by removing material.
[0053] In some exemplary embodiments, Method 500 includes treating the surface of a repair area of a thermoplastic component before placing a low-melting-point thermoplastic film on the repair area, the treatment including cleaning and polishing the repair area (Step 510). In some exemplary embodiments, treating the surface of a thermoplastic component significantly reduces the time required, energy consumption, or complexity compared to treating the thermoplastic surface to bond a thermosetting repair patch.
[0054] In several exemplary embodiments, each of a plurality of integrated thermoplastic stacks includes a thermoplastic composite ply positioned between a plurality of low-melting-point thermoplastic surface layers, and heating the thermoplastic repair patch to a processing temperature includes melting the low-melting-point thermoplastic surface layers (step 512). In these exemplary embodiments, the low-melting-point thermoplastic surface layers are joined together by melting them.
[0055] In some exemplary embodiments, the processing temperature is approximately 280°C to 340°C (step 514). In some exemplary embodiments, the processing temperature is less than 345°C (step 516). The processing temperature is selected so that the integration of thermoplastic components is maintained, but the low-melting-point thermoplastic material melts. The processing temperature is selected so that the integration of the integrated thermoplastic composite ply is maintained.
[0056] In some exemplary embodiments, Method 500 bonds a thermoplastic repair patch to a thermoplastic component by applying a pressure of less than 15 psi to the thermoplastic repair patch while heating the thermoplastic repair patch (Step 518). In some exemplary embodiments, Method 500 bonds a thermoplastic repair patch to a thermoplastic component by compressing the thermoplastic repair patch while heating the thermoplastic repair patch to a processing temperature (Step 520).
[0057] In some exemplary embodiments, Method 500 heats the low-melting-point thermoplastic film to a processing temperature before placing the multiple integrated thermoplastic stacks on the low-melting-point thermoplastic film (step 522). In some exemplary embodiments, the low-melting-point thermoplastic film and the multiple integrated thermoplastic stacks are placed in the repair area before heating the low-melting-point thermoplastic film to a processing temperature.
[0058] Referring to Figure 6, a flowchart of a method for repairing thermoplastic components according to an exemplary embodiment is shown. Method 600 can be performed to repair thermoplastic components of aircraft 100 in Figure 1. Method 600 can be performed to repair thermoplastic component 202 using thermoplastic repair patch 204 in Figure 2. Method 600 can be used to repair thermoplastic component 302 using thermoplastic repair patch 304 in Figure 3. The integrated thermoplastic stack 400 shown in Figure 4 may be one of several integrated thermoplastic stacks in Method 600.
[0059] Method 600 involves placing a low-melting-point thermoplastic film on the repair area of the thermoplastic component (step 602). Method 600 then places a first integrated thermoplastic stack on top of the low-melting-point thermoplastic film (step 604). Method 600 heats the first integrated thermoplastic stack to a processing temperature lower than the melting temperature of the thermoplastic component (step 606). Method 600 then places a second integrated thermoplastic stack on top of the low-melting-point thermoplastic film (step 608). Method 600 heats the second integrated thermoplastic stack to the processing temperature to form a thermoplastic repair patch on the repair area (step 610). Method 600 then terminates.
[0060] In some exemplary embodiments, Method 600 further includes forming a repair area by removing a portion of the thermoplastic component (Step 612). In some exemplary embodiments, Method 600 further includes treating the surface of the repair area of the thermoplastic component before placing a low-melting-point thermoplastic film on the repair area, the treatment including cleaning and polishing the repair area (Step 614).
[0061] In some exemplary embodiments, Method 600 further includes heating the low-melting-point thermoplastic film to a processing temperature before placing the first integrated thermoplastic stack on the low-melting-point thermoplastic film (Step 616). The processing temperature is selected so that the integration of the thermoplastic components is maintained, but the low-melting-point thermoplastic material melts.
[0062] In some exemplary embodiments, the first integrated thermoplastic stack includes thermoplastic composite plies positioned between a plurality of low-melting-point thermoplastic surface layers, and heating the first integrated thermoplastic stack to a processing temperature includes melting the low-melting-point thermoplastic surface layers (step 618). The processing temperature is selected so as to maintain the integration of the integrated thermoplastic composite plies.
