巴西专利BR112012013817A2 Replacement patch for composite repair process

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专利摘要:
SUBSTITUTE PATCH FOR PROCESS OFCOMPOSITE REPAIR. The present invention relates to an assembly ofreplacement patch for a rework area of a structure thatcomprises a replacement patch body which may be formed from amaterial to extract moisture from the rework area. the assembly patch may include a sensor mounted to the patch bodysubstitute. The sensor may comprise a thermal sensor to detect thetemperature of the rework area and on the replacement patch body. THEsensor may comprise a drive sensor to detect the driveextracted over the replacement patch body.
公开号:BR112012013817A2
申请号:R112012013817-0
申请日:2010-11-05
公开日:2021-08-31
发明作者:Michael W. Evens；Megan N. Watson；Mary H. Vargas
申请人:The Boeing Company；
IPC主号:

专利说明:

,, L d 1/36 Descriptive Report of the Patent of Invention for "SUBSTITUTE PATCH FOR COMPOSITE REPAIR PROCESS".
FIELD The present description relates generally to structural repair and, more particularly, to operations performed in preparation for repair of composite structures. . BACKGROUND Composite materials are used in increasing amounts f
W , in a wide variety of applications. For example, commercial aircraft 10 are incorporating increasing amounts of composite materials into "primary and secondary structure due to the favorable mechanical properties" of composite materials. Such favorable properties can be translated. . in a reduction in weight and an increase in payload capacity and fuel efficiency. In addition, composite materials can provide. q - 15 an extended aircraft life, compared to aircraft made of metallic construction. R , ,3 Rework is occasionally required on composite structures.
tas in order to remove an inconsistency. An inconsistency may comprise a breakage, delamination, void, depression, porosity or other inconsistencies in the composite structure. An inconsistency may require rework when the inconsistency is outside of desired tolerances. Removal of the inconsistency may require reshaping an area in the composite structure containing the inconsistency by removing a portion of the composite structure containing the inconsistency and replacing the removed material with a patch. The patch may be formed as a pile of pleats of composite material of the same or different type from which the composite structure is formed. The stacking and fiber orientation sequence of the composite pleats in the patch may correspond to the stacking and fiber orientation sequence of the pleats 30 that make up the composite structure. After assembling the pleat stack patch, the patch is typically attached to the rework area with the adhesive installed on the line of
. S' Q 2/36 connection between the patch and the rework area. Heat and pressure are typically applied to the adhesive, such as with a heating blanket and vacuum bag. The heating mantle can be used to raise the bond line to the proper adhesive cure temperature. Vacuum bag 5 can be used to consolidate the patch. During curing, the bond line can be retained within a relatively low temperature range. narrow, for a predetermined period of time in order to completely cure the adhesive. Furthermore, the entire area of the connecting line can be . -, retained within the temperature range without substantial variation across the bonding line. . " Before attaching the patch to the rework area, a survey
Thermal may be required for the rework area. The thermal search - P^' &
W - may be required to identify non-uniform heating sites j of the rework area by the heating blanket. Non-uniform heating may be caused by the adjacent structure which may act as a heat sink drawing heat away from localized portions of the rework area resulting in differential heating of the + % line is link. In this regard, thermal research can provide a means for identifying hot and cold spots in the rework area so that adjustments can be made by adding temporary insulation to the composite structure and/or adjusting the heating of the heating blanket. until the temperature is in the required range. A conventional thermal research process may require the assembly of a replacement patch which is a duplicate of the patch which must be permanently bonded to the composite structure. In this regard, the conventional replacement patch is formed from the same type of composite material and with the same number of pleats as the final patch. The construction of a conventional replacement adhesive is a time-consuming and labor-intensive process typically requiring manual cutting of multiple plies of the 30 composites each having a unique size and shape for each plies in the rework area to be replaced. After thermal research, the conventional replacement patch is typically discarded after a single
) use. In addition to the thermal survey, a moisture removal process may be required to remove unwanted moisture from the rework area to improve the final connection between the patch and the rework area, reducing the risk of porosity within the line. binding. A conventional moisture removal process comprises a cycle of . drying and may be required on the composite structure that is in service for a certain period of time and/or when certain adhesives are
V , used in the repair process. 10 Unfortunately, the conventional drying cycle typically requires more than 24 hours to complete, which can exceed the amount of time
M ^ . that may be available for the rework operations carried out in the «. - field as in in-service aircraft. Furthermore, the conventional practice of performing the thermal survey and the drying cycle as two separate processes results in the application of two heating cycles on F· the composite structure which can affect the service life. more, conventional thermal » - + m " research requires the labor intensive and time consuming process of manufacturing the conventional replacement patch after which the replacement patch is discarded after a single use. In this regard, the materials for forming the composite replacement patch can be relatively expensive, depending on the amount and type of material used. As can be seen, there is a need in the art for a system and method for performing a thermal survey that obviates the need to fabricate a duplicate of the final patch. Furthermore, there is a need in the art for a system and method for effecting a moisture removal process in a rework area on the composite structure that avoids applying an additional heat cycle to the composite structure.
SUMMARY 30 The aforementioned needs associated with thermal research and moisture removal from composite structure rework areas are addressed by providing a replacement patch assembly that obviates the need for a duplicate of the final patch. Replacement patch assembly can facilitate frame rework by including a replacement patch body formed of a material to extract moisture from the rework area. The replacement patch body may include at least one sensor mounted on the replacement patch body. The sensor can be configured as a thermal sensor to detect a . temperature at least that of the rework area and/or the replacement patch body. The sensor can also be configured as a humidity sensor. "Ability to detect moisture that has been extracted from the rework area by the substitute patch body material. ¶" In an additional embodiment, an assembly of
W - . replacement patch for a rework area of a composite structure ^. . wherein the replacement patch assembly comprises a replacement patch body having top and bottom surfaces and defining a substantially uniform thickness. The replacement patch body can be J formed from felt to draw moisture from the rework area. » " felt can have a thermal conductivity of approx.
Yà m
P 0.01-1.0 W/mk and a specific heat capacity of approximately 600 to 1100 J/(kgk). The replacement patch assembly may include a plurality of thermal sensors mounted on the replacement patch body to detect a temperature of the rework area and the replacement patch body. At least one of the thermal sensors can be built into the replacement patch body between the top and bottom surfaces. A plurality of moisture sensors can be mounted on the replacement patch body 25 on the top surface to detect moisture absorbed from the rework area. Also disclosed is a replacement patch system for repairing a structure with a patch that can be received within a rework area. The replacement patch system may comprise a replacement patch body formed of non-composite material having thermal properties which may be substantially similar to the thermal properties of the patch. Thermal properties may comprise specific heat capacity and/or thermal conductivity. The replacement patch system may include at least one thermal sensor mounted on the replacement patch body to detect a temperature thereof. The replacement patch system may include at least one moisture sensor to detect moisture extracted from the rework area. In addition, the replacement patch system may include at least one thermal sensor. mounted in the rework area to detect a temperature of the same. Furthermore, a method of repairing a composite ip W structure having upper and lower surfaces is disclosed. The method may comprise the steps of forming a substitute patch body of extra-material material. " Moisture tion of a composite structure rework area. The method- ". may comprise mounting at least one sensor in the replacement patch body and mounting at least one thermal sensor in the rework area. The replacement patch body may be installed in the rework area. The method may include performing at least one of a thermal J survey of the rework area and/or removing moisture from the rework area.
D and " rework into replacement patch body.
Q and In a further embodiment, a method of repairing a composite structure having upper and lower surfaces is disclosed. Method 20 may comprise the steps of forming a replacement patch body for extracting moisture from a rework area of the composite structure. The material may have a specific heat capacity and thermal conductivity that may be substantially similar to the specific heat capacity and thermal conductivity of the patch. The method may further include mounting a thermal sensor on the replacement patch body to detect a temperature of at least one of the rework area and the replacement patch body. The method may also include mounting a moisture sensor on the replacement patch body to detect moisture extracted from the rework area. A thermal sensor 30 may also be mounted on the upper surface of the composite structure opposite a heat sink location on the lower surface. A thermal sensor can be mounted on a bottom center and/or on a chamfer of the rework area.
The method may further include covering the rework area with a separation film and installing the replacement patch body in the rework area over the separation film. The method may also include covering the replacement patch body with a porous separation film and the vent layer, installing a heating blanket over the vent layer. ro, and installing a vent layer over the heating blanket. Replacement patch body and heating blanket can be bagged. "The rework area can be heated and a vacuum can be drawn over the bagging film." The method may include effecting by . µ & . minus one of a thermal survey of the rework and/or removal area % and , . of moisture from the rework area. í One embodiment of a replacement patch assembly for · - 15 a rework area of a frame including a patch body! f formed substitute of a material to extract moisture from the area of .

