Heat Shrink Laminated Composite Patch for Curved Surface Repair
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for repairing composite structures, particularly those with curved surfaces, face challenges in applying uniform and constant pressure during curing, making field repairs complicated and impractical with traditional manual or equipment-based methods.
Innovation Solution
A heat shrink laminated composite material comprising a fabric reinforcement sandwiched between adhesive layers, with a heat-activated shrink film providing uniform pressure as the adhesive cures, allowing for easy application and shaping in the field to repair curved surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual pressure application is used during adhesive curing, then the repair can be performed in the field, but uniform and constant pressure cannot be applied
Solution Approach 1:
The patent uses a flexible bag or membrane structure that can be conformally applied to curved surfaces. When pressure is applied to this flexible enclosure, it distributes uniformly across the adhesive surface, solving both the field repair requirement and the pressure uniformity requirement simultaneously
Solution Approach 2:
The flexible bag acts as an intermediary between the pressure source and the adhesive surface. It transforms concentrated pressure into distributed pressure while maintaining field repairability, mediating between the operator and the curing adhesive
2Manufacturing precision
If vacuum or autoclave equipment is used to apply constant pressure, then uniform pressure is achieved, but the repair process becomes complicated and impractical for field use
Solution Approach 1:
The patent extracts the essential function of pressure application from complex vacuum/autoclave systems and implements it through a simple flexible bag structure. This removes the unnecessary complexity while retaining the pressure uniformity benefit
Solution Approach 2:
The flexible bag provides a simple, lightweight structure that can be easily deployed in the field without requiring complex equipment infrastructure, yet still delivers constant uniform pressure during curing
3Ease of manufacture
If traditional repair materials are applied to curved surfaces, then the damage can be filled, but uniform pressure application during curing becomes difficult
Solution Approach 1:
The flexible bag can be conformally wrapped around curved surfaces, allowing the repair material to be applied to complex geometries while ensuring uniform pressure distribution during curing, thus maintaining both applicability and bond quality
Solution Approach 2:
The patent specifically addresses curved surface repair by using a flexible enclosure that can adapt to spherical or curved geometries, ensuring that pressure is applied uniformly across the curved adhesive surface during curing
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
Enables efficient, portable, and aesthetically pleasing repairs of composite structures with minimal equipment, suitable for various shapes and sizes, including curved surfaces, with short application and cure times, and customizable properties.
Implementation Method 1
a heat-activated shrink film providing uniform pressure as the adhesive cures
Data Source
AI summary
A sheet of heat shrink laminated composite for use creating repair patches for repairing or building up a surface formed of a composite material such as fiberglass-reinforced plastic. The sheet includes first and second layers of a heat-curable adhesive. The sheet includes a reinforcement layer sandwiched between the first and second layers of the adhesive. The sheet further includes a pressure application layer, which is formed of a heat-activated shrink wrap film, abutting an outer surface of the first layer of the adhesive. The reinforcement layer may include a sheet of a porous fabric or cloth, which may be fibers of carbon or glass such as unidirectional e-glass fibers. The adhesive is cured when heated to a temperature in a curing temperature range, and the shrink wrap film is activated when heated to a temperature in an activation temperature range that overlaps the curing temperature range of the adhesive.