Self-repair structures and methods for making the same

Patent metadata

Field	Value
Publication number	US-10000299-B2
Application number	US-201514838442-A
Country	US
Kind code	B2
Filing date	Aug 28, 2015
Priority date	Aug 28, 2015
Publication date	Jun 19, 2018
Grant date	Jun 19, 2018

Abstract

Methods and apparatuses are disclosed relating to multilayer 3D textile composite materials containing self-healing resins for use as protective structures on stationary objects, and moving objects including, without limitation, vehicles including spacecraft and aircraft.

First claim

What is claimed is:

1. A method for making a structure comprising the steps of:
assembling a first layer, said first layer comprising a three-dimensional textile composite material, said three-dimensional textile composite material comprising an interior surface and an exterior surface;
assembling at least one fiber-containing stiffener, said fiber-containing stiffener comprising a three-dimensional textile composite material, and said fiber-containing stiffener comprising an interior surface and an exterior surface;
wherein the fiber-containing stiffener is located proximate to the exterior surface of the first layer;
wherein, at least a portion of the interior surface of the fiber-containing stiffener contacts the exterior surface of the first layer to form a boundary of a cavity;
wherein the cavity comprises a predetermined amount of a resin-containing material, said resin-containing material comprising nanoparticles and a catalyst; and
joining the fiber-containing stiffener to the exterior surface of the first layer.

2. The method of claim 1 , wherein at least one of the first layer and the fiber-containing stiffener has a domed configuration.

3. The method of claim 1 , wherein a plurality of fiber-containing stiffeners are joined to the exterior of the first layer.

4. The method of claim 1 , wherein the step of joining the fiber-containing stiffener to the exterior surface of the first layer further comprises the step of thermo-stamping the fiber-containing stiffener to the first layer.

5. The method of claim 1 , wherein the three-dimensional fiber material comprises a thermoplastic material.

6. The method of claim 5 , wherein the thermoplastic material comprises: poly(p-phenyl sulfide); polyethylenimine; polyetherketone ketone; polyetherether ketone, or combinations thereof.

7. The method of claim 1 , wherein substantially all of the interior surface of the stiffener is in contact with the exterior surface of the first layer.

8. The method of claim 1 , wherein the three-dimensional textile composite material comprises an orthogonal three-dimensional weave, said weave further comprising a predetermined z-directional reinforcement.

9. A method for repairing the exterior of an aircraft component during flight comprising the steps of:
making an aircraft component, said component comprising:
a first layer, said first layer comprising a three-dimensional textile composite material, said three-dimensional textile composite material comprising an interior surface and an exterior surface; and
at least one fiber-containing stiffener, said fiber-containing stiffener comprising a three-dimensional textile composite material, and said fiber-containing stiffener comprising an interior surface and an exterior surface, and said fiber-containing stiffener interior surface located proximate to the exterior surface of the first layer;
a cavity between the exterior surface of the first layer and the interior surface of the fiber-containing stiffener, said cavity comprising a predetermined amount of a resin-containing material, said resin-containing material comprising nanoparticles and a catalyst; and
locating the aircraft component at a predetermined location on the aircraft; activating at least a portion of the catalyst in the resin-containing material; and curing the resin-containing material.

10. A material comprising:
a first layer, said first layer comprising a three-dimensional textile composite material, said three-dimensional textile composite material comprising an interior surface and an exterior surface; and
at least one fiber-containing stiffener, said fiber-containing stiffener comprising a three-dimensional textile composite material, and said fiber-containing stiffener comprising an interior surface and an exterior surface;
wherein the fiber-containing stiffener is located proximate to the exterior surface of the first layer;
wherein, at least a portion of the interior surface of the fiber-containing stiffener contacts the exterior surface of the first layer to form a boundary of a cavity; and
wherein the cavity comprises a predetermined amount of a resin-containing material, said resin-containing material comprising nanoparticles and a catalyst.

11. The material of claim 10 , wherein at least one of the first layer and the fiber-containing stiffener has a domed configuration.

12. The material of claim 10 , wherein the fiber-containing stiffener is joined to the exterior surface of the first layer.

13. The material of claim 10 , wherein a plurality of fiber-containing stiffeners is joined to the exterior of the first layer by thermo-stamping the fiber-containing stiffener to the first layer.

14. The material of claim 10 , wherein the three-dimensional textile composite material comprises a thermoplastic material.

15. The material of claim 14 , wherein the thermoplastic material comprises poly(p-phenyl sulfide); polyethylenimine; polyetherketone ketone; polyetherether ketone, or combinations thereof.

Assignees

• Boeing Co

Inventors

• Ashmawi Waeil M
• Apdalhaliem Sahrudine

Classifications

• B01J35/06

  Operations & Transport · mapped topic

• B29C65/54

  between pre-assembled parts · CPC title

• B29L2031/3082

  Fuselages · CPC title

• B01J31/06

  containing polymers {(organometallic polymers B01J31/123; polymer-bound organometallic complexes B01J31/165; coordination polymers B01J31/1691)} · CPC title

• B29K2713/00

  Use of textile products or fabrics for preformed parts, e.g. for inserts (B29K2105/06 takes precedence) · CPC title