[0063] In some exemplary embodiments, the processing temperature is approximately 280° to 340°C (step 620). In some exemplary embodiments, method 600 further includes bonding the first integrated thermoplastic stack to a thermoplastic component by applying a pressure of less than 15 psi to the first integrated thermoplastic stack while heating the first integrated thermoplastic stack (step 622). In some exemplary embodiments, method 600 further includes bonding the first integrated thermoplastic stack to a thermoplastic component by compressing the first integrated thermoplastic stack while heating the first integrated thermoplastic stack to the processing temperature (step 624).
[0064] In this specification, when the expression "at least one" is used in reference to the enumeration of elements, it means that one or more of the enumerated elements may be used in various combinations, and that only one of the enumerated elements may be required. For example, "at least one of elements A, B, and C" includes, but is not limited to, element A, element A and element B, or element B. This example also includes elements A, element B, and element C, or element B and element C. Naturally, all combinations of these elements are included. As another example, "at least one" includes, but is not limited to, two elements A, one element B, ten elements C, four elements B and seven elements C, or other appropriate combinations. Here, an element is, for example, a particular object, thing, or category. In other words, "at least one" means that any number of the enumerated elements can be used in any combination, and it is not a requirement to use all of the enumerated elements.
[0065] In this specification, when the expression "a predetermined number" is used in reference to an element, it means one or more elements.
[0066] The illustrated flowcharts and block diagrams of various embodiments illustrate the architecture, functions, and processes of several embodiments of the apparatus and methods in the exemplary embodiments. In this regard, each block in the flowcharts and block diagrams may represent at least one of a module, segment, function, or part of a process or step.
[0067] In addition, in some alternative embodiments of the exemplary embodiments, the functions shown in the blocks may be executed in a different order than shown. For example, two consecutive blocks shown in the illustration may be executed substantially simultaneously, or in some cases in reverse order, depending on the related functions. Also, other blocks may be added to the blocks shown in the flowchart or block diagram. Some blocks may be optional. For example, steps 508 to 522 may be optional. In another example, steps 612 to 624 may be optional.
[0068] Exemplary embodiments of this disclosure can be described in correspondence with the aircraft manufacturing and maintenance method 700 shown in Figure 7 and the aircraft 800 shown in Figure 8. First, referring to Figure 7, a block diagram is shown illustrating an aircraft manufacturing and maintenance method according to an exemplary embodiment. Before production begins, the aircraft manufacturing and maintenance method 700 includes the specification and design 702 of the aircraft 800 shown in Figure 8 and the procurement of materials 704.
[0069] During manufacturing, the production of parts and subassemblies of aircraft 800 706 and system integration 708 will take place. Subsequently, aircraft 800 will undergo certification and delivery 710 and enter service 712. During service 712, aircraft 800 will be incorporated into periodic maintenance and upkeep 714. Periodic maintenance and upkeep will include improvements, reconfigurations, modifications, or other maintenance and upkeep.
[0070] Each step of the Aircraft Manufacturing and Maintenance Method 700 may be performed or carried out by a system integrator, a third party, and / or an operator. In these examples, the operator is, for example, a customer. System integrators include, but are not limited to, any number of aircraft manufacturers and major system subcontractors. Third parties include, but are not limited to, any number of sellers, subcontractors, and suppliers. Operators include, for example, airlines, leasing companies, military organizations, service organizations, etc.
[0071] Next, referring to Figure 8, a block diagram is shown illustrating an aircraft capable of carrying out an exemplary embodiment. In this example, the aircraft 800 produced by the aircraft manufacturing and maintenance method 700 shown in Figure 7 includes a fuselage 802 with a plurality of systems 804 and interior 806. Examples of systems 804 include one or more of the propulsion system 808, electrical system 810, hydraulic system 812, and environmental system 814. It may also include any number of other systems.
[0072] The apparatus and methods embodied herein can be used in at least one stage of an aircraft manufacturing and maintenance method 700. One or more exemplary embodiments may be manufactured or used in at least one of the following: manufacturing of parts and subassemblies 706, system integration 708, service life 712, or maintenance and servicing 714, as shown in Figure 7.
[0073] According to exemplary embodiments, a thermoplastic repair patch comprising a low-melting-point thermoplastic film is provided. The use of a low-melting-point thermoplastic film allows for the simultaneous melting of the thermoplastic resin into the structure to be repaired. According to exemplary embodiments, the patch can be bonded to the material by low-temperature and low-pressure processing. According to exemplary embodiments, the equipment, machinery, and amount of heating required can be reduced compared to repairs using higher-temperature thermoplastic materials.