H rework; I
F at least one sensor mounted on the replacement patch body and being configured as one of the following: 20 a thermal sensor for detecting a temperature of at least one of the rework area and the replacement patch body; and a moisture sensor for detecting moisture in the replacement patch body The embodiment of the replacement patch assembly wherein the moisture sensor comprises at least one of a moisture sensing strip and an electrochemical impedance spectroscopy (ELS) sensor . The embodiment of the replacement patch assembly wherein the replacement patch body includes a top surface having a plurality of moisture sensors mounted thereon. The embodiment of the replacement patch assembly wherein the replacement patch body has top and bottom surfaces, at least one of the sensors being mounted in one of the following locations: the top surface, the bottom surface, embedded in the patch body substitute between the top and bottom surfaces. The embodiment of the replacement patch assembly wherein the replacement patch body comprises a plurality of layers; at least one of the sensors being sandwiched between a pair of layers. The Substitute Patch Assembly Mode comprises ~"one of natural and synthetic material including at least one of the following: Wool, cotton, silk, linen, polyester, nylon, acrylic. n" The Substitute Patch Assembly Mode in which the . and > , material comprises felt. . 0 Substitute patch assembly mode in which the 6
W. replacement patch body is conformable in three dimensions so · - 15 the replacement patch body is conformable to the rework area. ! Substitute patch assembly mode in which the á- . " rework area is configured to receive a patch;
P ~ 0 the replacement patch body having a specific heat capacity and a thermal conductivity that is substantially equivalent to at least one of the specific heat capacity and thermal conductivity of the patch. The embodiment of the replacement patch assembly is formed of material having a thermal conductivity in the range from approximately 0.01 W/mk to approximately 1.0 W/mk. 25 The patch assembly embodiment in which the replacement patch body is formed of material having a specific heat capacity in the range from approximately 600 J/(kgk) to approximately 1,100 J/(kgk) . Another embodiment of a replacement patch assembly for a rework area of a composite structure, including a replacement patch body having top and bottom surfaces and defining a substantially uniform thickness, the replacement patch body being formed of felt to extract moisture from the rework area, the felt having a thermal conductivity of approximately 0.01-1.0 W/mk and a specific heat capacity of approximately 600 to 1,100 J/(kgk); a plurality of thermal sensors mounted on the replacement patch body for detecting a temperature of the rework area and the replacement patch body, at least one of the sensing thermal sensors. the embedded in the replacement patch body between the top and bottom surfaces; and top and bottom, and 0
And a plurality of moisture sensors mounted on the replacement patch body on the top surface for the detection of ab-moisture. " sorbed from the rework area.
W An embodiment of a replacement patch system for re- and . L-. stop a structure with a patch that can be received inside a . rework area, the system including a replacement patch body for- · . 15 made of non-composite material having substantial thermal properties. similar to the thermal properties of the patch, the thermal properties comprising at least one of the specific heat capacity and the
W of thermal conductivity; at least one thermal sensor mounted on the replacement patch body 20 for detecting a temperature of the replacement patch body; and at least one thermal sensor mounted in the rework area to detect a temperature of the rework area. The embodiment of the replacement patch system wherein the replacement patch body 25 has at least one of the following thermal properties: a thermal conductivity in the range from approximately 0.01 W/mk to approximately 1.0 W/mk; a specific heat capacity in the range of approximately 30 t and 600 J/(kgk) to approximately 1100 J/(kgk). The embodiment of a substitute patch system in which the substitute patch body is formed of a material to extract moisture.
from the rework area. The embodiment of a replacement patch system wherein the replacement patch body includes a plurality of moisture sensors mounted thereon. The embodiment of a replacement patch system wherein the replacement patch body comprises a plurality of layers; and at least one of the thermal sensor and humidity sensors being sandwiched between a pair of layers.
W « The embodiment of a substitute patch system wherein the structure includes top and bottom surfaces and having at least one dissi- . "heater mounted on the lower surface adjacent to the rework area, the system further includes: .
W at least one top surface mounted thermal sensor and . opposite the location of the heat sink on the bottom surface. · - 15 An embodiment of a method of repairing a structure '! composite having top and bottom surfaces, including the steps of:
W ~ . form a substitute patch body of material for the extraction W
W ation of moisture from a composite structure rework area; mounting at least one sensor on the replacement patch body; 20 install the replacement patch body in the rework area; and carry out at least one of the following: carry out a thermal survey of the rework area; remove moisture from the rework area. The embodiment of a method of repairing the composite structure 25 further including the step of: mounting at least one thermal sensor in the rework area. The embodiment of a method of repairing a composite structure further including at least one of the following steps: forming the replacement patch body to have a thermal conductivity in the range of approximately 0.01 W/mk to approximately 1.0 0 W/mk; form the replacement patch body to have a specific heat capacity in the range of approximately 600 J/(kgk) to approximately 1,100 J/(kgk)- The modality of the method of repairing a composite structure further including the step of: 5 form the felt substitute patch body. The embodiment of a method for repairing a composite structure. site where the step of mounting at least one sensor in the rework area comprises:
W mount at least one thermal sensor on the replacement patch body to detect a temperature of at least one of the rework area and the replacement patch body; and â ~ mount at least one moisture sensor on the re-body.
THE - . substitute for detecting moisture extracted from the . rework; · ) - 15 The modality of a method of repairing a composite structure, including the steps of:
W and "W" vacuum bag the replacement patch body to the top surface with a bagging film; and » extract a vacuum over the bagging film. 20 The modality of a method of repairing a composite structure, including the step of: heating the rework area. Another embodiment of a method of repairing a composite structure comprised of a plurality of pleats, the structure having upper and lower surfaces, the upper surface including a rework area for receiving a patch, the lower surface having at least one heat sink disposed therein, the method comprising the steps of: forming a replacement patch body of material to extract moisture from the rework area, the replacement patch body having a specific heat capacity and thermal conductivity substantially similar to that of specific heat capacity and thermal conductivity of the patch;
mounting a thermal sensor on the replacement patch body to detect a temperature of at least one of the rework area and the replacement patch body; mount a moisture sensor on the replacement patch body to detect moisture extracted from the rework area; ° mount a thermal sensor on the top surface of the structure. r composite opposite a heat sink location on the bottom surface; 0 « mounting a thermal sensor on at least one of a bottom center and a chamfer of the rework area; * m national phase r R q
The replacement patch and heating blanket can be tested.
The
W. . vacuum sealed to the top surface of the structure with a bagged film. at the moment. The rework area can be heated and a vacuum can be ex- · . 15 betrayed about the bagging film. The method may include performing at least one thermal survey of the rework and/or removal area and
G" of moisture from the rework area. a, An embodiment of a replacement patch assembly for
W a rework area of a structure including a substitute patch body 20 formed of a material to extract moisture from the rework area; and at least one sensor mounted on the replacement patch body and being configured as one of the following: a thermal sensor for detecting a temperature of at least one of the rework area and the replacement patch body; and a moisture sensor for detecting moisture in the replacement patch body.
The mode of replacement patch assembly wherein the moisture sensor comprises at least one of a moisture detection strip 30 and an electrochemical impedance spectroscopy (ELS) sensor. The embodiment of the replacement patch assembly wherein the replacement patch body includes a top surface having a plurality of moisture sensors mounted thereon. The embodiment of the replacement patch assembly wherein the replacement patch body has top and bottom surfaces, at least one of the sensors being mounted in one of the following locations: the top surface, the bottom surface, embedded in the body of replacement patch between top and bottom surfaces. - The replacement patch assembly mode in which the W
