Composite Repair Patch for Rapid Structural Reinforcement
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Solution Overview
Problem
Conventional methods for repairing composite structures, such as solid laminates and sandwich panels, are time-consuming and require specialized equipment, making it difficult to rapidly restore design strength in challenging environments.
Innovation Solution
A structural reinforcement system comprising a patch with embedded fibers in a matrix material, adhesively bonded to the composite structure, and covered by a pressure-sensitive tape, which is applied over abnormalities to restore and exceed the structural strength of the composite.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional repair methods are used for composite structures, then the repair can restore structural strength, but the repair process is time-consuming and requires specialized equipment
Solution Approach 1:
The patch is pre-saturated with adhesive and pre-cured to form a rigid structural component before application. This preliminary preparation eliminates the need for time-consuming adhesive application and curing processes during the actual repair operation, enabling rapid restoration of structural strength without specialized equipment
Solution Approach 2:
The repair system is divided into distinct functional components: a pre-cured patch providing structural reinforcement, pre-applied adhesive layers for bonding, and a protective tape for containment. This segmentation allows each component to be optimized independently and facilitates rapid assembly during repair without requiring complex equipment
2Strength
If conventional repair methods are used for composite structures, then the repair can restore structural strength, but specialized equipment is required
Solution Approach 1:
The adhesive is pre-applied to the patch and the protective tape is pre-positioned during manufacturing, transforming a multi-step process requiring specialized equipment into a simple wrap-and-press operation that can be performed with basic tools in field conditions
Solution Approach 2:
The pre-cured patch design allows the repair to be self-contained, with the adhesive already in place and the protective tape providing both containment and bonding assistance. This eliminates the need for external adhesive dispensing equipment, heating devices, or complex bonding machinery
3Strength
If a patch with multiple plies and adhesive is used, then the repair strength can exceed design tolerance, but the manufacturing process becomes more complex
Solution Approach 1:
Multiple plies are laminated together during manufacturing to form a single integrated patch structure with adhesive already bonded between layers. This merging of multiple components into one pre-assembled unit simplifies the field repair process while maintaining the cumulative strength of multiple plies
Solution Approach 2:
The adhesive bonding between multiple plies is performed in advance during patch manufacturing, allowing the complex multi-ply construction to be completed under controlled factory conditions. This preliminary bonding eliminates the need for complex adhesive application procedures during field repair
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system efficiently and customizably increases the structural strength of composite structures by providing a repair strength equal to or exceeding the design tolerance, facilitating quick repairs even in challenging conditions.
Implementation Method 1
a pressure-sensitive tape comprising a metallic material and a tape adhesive, fixed to the metallic material, wherein the pressure-sensitive tape is fixed to and covers an entirety of the second side of the patch
Data Source
AI summary
Disclosed herein are a repair apparatus, system, and method for structurally reinforcing an abnormal composite structural member. The repair is suited for reinforcing a cured composite structure that defines a strength tolerance and has an abnormality that reduces the structural strength relative to the strength tolerance of the cured composite. The structural reinforcement repairs the abnormality in the cured composite and provides the repair strength so that the repaired composite has a structural strength that meets or exceeds the strength tolerance. The structural reinforcement has a composite patch that is coupled to the cured composite over the abnormality and is covered by pressure-sensitive tape.