Thermal composite material repair utilizing vacuum compression

Patent metadata

Field	Value
Publication number	US-10189218-B2
Application number	US-201615132614-A
Country	US
Kind code	B2
Filing date	Apr 19, 2016
Priority date	Apr 19, 2016
Publication date	Jan 29, 2019
Grant date	Jan 29, 2019

Abstract

Thermal curing of a potting material within a hole in a surface of a composite material is described utilizing a flexible vacuum compression device that includes a chemical-based heating pack. The vacuum compression device includes an internal compartment within a cavity that retains the chemical-based heating pack, and a vacuum port having a passage into the cavity. An end of the vacuum compression device includes an interface that forms an air-tight seal between the cavity and the surface when applied to a surface of the composite material. Drawing a vacuum via the vacuum port collapses the vacuum compression device and positions the chemical-based heating pack proximate to the surface, enabling heat from the chemical-based heating pack to thermally cure the potting material.

First claim

The invention claimed is:

1. An apparatus comprising:
a flexible vacuum compression device for thermally curing a potting material within a hole in a surface of a composite material, the flexible vacuum compression device including:
a first end that is closed;
a second end opposite the first end that is open to form a cavity between the first end and the second end, wherein the second end includes an interface that is configured to generate an air tight seal when applied to the surface;
a partition, which extends from and is connected to a side wall of the flexible vacuum compression device, that traverses at least partially across the cavity to form a compartment within the cavity; and
a vacuum port having a passage through the first end and into the cavity;

a breathable insulator disposed within the compartment; and
a chemical-based heating pack disposed between the breathable insulator and the partition;
wherein a bottom surface of the partition includes a breathable pattern that, upon application of a vacuum source to the vacuum port, draws a vacuum within the cavity to cause the cavity to collapse and press the chemical-based heating pack and the partition proximate to the surface to thermally cure the potting material.

2. The apparatus of claim 1 wherein:
at least one of the breathable insulator and the chemical-based heating pack are removable from the compartment.

3. The apparatus of claim 1 wherein:
the partition is thermally conductive to allow a heat transfer from the chemical-based heating pack to the potting material.

4. The apparatus of claim 1 wherein:
the flexible vacuum compression device is formed from silicone rubber.

5. The apparatus of claim 1 further comprising:
a removable release film disposed between the partition and the surface of the composite material.

6. The apparatus of claim 5 wherein:
the removable release film comprises Fluorinated Ethylene Propylene (FEP).

7. The apparatus of claim 1 wherein:
an exothermic material utilized for the chemical-based heating pack is selected to reach a target temperature of approximately 200 degrees Fahrenheit.

8. The apparatus of claim 1 wherein:
the breathable pattern comprises a pattern of holes that allow a vacuum to be drawn within the cavity to cause the chemical-based heating pack and the partition to be pressed towards and proximate to the surface to thermally cure the potting material.

9. The apparatus of claim 1 further comprising:
a vacuum seal disposed on a back surface of the composite material proximate to the hole that is configured to form an air tight seal.

10. An apparatus comprising:
a flexible vacuum compression device, having a cavity, for thermally curing a potting material within a hole in a surface of a composite material, the flexible vacuum compression device including:
a partition, which extends from and is connected to a side wall of the flexible vacuum compression device, that is thermally conductive and traverses across a portion of the cavity to form an internal compartment within the cavity;
a vacuum port having a passage into the cavity; and
an interface proximate to the partition that is configured to generate an air-tight seal between the cavity and the surface;

a removable breathable insulator within the interior compartment;
a removable chemical-based heating pack between the breathable insulator and the partition;
wherein a bottom surface of the partition that is proximate to the surface includes a grid pattern that, upon application of a vacuum source to the vacuum port, draws a vacuum within the cavity to deflate the cavity and press the removable chemical-based heating pack and the partition proximate to the hole to thermally cure the potting material.

11. The apparatus of claim 10 wherein:
the flexible vacuum compression device is formed from silicone rubber.

12. The apparatus of claim 10 further comprising:
a removable release film disposed between the partition and the surface of the composite material.

13. The apparatus of claim 12 wherein:
the removable release film comprises Fluorinated Ethylene Propylene (FEP).

14. The apparatus of claim 10 wherein:
an exothermic material utilized for the removable chemical-based heating pack is selected to reach a target temperature of approximately 200 degrees Fahrenheit.

15. The apparatus of claim 10 further comprising:
a vacuum seal disposed on a back surface of the composite material proximate to the hole that is configured to form an air tight seal.

16. A method for thermally curing a potting material within a hole in a surface of a composite material, the method comprising:
providing the apparatus of claim 1 , the partition being thermally conductive and the compartment being located between the first end of the flexible vacuum compression device and the partition;
positioning the flexible vacuum compression device over the potting material such that the interface generates an air-tight seal between the cavity of the flexible vacuum compression device and the surface;
activating the chemical-based heating pack, the chemical-based heating pack being located in the compartment and between the breathable insulator and the partition; and
drawing a vacuum within the cavity of the flexible vacuum compression device via the vacuum port to cause the cavity to collapse and press the chemical-based heating pack and the partition proximate to the surface to thermally cure the potting material.

17. The method of claim 16 wherein:
the partition is thermally conductive to allow a heat transfer from the chemical-based heating pack to the potting material.

18. The method of claim 16 wherein:
the flexible vacuum compression device is formed from silicone rubber.

19. The method of claim 16 further comprising:
applying a removable release film to the surface prior to positioning the flexible vacuum compression device.

20. The method of claim 19 wherein:
the removable release film comprises Fluorinated Ethylene Propylene (FEP).

21. The method of claim 16 wherein:
an exothermic material utilized for the chemical-based heating pack is selected to reach a target temperature of approximately 200 degrees Fahrenheit upon activation.

22. The method of claim 16 further comprising:
applying a vacuum seal on a back surface of the composite material proximate to the hole to form an air tight seal.

Assignees

• Boeing Co

Inventors

• Zhu Alex

Classifications

• B29C37/0075

  using release sheets · CPC title

• B29C73/12

  Apparatus therefor, e.g. for applying (B29C73/30 takes precedence) · CPC title

• B29C33/68

  Release sheets · CPC title

• B29K2827/12

  containing fluorine · CPC title

• B29C2043/3657

  additional materials, e.g. permeable bleeder or breather sheets, cloths, blankets · CPC title