Veil-Based Composite Repair Assembly
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Solution Overview
Problem
Existing methods for repairing composite structures, such as heating mats and autoclaves, face challenges in maintaining precise temperature control, which is crucial for optimizing the strength of the repair, and often expose the parent composite structure to excessive heat.
Innovation Solution
A repair assembly comprising a composite patch, an adhesive, and a heat-generating veil, where the veil is placed between the composite structure and the patch, allowing for precise heat application directly to the adhesive, reducing stress on the damaged area and maintaining temperatures within a tight window without exceeding the parent composite's service temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heating mats or autoclaves are used to cure adhesive, then the adhesive can be cured, but the parent composite structure is exposed to excessive heat
Solution Approach 1:
The patent applies heating elements directly within the adhesive layer at the repair site, creating localized heat generation only where needed for curing. This allows the adhesive to reach curing temperature while the parent composite structure remains below its service temperature limit, as the heat is confined to the immediate repair area rather than applied globally.
Solution Approach 2:
The adhesive layer itself serves as the intermediary medium that conducts heat from the heating elements to the surrounding materials. By placing heating elements within or in direct contact with the adhesive, the adhesive acts as the primary heat transfer path, ensuring efficient curing while limiting heat propagation to the parent composite structure.
2Temperature
If heating mats or autoclaves are used, then curing can be achieved, but temperature control precision is difficult to maintain
Solution Approach 1:
The patent incorporates temperature sensors that provide real-time feedback on the adhesive layer temperature. This feedback is used to dynamically adjust the power supplied to the heating elements, maintaining the temperature within the optimal curing window. The closed-loop control system responds to temperature variations and modifies heating intensity accordingly, ensuring precise temperature maintenance.
Solution Approach 2:
The heating system is divided into multiple independent heating zones or elements distributed within the adhesive layer. This segmentation allows for localized temperature control and adjustment, enabling precise management of different areas of the adhesive layer simultaneously. Each zone can be independently controlled to maintain uniform temperature distribution across the repair area.
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
This approach enables more precise control of heat application, optimizing the strength of the repair while preventing overheating of the parent composite structure, thereby ensuring a robust and reliable repair.
Implementation Method 1
The veil generates heat in response to electric power being applied to the veil
Data Source
AI summary
One example includes a repair assembly that is comprised of a composite patch, an adhesive, and a veil. The adhesive is disposed between a composite structure that includes an anomaly to be repaired and the composite patch and the composite patch. The veil is disposed between the composite structure and the composite patch. The veil generates heat in response to electric power being applied to the veil, with the adhesive being cured with the heat generated with the veil to repair the composite structure including the anomaly.