[0074] According to exemplary embodiments, the robustness of the repair structure and repair process can be increased compared to thermosetting repair materials. According to exemplary embodiments, the complexity of the required surface treatment can be reduced compared to when thermosetting patches are used to repair thermoplastic parts. The treatment and bonding of thermoplastic resins are less affected by surface treatment and other boundary conditions compared to the treatment of repair methods using thermosetting resins.
[0075] According to the exemplary embodiment, the time required to repair thermoplastic parts can be reduced compared to the case where thermosetting patches are used. The time required for processing the thermoplastic resin is only a fraction of the time required for processing the thermosetting resin.
[0076] The selection of low-melting-point thermoplastic film formulations is compatible with the base structural thermoplastic material. According to the exemplary examples, the low-melting-point thermoplastic film can melt and structurally and chemically bond with the base structural material at lower temperatures and pressures than during processing. According to the exemplary examples, the structural material does not soften or collapse during the repair process.
[0077] In exemplary embodiments, the base thermoplastic material is melted / integrated at high temperatures. In some exemplary embodiments, the high-temperature melting / integration of the base thermoplastic material occurs at temperatures above 380 degrees Celsius. According to exemplary embodiments, a thermoplastic film is provided that melts at a melting temperature of 260 degrees Celsius to 335 degrees Celsius and bonds to a high-temperature thermoplastic material.
[0078] According to exemplary embodiments, a method is provided which involves performing a heating / pressure process to form a co-cured / co-melted structure between a substrate thermoplastic material and a low-melting-point thermoplastic material. In some exemplary embodiments, such heating / pressure process includes applying a temperature of less than 345 degrees Celsius. In some exemplary embodiments, such heating / pressure process includes applying a pressure of less than 15 psi.
[0079] In exemplary embodiments, an external heat source is used. In some exemplary embodiments, the external heat source is a heating blanket that conforms to the surface of the structure to be repaired, and the surface may include a scarf-shaped cross-section.
[0080] The first low-melting-point thermoplastic film layer is bonded to the underlying thermoplastic material / substrate. The scarf-shaped voids can be filled with the thermoplastic material. The filler material consists of custom-made plies prepared in advance for this purpose. Each repair filler ply is a sandwich structure with the thermoplastic material substrate sandwiched between two low-melting-point films. The thermoplastic material forming the central part of the sandwich structure can consist of a single unidirectional ply or 2 to 6 multidirectional plies. An example of a thermoplastic composite ply is three thermoplastic layers with orientations of 45° / 0° / -45°. The thermoplastic composite ply can contain any desired number of plies. Fewer plies result in better room-temperature conformity to the scarf shape of the area to be filled.
[0081] In some exemplary embodiments, the filler material is fabricated as a large sheet, and plies to fill scarf-shaped voids are cut from the sheet to match the shape. Once the cut-out integrated thermoplastic stacks are placed in the voids, pressure is applied by a vacuum bag. A heating blanket is then placed over them, and the patches are processed according to the integration temperature profile of the low-melting-point thermoplastic film.
[0082] In some exemplary embodiments, patches may be heated and added sequentially based on the heat transfer characteristics of the environment to which they are applied. In some exemplary embodiments, if the thermoplastic repair patch is too thick and the heat from the external heating blanket is not transferred to the entire repair area and does not reach the melting temperature, the integrated thermoplastic stacks can be placed and heated one by one or in sets of several stacks. In some exemplary embodiments, a set of integrated thermoplastic stacks can be placed by placing and heating a small amount of filler material and repeating this lamination process until the repair is complete. After the completion of this thermal cycle, the repair area may be inspected.
[0083] The various exemplary embodiments described above are presented for illustrative and explanatory purposes only and are not intended to be exhaustive or limit the disclosed embodiments. Many variations and modifications will be apparent to those skilled in the art. Different exemplary embodiments may offer different features from other exemplary embodiments. The selected one or more embodiments have been chosen and described to best illustrate the principles and practical applications of the embodiments and to make the disclosure of various embodiments with various modifications to suit the specific intended use understandable to those skilled in the art.