The replacement patch body comprises a plurality of layers; 10 at least one of the sensors being interleaved between a pair of . W layers. + ã r The Replacement Patch Assembly Mode comprises
W W one of natural and synthetic material including at least one of the following: wool,
H - cotton, silk, linen, polyester, nylon, acrylic.
- . 15 The substitute patch assembly modality in which the
Í » material comprises felt. 0 - Substitute patch assembly mode in which the .
V replacement patch body is conformable in three dimensions so that the replacement patch body is conformable to the rework area. 20 The replacement patch assembly mode in which the rework area is configured to receive a patch; the replacement patch body having a specific heat capacity and thermal conductivity that is substantially equivalent to at least one of the specific heat capacity and thermal conductivity of the patch. The embodiment of the replacement patch assembly is formed of material having a thermal conductivity in the range from approximately 0.01 W/mk to approximately 1.0 W/mk. The patch assembly embodiment wherein the replacement patch body is formed of material having a specific heat capacity in the range from approximately 600 J/(kgk) to approximately 1,100 J/(kgk) .
Another embodiment of a replacement patch assembly for a rework area of a composite structure, including a replacement patch body having top and bottom surfaces and defining a substantially uniform thickness, the replacement patch body being formed of felt to extract moisture from the rework area, the felt having a thermal conductivity of approximately 0.01-1.0 W/mk
. and a specific heat capacity of about 600 to 1100 J/(kgk); a plurality of thermal sensors mounted on the body of
·"¢" replacement patch to detect a temperature of the rework area and 10 of the replacement patch body, at least one of the thermal sensors sen- . " from the embedded in the replacement patch body between the top and r surfaces
". " background; and top and bottom, and
« m a plurality of humidity sensors mounted on the body of a
, replacement patch on top surface for ab- moisture detection. , 15 sorbed from the rework area. . One embodiment of a replacement patch system for re-0
" stopping a structure with a patch that can be received within a rework area, the system including a replacement patch body formed of non-composite material having thermal properties substantially similar to the thermal properties of the patch, the thermal sensors comprising at least one of the specific heat capacity and thermal conductivity; at least one thermal sensor mounted on the replacement patch body for detecting a temperature of the replacement patch body; and at least one thermal sensor mounted in the rework area to detect a temperature of the rework area.
The embodiment of the replacement patch system wherein the replacement patch body has at least one of the following thermal properties: a thermal conductivity in the range from approximately 0.01 W/mk to approximately 1.0 W/mk;
a specific heat capacity in the range of approximately 600 J/(kgk) to approximately 1,100 J/(kgk). The embodiment of a replacement patch system wherein the replacement patch body is formed of a material to extract moisture from the rework area. The modality of a surrogate patch system in which the . replacement patch body includes a plurality of moisture sensors mounted thereon.
B m The embodiment of a replacement patch system wherein the replacement patch body comprises a plurality of layers; . - at least one of the thermal sensor and humidity sensors being r .
B sandwiched between a pair of layers.
P D The embodiment of a substitute patch system wherein the b and j structure includes top and bottom surfaces and having at least one dissi- . . 15 heat pad mounted on the bottom surface adjacent to the retraction area. " work, the system further including: r - at least one top surface mounted thermal sensor
U opposite the location of the heat sink on the bottom surface. One embodiment of a method of repairing a composite structure 20 having top and bottom surfaces, including the steps of: forming a substitute patch body of material for extracting moisture from a rework area of the composite structure; mounting at least one sensor on the replacement patch body; install the replacement patch body in the rework area; and 25 perform at least one of the following: perform a thermal survey of the rework area; remove moisture from the rework area. The embodiment of a method of repairing the composite structure further including the step of: mounting at least one thermal sensor in the rework area. The embodiment of a method of repairing a composite structure further including at least one of the following steps:
forming the replacement patch body to have a thermal conductivity in the range of approximately 0.01 W/mk to approximately 1.0 W/mk; form the replacement patch body to have a specific heat capacity in the range of approximately 600 J/(kgk) to approximately 1100 J/(kgk).
and The modality of the method of repairing a composite structure, further including the step of: -
W form the felt substitute patch body.
n 10 The modality of a method for repairing a composite structure in which the step of mounting at least one sensor in the rework area - comprises: + « mounting at least one thermal sensor on the repair body © q of the surrogate to detect a temperature of at least one of the rework area and the replacement patch body; and - . 15 ob mount at least one humidity sensor on the re-
W - substitute mendo for the detection of moisture extracted from the q rework area; The embodiment of a method of repairing a composite structure further including the steps of: vacuum bagging the replacement patch body to the top surface with a bagging film; and extracting a vacuum over the bagging film. The modality of a method of repairing a composite structure, further including the step of: heating the rework area. Another embodiment of a method of repairing a composite structure comprised of a plurality of pleats, the structure having upper and lower surfaces, the upper surface including a rework area for receiving a patch, the lower surface having at least one heat sink disposed therein, the method comprising the steps of: forming a replacement patch body of material to extract moisture from the rework area, the replacement patch body having a specific heat capacity and a thermal conductivity substantially similar to the capacity specific heat and thermal conductivity of the patch; 5 mounting a thermal sensor on the replacement patch body to detect a temperature of at least one of the rework area and . of replacement patch body; mount a moisture sensor on the replaced patch body
H " tuto for the detection of moisture extracted from the rework area; ...
. 10 mounting a thermal sensor on the upper surface of the composite structure opposite a heat sink location on the lower in- b. -" surface; and and mounting a thermal sensor on at least one of a 0 center, bottom and a chamfer of the rework area; V 15 cover the rework area with a porous separation film; ^
D install the replacement patch body in the rework area over the separation film; cover the replacement patch body with a vent layer; 20 install a heating blanket over the vent layer; install a vent layer over the heating blanket; vacuum bag the replacement patch body and heating blanket with a bagging film; heat the rework area; 25 draw a vacuum over the bagging film; and perform at least one of the following: carry out a thermal survey of the rework area; remove moisture from the rework area. The features, functions and advantages that have been discussed 30 can be obtained independently from the various modalities of the present description or can be combined in still other modalities, others details of which may be seen with reference to the following description and the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS These and other features of the present description will become more apparent with reference to the drawings, in which like numerals refer to completely equal parts and in which: Figure 1 is a perspective illustration of a portion of . a composite structure having a rework area formed therein; Figure 2 is a top view illustration of a composite structure having a vacuum bag assembly and heating mantle installed on a patch mounted within the rework area; Figure 3 is a sectional illustration of the bag assembly a
W - -" vacuum mounted on the composite structure taken along line 3-3 of figure 2 and illustrating a heat sink comprising a stringer located on a lower surface of the composite structure opposite a . , Figure 4 is an exploded sectional illustration of a replacement patch system comprising a replacement patch body formed as a plurality of layers arranged in stacked formation. gives; Figure 5 is an exploded sectional illustration of the replacement patch body formed as a unitary structure; Figure 6 is a top view illustration of the replacement patch assembly taken along line 6-6 of Figure 5 and illustrating a plurality of thermal sensors and humidity sensors mounted on the replacement patch body 25 and composite structure; Figure 7 is an exploded sectional illustration of the vacuum bag assembly as it may be installed over the replacement patch assembly to conduct a thermal survey of the rework area; Figure 8 is a sectional illustration of an embodiment of the replacement patch assembly mounted within the rework area under the application of a vacuum during a de-moisture process; Figure 9 is a block diagram of a replacement patch system; Figure 10 is an illustration of a flow diagram for a methodology for repairing a composite structure; Figure 11 is a flowchart of an aircraft production and service methodology; and Figure 12 is a block diagram of an aircraft.
