Polymer Matrix Composite Patch Wrapping for Flange Repair
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Solution Overview
Problem
Structural components in aerospace vehicles face stress fatigue damage due to adverse loadings, leading to costly and time-consuming repairs, and existing polymer matrix composite patches often separate or peel away, causing further failure.
Innovation Solution
A polymer matrix composite patch is formed around a structural component's flange-like member by wrapping partially cured layers with embedded fibers, applying an adhesive and a corrosion-resistant layer, and curing the patch in-situ using a heating blanket and vacuum bagging to enhance bonding and conformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a small pre-formed polymer matrix composite patch is positioned over the planar surface to provide additional strength, then the structural strength is improved, but the patch may separate or peel away from the surface over time
Solution Approach 1:
The patch is wrapped around the perimeter of the flange-like member in a three-dimensional configuration, transitioning from a two-dimensional planar patch to a three-dimensional wrapped structure. This dimensional change allows the patch to conform to the structural component's geometry and provides mechanical interlocking that prevents peeling and separation, thereby maintaining bonding reliability while preserving structural strength enhancement.
2Reliability
If the patch is wrapped around the perimeter of the flange-like member, then the bonding and peel strength are improved, but the manufacturing process becomes more complex
Solution Approach 1:
The polymer matrix composite is applied in a partially cured state before being wrapped around the flange-like member. This preliminary action allows the material to be more pliable and easier to conform to the structural geometry during the wrapping process, reducing manufacturing complexity. After wrapping, the patch is cured in its final position to achieve the desired bonding strength and structural integrity.
3Reliability
If the structural component is replaced when damaged, then the structural integrity is restored, but the aircraft is non-functional for an excessive amount of time
Solution Approach 1:
Instead of replacing the entire damaged structural component, the invention applies a polymer matrix composite patch to the damaged area. This selective repair approach discards only the damaged portion and recovers the functional capability of the entire structural component, significantly reducing aircraft downtime while restoring structural integrity through the wrapped patch configuration.
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 solution improves the patch's peel strength and bonding, reducing stress concentration and the likelihood of separation, thus providing a durable and effective repair that resists further damage.
Implementation Method 1
An adhesive is applied to a surface of a flange-like member of the structural component
Implementation Method 2
The layers are cured to form a patch
Implementation Method 3
vacuum bagging to enhance bonding and conformity
Data Source
AI summary
An assembly is provided including a structural component having a flange-like member. A partially cured polymer matrix composite patch is wrapped around a perimeter of the flange-like member. The patch includes a plurality of layers, each layer having a plurality of fibers arranged therein. The layers of the polymer matrix composite patch are cured after being wrapped around the flange-like member of the structural component.