Claims
1. Thermoplastic parts with thermoplastic repair patches, A composite material having a first melting temperature and including a notch that forms a repair area, A thermoplastic component comprising: a thermoplastic repair patch disposed in the notch, wherein the thermoplastic repair patch comprises a plurality of integrated thermoplastic stacks, each integrated thermoplastic stack comprising a thermoplastic composite ply disposed between a plurality of low-melting-point thermoplastic surface layers having a second melting temperature lower than the first melting temperature.
2. The thermoplastic component according to claim 1, further comprising a low-melting-point thermoplastic film disposed between the thermoplastic repair patch and the repair area.
3. The thermoplastic component according to claim 1, wherein the first melting temperature is higher than 340 degrees Celsius.
4. The thermoplastic component according to claim 1, wherein the second melting temperature is between 260 degrees Celsius and 335 degrees Celsius.
5. The thermoplastic component according to any one of claims 1 to 4, wherein the plurality of integrated thermoplastic stacks are joined together by the plurality of low-melting-point thermoplastic surface layers.
6. A method for repairing thermoplastic parts, Placing a low-melting-point thermoplastic film in the repair area of a thermoplastic component, A thermoplastic repair patch is formed by arranging multiple integrated thermoplastic stacks on the low-melting-point thermoplastic film, A method comprising heating the thermoplastic repair patch to a processing temperature lower than the melting temperature of the thermoplastic component.
7. The method according to claim 6, wherein each integrated thermoplastic stack in the plurality of integrated thermoplastic stacks includes a thermoplastic composite ply disposed between a plurality of low-melting-point thermoplastic surface layers, and heating the thermoplastic repair patch to the processing temperature includes melting the plurality of low-melting-point thermoplastic surface layers.
8. The method according to claim 6, wherein the processing temperature is 280 degrees Celsius to 340 degrees Celsius.
9. The method according to claim 6, further comprising applying a pressure of less than 15 psi to the thermoplastic repair patch while heating the thermoplastic repair patch, thereby bonding the thermoplastic repair patch to the thermoplastic component.
10. The method according to claim 6, further comprising compressing the thermoplastic repair patch while heating the thermoplastic repair patch to the processing temperature, thereby joining the thermoplastic repair patch to the thermoplastic component.
11. The method according to claim 6, further comprising heating the low-melting-point thermoplastic film to the processing temperature before arranging the plurality of integrated thermoplastic stacks on the low-melting-point thermoplastic film.
12. The method according to any one of claims 6 to 11, further comprising removing a portion of the thermoplastic component to form the repair area.
13. The method according to claim 12, further comprising treating the surface of the repair area of the thermoplastic component before placing the low-melting-point thermoplastic film in the repair area, wherein the treatment includes cleaning and polishing the repair area.
14. A method for repairing thermoplastic parts, Placing a low-melting-point thermoplastic film in the repair area of a thermoplastic component, The first integrated thermoplastic stack is placed on the low-melting-point thermoplastic film, The first integrated thermoplastic stack is heated to a processing temperature lower than the melting temperature of the thermoplastic component, The second integrated thermoplastic stack is placed on the low-melting-point thermoplastic film, A method comprising heating the second integrated thermoplastic stack to the processing temperature, thereby forming a thermoplastic repair patch in the repair area.
15. The method according to claim 14, wherein the first integrated thermoplastic stack includes thermoplastic composite plies disposed between a plurality of low-melting-point thermoplastic surface layers, and heating the first integrated thermoplastic stack to the processing temperature includes melting the plurality of low-melting-point thermoplastic surface layers.
16. The method according to claim 14, wherein the processing temperature is 280 degrees Celsius to 340 degrees Celsius.
17. The method according to claim 14, further comprising applying a pressure of less than 15 psi to the first integrated thermoplastic stack while heating the first integrated thermoplastic stack, thereby joining the first integrated thermoplastic stack to the thermoplastic component.
18. The method according to claim 14, further comprising compressing the first integrated thermoplastic stack while heating the first integrated thermoplastic stack to the processing temperature, thereby joining the first integrated thermoplastic stack to the thermoplastic component.
19. The method according to claim 14, further comprising heating the low-melting-point thermoplastic film to the processing temperature before placing the first integrated thermoplastic stack on the low-melting-point thermoplastic film.
20. The method according to any one of claims 14 to 19, further comprising removing a portion of the thermoplastic component to form the repair area.
21. The method according to claim 20, further comprising treating the surface of the repair area before placing the low-melting-point thermoplastic film on the repair area of the thermoplastic component, wherein the treatment includes cleaning and polishing the repair area.