. DETAILED DESCRIPTION Referring now to the drawings in which the samples are pa-,. "For purposes of illustrating the preferred and varied embodiments of the disclosures 10 only and not for the purpose of limiting the same, there is shown in Figure 1 a perspective illustration of a composite structure 10 upon which a
B ^ -" repair process can be implemented using an assembly of
The * 0 , replacement patch as illustrated in figures 4 to 9. More specifically, the preparation of a rework area 20 may include a thermal survey · . 15 and/or a moisture removal process that may employ replacement patch assembly 50 (Figures 4 through 9), as disclosed herein. " ment, and which can be manufactured from low-cost material in a period
The relatively short time, as will be described in more detail below. In Figures 1 to 2, the composite structure 10 may include a skin 20 14 formed from pleats 12 of composite material and wherein the skin 14 may have upper and lower surfaces 16, 18. The composite structure 10 may include the rework area 20 formed in the skin 14 and from which the composite material can be removed in preparation for receiving a patch 40. As can be seen in Figure 3, the rework area 20 can be formed in the upper surface 16 and can be extend at least partially through the skin 14, although the rework area 20 may be formed on the lower surface 18 and/or may extend through a thickness of the skin 14. The various heat sinks 28 may be mounted on the lower surface 18 opposite the rework area 20 such as, without limitation, stringers, stiffeners, 30 and chamfers that can draw heat away from the rework area 20 during the repair. For example, figures 2 to 3 illustrate a stringer 30 mounted
on a bottom surface 18 and having flanges 32 which extend along a portion of the rework area 20 on a right side thereof and which can extract heat from the rework area 20. The remainder of the rework area 20. rework 20 may be devoid of any structure 5 that might otherwise draw heat away from the rework area 20. In this regard, thermal research can help identify the
. locations of a bond line 46 (Figure 3) between the patch 40 and the rework area 20 that require a greater amount of heat input than other areas of the bond line.
Thermal research can also help to identify locations in the rework area 20 that may require *, "temporary application of insulation to the composite structure 10 in order to -" achieve substantial temperature uniformity throughout the bond line 46
& . . (figure 3). d Figures 2 to 3 show a vacuum bag assembly
. , 15 100 for use during the final repair process or during · pre-repair operations of the thermal survey and/or moisture removal process.
The vacuum bag assembly 100 may comprise a heating mantle 104 or heating equipment.
The heating blanket 104+ may include wiring 106 coupled to a power supply (not shown) for heating the rework area 20 to the desired temperature during the thermal survey or moisture removal process.
The vacuum bag assembly 100 may include a bagging film 116 covering the heating mantle 104 and may be sealed to the top surface 16 of the composite structure 10 by means of sealing tape 122. A 25" probe Vacuum 118 may extend from bagging film 116 to provide a means to evacuate volatiles, air, and/or gas from rework area 20. As shown in Figure 3, the bag assembly vacuum 100 may comprise a hood plate 102 positioned above a non-porous separating film 30 108 (e.g., peel pleat) to facilitate the application of uniform pressure to the patch 40. The separating film may prevent adhesion of the hood plate. hood 102 to the layers directly below the hood plate 102. The separation film may, in turn, be positioned over a porous bleed layer 112 which can be positioned over a porous separation film 110 to facilitate the escape of volatiles during heating. patch link 40 to the composite structure 10. The patch 40 5 may be received within the rework area 20 and may include a bevel 44 formed at the edge of the patch 42 and substantially equaling the bevel 24 formed at a rework tapered angle Qa, and the rework area retra- . 20. Replacement patch body 52 may include a plurality of
, " pleats corresponding to pleats 12 of the composite structure 10. 10 Referring to figure 4, a replacement patch assembly 50 is shown as it can be used to conduct a survey- & - »
- thermal sa and/or moisture removal from the rework area 20 before + 8 of the final connection of the patch to the rework area 20. As can be seen in " 0
4, the replacement patch assembly 50 may comprise a body. , 15 of replacement patch 52 which may be formed of a material to extract moisture from the rework area 20. The material may comprise f
"a non-composite material including natural and/or synthetic material such as, without limitation, wool, cotton, silk, linen, polyester, nylon and acrylic and any other material or combination thereof.
However, it is also contemplated that embodiments of the replacement patch body may include composite material such as, without limitation, fiber-reinforced polymeric materials.
The replacement patch assembly 50 may further include one or more sensors such as a thermal sensor 70 that can be mounted on the replacement patch body 52 for sensing the temperature of the rework area 20 during a thermal survey.
The sensor may also comprise a moisture sensor 74 for detecting moisture that can be drawn from the rework area 20 into the replacement patch body 52 during the moisture removal process.
Thermal sensor 30 70 may comprise any appropriate temperature measuring instrumentation including, but not limited to, thermocouples 72 and any other elements suitable for sensing the temperature of rework area 20 and/or replacement patch body 52 As indicated above, the replacement patch body 52 of the replacement patch assembly 50 is preferably formed from a material that has similar thermal properties to the composite material 5 from which the final patch 40 (Figure 3) is made. formed. In this regard, the replacement patch body 52 is preferably formed of a material which has a specific heat capacity and/or a thermal conductivity that is substantially equivalent to the specific heat capacity and thermal conductivity of the The thermal conductivity of the patch is preferably measured in the out-of-plane transverse direction in order to simulate the direction along which heat may flow during the repair process. + m" - Patch 40 (figure 3), in one embodiment, may be fabricated from epoxy pre-impregnated carbon fiber tape and/or fabric. ". However, the composite material from which the patch can be formed is . , 15 may comprise any suitable pre-preg or wet-storage composite material and is not limited to the materials disclosed in the price. " feels document. The specific heat capacity, thermal conductivity and other thermal properties of the composite material are preferably the
T properties exhibited by the composite material when fully cured and at a specific or certain fiber content and bulk density. For the aforementioned epoxy pre-impregnated carbon fiber tape material having a fiber volume content of 0.56 and a density of
5.64E-2 |b/en|.3, thermal properties may comprise a thermal conductivity in the range of approximately 0.01 W/mk to approximately 1.0 W/mk, where such properties are measured at a temperature Tq of approximately 20°C (i.e. room temperature). In this regard, the replacement patch body 52 may be formed from a material that has a thermal conductivity similar to the aforementioned range of 0.01 W/mk to approximately 1.0 W/mk. In one embodiment, the thermal conductivity of the replacement patch body 52 may be approximately 0.04 W/mk. However, the replacement patch body 52 may be formed from a material with a thermal conductivity.
mica that is complementary to or substantially equal to the thermal conductivity of the material from which the patch 40 (Figure 3) is formed. Advantageously, by forming the replacement patch body 52 of material that has a thermal conductivity that is substantially similar to the thermal conductivity of the composite material of the patch, the heating characteristics of the patch can be substantially duplicated without the need for . manufacture a conventional single-cut composite pleat replacement patch as described above. In this regard, cost and time normally. , te associated with conventional substitute composite patches can be substantially reduced.
· "Replacement patch body 52 may be formed from a material that may have a specific heat capacity that is preferably in the range of specific heat capacity of the composite material at . from which the patch 40 (Figure 3) can be formed. For example, the replacement patch body 52 may be formed of material having a specific heat capacity in the range of approximately 600 J/(kgk) to a- . " approximately 1,100 J/(kgk) and preferably approximately 830 J/(kgk), measured at a temperature of approximately T0 approx. 273K (ie room temperature). As indicated above, this specific heat capacity and thermal conductivity represent the specific heat capacity and thermal conductivity of the epoxy pre-impregnated carbon fiber tape and/or fabric from which the patch can be formed. and should not be construed as limiting the alternative thermal properties of the replacement patch assembly 50. 25 Referring further to Figure 4, in one embodiment, the material of the replacement patch body 52 may be formed of natural or synthetic material or any other material. combination thereof. For example, the material from which the replacement patch body 52 may be formed may comprise wool, cotton, silk, linen, polyester, nylon and acrylic or any other suitable material that can substantially duplicate the thermal properties (i.e. that is, the specific heat capacity and thermal conductivity) of the material from which the final patch can be formed. In one embodiment, the material may comprise a non-woven material or cloth which may be comprised of bonded fibers. For example, the replacement patch body 52 may be formed of felt due to its favorable wick-forming properties and favorable thermal insulation properties. The wick forming properties of felt are such that fluid can be drawn away from the rework area 20 and into the replacement patch body 52 due to capillary action on the felt material. tro. The thermal conductivity of wool felt, in one embodiment, is approx. " approximately 0.04 W/mk, which may be compatible with the thermal conductivity of composite materials from which the patch can be formed." - - - Although the replacement patch body 52 can preferably . & « , be formed of felt, the replacement patch body 52 may be formed of any suitable material that can extract moisture from the area of . V , 15 rework 20 when the replacement patch body 52 is brought into contact with it. For example, the replacement patch body 52 may be formed from alternative materials such as fabric materials that have high absorbency at elevated temperatures similar to curing temperatures.
V associated with the repair of composites. In this regard, the material of the replacement patch body 20 52 is preferably such that heat, such as from a heating blanket 104, penetrates the thickness of the replacement patch body 52 to facilitate accurate measurement. the temperature at the connecting line 48 between the replacement patch body 52 and the rework area 20. Referring further to Figure 4, the replacement patch body 52 may be formed from a plurality of layers 60 which may be arranged in a stacked formation. The layers of the patch assembly 60 may be formed so that the edges of the layers 62 collectively define a tapered angle, which is substantially similar to the tapered angle of the rework ()rework area as illustrated in Figure 4. Although shown as having a generally conical arrangement in which the layers 60 are of a decreasing width and/or diameter, the layers 60 of the
Substitute 52 may be of substantially equivalent width so that when layers 60 are assembled in the stacked arrangement, the edges of layers 62 are in substantial alignment with each other.
In this regard, the assembled replacement patch body 52 may comprise the plurality of layers 60 that can be received within the rework area 20. In Figure 4, the replacement patch assembly 50 may be shown. stopping the rework zone 20 by a separating film that can be
,, " a non-porous separation film 108 or a porous separation film . - 10 110. The replacement patch assembly 50 may include one or more sensor-
6" thermal res 70 mounted in strategic locations over the rework area ar -" 20 in order to monitor temperatures at these locations of the rework area
. 6 . . 20 during application of heat.
As part of a thermal survey con- . Optionally, thermal sensors 70 and thermocouples 72 can be installed. , 15 on a background 26 of the rework area 20 and on a taper · of the limit 22 of the rework area 20 in order to monitor the temper profile. " ture.
Likewise, the replacement patch body 52 may include one or more thermal sensors 70 in order to measure temperatures during testing. thermal want. For example, the replacement patch body 52 may include a thermal sensor 70 mounted on a top surface 54 such as at a center thereof, as illustrated in Figure 4. A thermal sensor 70 may also be mounted within the patch body. substitute 52 as between the top and bottom surfaces 54, 56. In this regard, fabrication of the substitute patch body 25 52 as a stack of layers 60 can facilitate installation of thermal sensors 70 at different locations within the patch body replacement 52. Thermal sensors 70 may also be disposed along a perimeter 58 of replacement patch body 52. Sensors may be attached to replacement patch body 52 by any appropriate means, including, but not limited to, mechanical connection and fixation.
Notably, the thermal sensors 70 can be mounted anywhere within the rework area 20 such as the chamfer 24 of the rework area.
20 or at the bottom center 26 of the rework area 20 or in locations that are opposite the location of the heat sinks such as the stringer 30 which can at least partially overlap a portion of the rework area 20. replacement patch 50 may further include moisture sensors 74 to detect the presence of moisture and/or the
Relative W of moisture that may be contained within the rework area 20. Moisture sensors of 74, in one embodiment, may comprise 4, "conventional moisture sensing strips, such as, without limitation, sensing strips. - 10 of cobalt chloride moisture or other + detection strips: chemical composition moisture that can change color in the presence of +
V a sufficiently high level of humidity or water. However, any sensor configuration appropriate for detecting the presence of moisture, such as R . W m like water, can be implemented for replacement patch assembly. , 15 50. For example, the humidity sensor 74 may comprise sensors that · operate using electrochemical impedance spectroscopy (ELS), or any other appropriate sensing technology. The humidity sensors 74 may be selectively configured to provide an indication (eg, a visual indication) as to the presence of moisture 20 in the replacement patch body 52 that can be extracted from the rework area 20. Such moisture can be extracted from the rework area 20. rework 20 when the replacement patch body 52 is in contact with them and/or during the application of heat. Moisture sensors 74 are preferably mounted in a proper arrangement on the replacement patch body 25 52 such as in spaced relationship to each other along the top surface 54 of the replacement patch body 52 as illustrated in Figure 6 and described in greater detail below. Referring to Figure 5, the sub-patch assembly is shown. 50 wherein the replacement patch body 52 is provided in an embodiment comprising a unitary structure of a single layer or pleat or layers opposite the arrangement of layers 60 illustrated in the figure.
4. In Figure 5, the replacement patch body 52 may be formed as a thickness approaching the thickness of the rework area 20 in which the replacement patch body 52 is received. In addition, the perimeter 58 of the replacement patch body 52 may include a chamfer 64 formed at a conical patch angle f), which is preferably complementary to the conical rework angle ()á, ea rework so that the replacement patch body 52 is received in intimate contact with the rework area 20. As indicated above, the replacement patch body 52 "may be separated from the rework area 20 by the porous separation film." or non-porous 108, such as fluorinated ethylene propylene (FEP) or other similar heat-resistant and/or non-adherent material to allow for release of the replacement patch body 52 from the rework area 20 after the " Completion of the thermal survey and/or moisture removal process. co-,
As can be seen in figure 5, the thermal sensors 70 can be mounted in the rework area 20 in the indicated areas as well as in the adjacent areas. . . 15 tees to the rework area 20 and can be coupled to instrumentation (not shown) such as a data acquisition system (not shown) via sensor wiring 76 or wirelessly. , thermal sensors 70 and/or humidity sensors 74 mounted on the body of and replacement patch 52 may be coupled to the instrumentation via sensor wiring 76 to facilitate measurement and recording of temperature and/or humidity within the body of Replacement patch 52. Referring to Figure 6, there is shown a plan view of an installation of thermocouples 72 and/or humidity sensors 74 over replacement patch body 52 and composite structure 10 adjacent to rework area 20. As can be seen, thermal sensors 70 may be located on top surface 54 of composite structure 10 opposite stringer 30 which can draw heat away from rework area 20. Thermal sensors 70 may provide a means of monitoring the temperature to indicate that insulation may be required in the stringer 30 or 30 that separate heating of the stringer 30 or areas adjacent thereto may be required in order to heat the rework area 20 at the desired rate and maintain the patch within the desired temperature range. As powder-
The replacement patch body 52 may include one or more moisture sensors 74, such as the moisture sensor 74 located in the center of the replacement patch body 52, however. However, the moisture sensors 74 may be distributed along the top surface 54 of the replacement patch body 52 to facilitate identification of areas in the work area 20 from which moisture is drawn. Thermal sensors 70 . and/or humidity sensors 74 can provide data relating to a thermal profile and/or humidity profile of the rework area 20.
m Referring to figure 7, the patch system is shown. - 10 replacement 48 which may comprise the replacement patch assembly 50" and which may further include a vacuum bag assembly 100 comprising a bagging film 116 surrounding the heating mantle i..
W. m. 104 which can cover the patch assembly when installed within the & rework area 20. As can be seen in Figure 7, the patch body . , 15 substitute 52 may be separated from the rework area 20 by porous and/or non-porous separating film 110, 108, depending on whether the
W" thermal survey may include a moisture removal process. As *mentioned above, the replacement patch assembly 50 as disclosed
U in the present document provides a means to combine thermal scanning 20 and moisture removal so that a single heat cycle is imposed on composite structure 10. Vacuum bag assembly 100 can be seen as including bagging film 116 which can be sealed to the top surface 54 of the composite structure 10 by means of the seal 122, such as the sealing tape 122 conventionally used in vacuum bagging operations. The bagging film 116 may surround a vent layer 114 which may cover a heating mantle 104 and which may extend on one or both sides of the heating mantle 104 to the area of the seal 122. The vent layer 114 may be extend beneath t 30 of a vacuum probe 118 which may be disposed on one side of the heating mantle 104 to facilitate substantially uniform application of vacuum pressure to the replacement patch body 52 during the thermal cycling and/or heating process. moisture removal. A hood plate 102 may be positioned beneath the heating mantle 104 to provide uniform application of pressure to the replacement patch body 52. The hood plate 102 may be formed of any suitable rigid or semi-rigid material. including, but not limited to, a rubber boot material such as cured silicone rubber sheet and/or a metal or metal material. any combination of metallic and non-metallic materials. The hood plate 102 may be separated from the replacement patch body 52 by means of the "separation film which may be formed of any suitable material". - 10 for preventing the hood plate 102 from sticking or contacting the area. of " rework 20 and/or replacement patch body 52. For example, the separation film -" may be perforated (i.e. porous) or non-perforated (i.e.
a. . non-porous) and may be formed from any suitable material including . fluorinated ethylene propylene (FEP), or any other suitable material. ·- ~ 15 With reference to figure 8, a cross-section illustration is shown of the replacement patch body 52 having the vacuum bag mon- .
It is kept the same without the heating mantle 104. Such an arrangement can be implemented during a moisture removal process. Optionally,
The assembly can be installed in an oven or autoclave to facilitate the application of heat to the composite structure 10. As can be seen in Figure 8, the vacuum bag includes the vacuum probe 118 to extract gases out of the area involved. by the bagging film 116. A vacuum gauge 120 on an opposite side of the bag opposite the vacuum bag assembly 100 provides a means for monitoring the vacuum pressure within the vacuum bag. Replacement patch body 52 can be seen as having a substantially uniform thickness. Replacement patch body 52 may be formed from any of the aforementioned materials. In this regard, the replacement patch body 52 may be formed of a resiliently flexible material capable of conforming to the contour or shape of the rework area 20 in three dimensions. The perimeter 58 of the replacement patch body 52 can be seen as conforming or partially compressing under pressure from the vacuum bag. Replacement patch body 52 may be separated from bagging film 116 by a vent layer 114 to allow moisture to escape. The replacement patch body 52 may be separated from the rework zone 20 by means of a porous separating film 108 5 to prevent contact therebetween while allowing moisture to escape from the rework area 20. Thermocouples 72 or other thermal sensors 70 can be installed at strategic locations within the rework area 20 as illustrated in Figure 8 and described above. Likewise, the replacement patch body 52 may include thermal sensors
T. , 10 70 and/or humidity sensors 74 in locations along the patch body" substitute 52 to monitor temperature and moisture removal.
W Referring briefly to figure 9, a diagram is shown. . block diagram illustrating a replacement patch system 48 as may be used to conduct a thermal survey and/or a moisture removal process. As can be seen in Figure 9, the patching system of the substitute 48 may comprise a vacuum bag assembly 100, the "+" which may include a bagging film 116 mounted to the frame 10 by means of the seal 122. Bagging film 116 may enclose a number of layers, such as a vent layer 114, heating blanket 104, hood plate 102, bleed layer 112, separation film 108, 110 as well as the Replacement patch assembly 50 comprising replacement patch body 52. Replacement patch body 52 may have a center patch 68 and a perimeter 58. One or more sensors such as humidity sensors 74 or thermal sensors 70 (i.e. thermocouples) 25 72) may be mounted to the replacement patch body 52 such as along the perimeter 58 and/or center of the patch 68 or recessed within the replacement patch body 52. The replacement patch body 52 may be mounted in the rework area 20 and can be separated from it through the film of separation. The rework area 20 may be formed on the frame 10, 30 as well as along an upper surface 16 thereof. The rework area 20 may include the bottom center 26 within which a sensor such as a humidity sensor 74 and/or a thermal sensor 70 (i.e. thermocouple) can be mounted. Likewise, one or more sensors such as thermal sensors 70 can be mounted on a chamfer 24 of the rework area.
20. Likewise, the upper surface 16 of the frame 10 surrounding the rework area 20 may include thermal sensors 70 as thermocouples 5 72 in order to identify temperature variations that may occur as a result of heat extracted from the rework area. 20 for the heatsinks. 28, such as Iongarins 30. Referring to Figure 10, there is shown an illustration of a flowchart for a methodology for repairing a structure such as a composite structure having a rework area. structure may "include upper and lower surfaces and may include at least one heat sink 4.. , -" which may be disposed in one location with respect to the rework area such as on a lower surface of the adjacent structure to the rework area. The method may comprise step 200 including forming the replacement patch body which may optionally be formed and molded in addition to the shape of the rework area. For example, the body of a rework area. "Replacement patch can be formed from woven or non-woven material to draw moisture from the rework area. The patch body replaces. The tuto may have top and bottom surfaces and is preferably formed of a material for extracting moisture from the rework area such as during a moisture removal process. Furthermore, the replacement patch body preferably has thermal properties that are substantially similar to or complementary to the thermal properties of the composite material from which the patch may be formed. 25 For example, the replacement patch body may have a specific heat capacity and/or thermal conductivity that is substantially equivalent to a specific heat capacity and/or thermal conductivity of fiberglass tape and fabric. carbon pre-impregnated with epoxy. However, the thermal properties of the composite material can comprise the thermal properties of any composite material and are not limited to carbon fiber or epoxy pre-impregnated tapes, but may include wet and/or non-wet storage systems. pre-
impregnated. As described above, the replacement patch body may include at least one thermal sensor which may be mounted to the replacement patch body on the top surface, bottom surface or which may be embedded within the replacement patch body or any combination of the above. The replacement patch body may further include at least one moisture sensor which can be mounted to the replacement patch body at any location such as at a center of the patch or along a perimeter of the replacement patch body or a combination. 10 Referring further to Figure 10, step 202 may comprise mounting one or more thermal sensors on the replacement patch body and , ·" to detect the temperature of the rework area and/or or replacement patch body. For example, thermal sensors such as, without limitation, ter- *
W. V 0 mopars, can be mounted on top and/or bottom surfaces .- 15 of the replacement patch body. Thermal sensors can optionally be built into the replacement patch body as illustrated in / ^ " figure 4 and described above. Thermal sensors on the bottom surface of the replacement patch body can monitor the temperature of the area of rework and/or the temperature of the replacement patch body. Step 204 20 may comprise mounting one or more moisture sensors on the replacement patch body to detect moisture that can be extracted from the rework area to inside the replacement patch body. In this regard, the replacement patch body may be formed from any material having a relatively high moisture absorption capacity 25 as indicated above. In this regard, the replacement patch body may be formed from materials which have relatively high absorbency at elevated temperatures associated with processing composite materials. Referring further to Figure 10, step 206 may include assembling one or more thermal sensors on the upper surface of the composite structure 30. For example, thermal sensors can be mounted on the top surface of the composite structure opposite the location of one or more heat sinks that can be arranged adjacent to the surface.
) at the bottom of the composite structure, or at any location on the top surface. Step 208 may comprise mounting one or more of the thermal sensors in the rework area such as at the bottom center of the rework area and/or over the chamfer (i.e. the tapered angle) of the rework area 5 to monitor the temperatures in the rework zone. Step 210 in the frame repair methodology may include covering the rework area with a
W porous separation film such as fluorinated ethylene propylene (FEP) or any other suitable film material to prevent body contact, "replacement patch with the composite structure and rework area. No. : 10 However, it is contemplated that the material from which the replacement patch body is formed may obviate the need for a separation film. 4 P Step 212 may include installing the replacement sd V patch assembly within the rework area such as over the 2nd separation film
O, porous and/or non-porous. For example, the replacement patch might be insta- .- . 15 in a manner illustrated in Figure 8 wherein the replacement patch body -j may be formed as a unitary or single-layer structure of substantially constant thickness that is substantially conformable to the shape and/or contour of the patch area. rework. Alternatively, the re-body. Substitute patch may be formed from a plurality of layers arranged in stacked formation, as illustrated in Figure 4 and wherein the layers of material making up the replacement patch body are conformable or resiliently flexible or compressible in order to allow conformation. the replacement patch body to the contour or shape of the rework area. Referring further to Figure 10, step 214 of methodology 25 may further include covering the replacement patch body and rework area with a vent layer to facilitate substantially uniform application of vacuum pressure to the replacement patch body. The method may further include the step of installing a heating mantle or other appropriate heating equipment at step 216 and, as illustrated in Figures 7 and 8. The heating mantle may facilitate heating. of the rework area and the replacement patch body during the thermal survey and/or during the moisture removal process. A piece of coi-
fa 102 (figure 7) may optionally be included between the vent layer and the heating mantle 104 as illustrated in figure 7 in order to provide uniform pressure distribution to the replacement patch body. Step 218 of Figure 10 may comprise installing a vent layer over the heating mantle, as illustrated in Figure 7, followed by vacuum bagging at step 220 so that the replacement patch body and heating mantle are enveloped by a bagging film that can be veiled onto the top surface of the composite structure 10, as illustrated in Figure 8. Vacuum can be applied through... 10 of the vacuum probe illustrated in Figure 8, in order to extract a vacuum over the "bagging film which can be monitored by means of a vacuum gauge ¢ ~ -" installed as illustrated in figure 8. Heat can be applied such
B « O - © as by the heating mantle at step 222 during vacuum extraction & at step 224 so that the thermal survey and/or moisture removal process can be carried out over the rework area at step 226 .~. The thermal search process can be similar to what is con- ± j
U ventionally performed where the rework area can be heated and the temperature monitored. Depending on the temperature measurements, the iso- . Wlament may be locally added to areas of the composite structure such as adjacent to heat sinks or to other areas as indicated above in order to achieve substantial temperature uniformity throughout the bond line. Rework area heating can also be adjusted by adjusting the heating blanket during thermal research to achieve substantial temperature uniformity. The moisture removal process may comprise heating the rework area through the heating blanket and recording moisture data provided by moisture sensors mounted within the replacement patch body. The moisture removal process can be carried out before and/or during the thermal survey. Advantageously, the configuration of the replacement patch body 30 can facilitate the performance of the thermal survey and de-moisture process in a way that can eliminate an additional heat cycle typically required in separate thermal survey and de-moisture processes from manufacturing operations. conventional post-repair.
In one embodiment, the moisture removal process may comprise weighing the replacement patch body prior to installation in the rework area.
After the thermal survey and/or moisture removal process is completed, the replacement patch body can be reweighed to determine the level of moisture absorption, which may
. then be correlated with the moisture content of the rework area.
More specifically, the moisture removal process may comprise the +
. Weighing the replacement patch body before installing the re-body. 10 Substitute patch within the rework and bagging area of the "Substitute Patch" body.
The method may include heating the retract area after drawing a vacuum over the bagging film.
alternative
¶ © , , however, the heating mantle can be omitted and the composite structure
. can be heated by means of an oven or in an autoclave.
During .-" . 15 heating, the temperature of the rework area can be monitored
·7 using the data from the thermal sensors.
Heating can result in drying (ie, removal of moisture) of the composite structure rework area.
The patch mount replacement patch body ¶
substitute can be removed from the rework area and can be weighed in order to determine the amount of moisture drawn out of the rework area.
With reference to Figures 11 to 12, the embodiments of the description may be described in the context of an aircraft manufacturing and service method 300 as shown in Figure 11 and an aircraft 302 as shown in Figure 12. production, exemplary method 300 may include specification and design 304 of aircraft 302 and procurement of material 306. During production, component and fabrication of subassembly 308 and system integration 310 of aircraft 302 occurs .
Thereafter, aircraft 302 can go through certification and clearance 312 in order to be placed in service 314. While in service by a customer, aircraft 302 is scheduled for routine maintenance and service 316 (which also - may also include modification, reconfiguration, recovery, and so on.
before). Each of the processes of method 300 may be performed or performed by a system integrator, a third party, and/or an operator (eg, a customer). For the purposes of the present description, a system integrator may include, without limitation, any number of aircraft manufacturers and subcontractors of larger systems; third parties may include, without limitation, any number of suppliers, subcontractors and suppliers; and an operator can be an airline, leasing company, military entity, service organization, and so on. a frame 318 with a plurality re -' of systems 320 and an interior 322. Examples of high-level systems 320 , 8 r 0 » < , ád include one or more of a propulsion system 324, an electrical system, 326, a hydraulic system 328, and an environmental system 330. Any number of other systems can be included. Although an aerospace example is shown, the principles of the disclosed modalities can be applied to other industries. , such as the automotive industry.
The apparatus and methods embodied in this document may be used. may be employed in any one or more of the phases of the production and service method 300. For example, components or subassemblies corresponding to the production process 308 may be fabricated or otherwise similar to the components or subassemblies produced while the aircraft 302 is in service. Also, one or more embodiments of the apparatus, embodiments of the method, or a combination thereof may be used during the production stages 308 and 310, for example, substantially expediting the assembly of or reducing the cost of an aircraft 302. Similarly, one or more of the embodiments of the apparatus, the embodiments of the method, or a combination thereof may be used while the aircraft 302 is in service, for example, and without limitation, for maintenance and service 316. Modifications and further improvements of the present disclosure may be apparent to those skilled in the art. Thus, the particular combination of parts described and illustrated herein is intended to represent only certain embodiments of the present disclosure and is not intended to serve as limitations of alternative embodiments or devices within the spirit and scope of the disclosure.
^ -m -t d- W
G :X n 4 h, 0 ¥ W.W
W f 4 "'J

权利要求:
Claims (15)
[1]
1. Replacement patch assembly (50) for a rework area of a structure (10) comprising: a replacement patch body (52) formed of a material 5 for extracting moisture from the rework area; and at least one sensor (70, 74) mounted on the replacement patch body (52) and being configured as one of the following: a thermal sensor (70) for detecting a temperature of at least one of the rework area and the patch body substitute (52); and a moisture sensor (74) for detecting moisture in the replacement patch body (52).
[2]
The replacement patch assembly of claim 1, wherein: the moisture sensor (74) comprises at least one of a moisture sensing strip and an electrochemical impedance spectroscopy (EIS) sensor;
[3]
The replacement patch assembly of claim 1, wherein: the replacement patch body (52) includes a top surface having a plurality of moisture sensors (74) mounted thereon.
[4]
4. Replacement patch assembly according to claim 1, wherein: the replacement patch body (52) has top and bottom surfaces, at least one of the sensors (70, 74) being mounted to one of the the following locations: on the top surface, on the bottom surface, embedded in the replacement patch body (52) between the top and bottom surfaces.
[5]
The replacement patch assembly according to claim 1, wherein: a replacement patch body (52) comprises a plurality of layers; at least one of the sensors (70, 74) being interleaved between a pair of layers.
[6]
6. Replacement patch assembly, in accordance with claim 1, wherein: the rework area is configured to receive a patch; the replacement patch body (52) having a specific heat capacity and a thermal conductivity that is substantially equivalent to at least one of the specific heat capacity and thermal conductivity of the patch.
[7]
7. Replacement patch system (48) for repairing a structure (10) with a patch that can be received within a rework area, the system comprising: a replacement patch body (52) formed from non-replaceable material; composite having thermal properties substantially similar to the thermal properties of the patch, the thermal properties comprising at least one of specific heat capacity and thermal conductivity; at least one thermal sensor (70) mounted on the replacement patch body (52) for detecting a temperature of the replacement patch body (52); and at least one thermal sensor (40) mounted over the rework area to detect a temperature of the rework area.
[8]
A replacement patch system as claimed in claim 7, wherein: the replacement patch body (52) is formed from a material extracting moisture from the rework area.
[9]
A replacement patch system as claimed in claim 7, wherein: the replacement patch body (52) includes a plurality of moisture sensors (74) shown therein.
[10]
The replacement patch system as claimed in claim 9, wherein: the replacement patch body (52) comprises a plurality of layers; at least one of the thermal sensor (70) and the humidity sensors
(74) being interleaved between a pair of layers.
[11]
A replacement patch system as claimed in claim 7, wherein the frame (10) includes upper (16) and lower (18) surfaces and having at least one heat sink (28) mounted on the lower surface. (18) adjacent to the rework area, the system further comprising: at least one thermal sensor (70) mounted on the top surface (16) opposite the location of the heat sink (28) on the bottom surface (18) .
[12]
12. A method of repairing a composite structure (10) having upper (16) and lower (18) surfaces, comprising the steps of: forming (200) a replacement patch body (52) of material to extract moisture from a composite structure rework area (10); mounting (202, 204) at least one sensor (70, 74) on the replacement patch body (52); installing (212) the replacement patch body (52) in the rework area; and perform (226) at least one of the following: conduct a thermal survey of the rework area; remove moisture from the rework area.
[13]
The method of claim 12, further comprising the step of: mounting (208) at least one thermal sensor (70) in the rework area.
[14]
The method of claim 12, wherein the step of mounting at least one sensor in the rework area comprises: mounting (202) at least one thermal sensor (70) on the replacement patch body (52) to detect a temperature of at least one of the rework area and the replacement patch body (52); and mounting at least one moisture sensor (74) on the replacement patch body (52) to detect moisture drawn from the retraction area.
bath.
[15]
The method of claim 12, further comprising the steps of: vacuum bagging (220) the replacement patch body (52) to the top surface (16) with a bagging film (116); and extracting (224) a vacuum from the bagging film (116).

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KR20120112385A|2012-10-11|

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法律状态:
2021-09-21| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

2021-09-21| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

2022-01-25| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

优先权:

申请号 | 申请日 | 专利标题

US12/633,753|2009-12-08|

US12/633,753|US8545650B2|2009-12-08|2009-12-08|Method of repairing a composite structure|

PCT/US2010/055684|WO2011071622A1|2009-12-08|2010-11-05|Surrogate patch for composite repair process|

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