Installation tool and associated method for applying a patch to a surface

Patent metadata

Field	Value
Publication number	US-2016136941-A1
Application number	US-201414547643-A
Country	US
Kind code	A1
Filing date	Nov 19, 2014
Priority date	Nov 19, 2014
Publication date	May 19, 2016
Grant date	—

Abstract

An installation tool and method are provided to apply a patch to a structure while controlling the porosity in the bond line. An installation tool is provided that includes a frame defining an internal cavity. The installation tool also includes a flexible membrane that divides the internal cavity into a first chamber proximate the surface and a second chamber separated from the surface by the first chamber and the flexible membrane. The flexible membrane is releasably attached to the patch such that the patch faces the surface. The frame includes first and second vacuum ports into the first and second chambers, respectively, such that pressure therewithin is separately controllable. The pressure within the first and second chambers is controlled such that the adhesive is degassed while the patch remains spaced from the surface and the flexible membrane is thereafter caused to be stretched to urge the patch toward the surface.

First claim

That which is claimed:

1 . An installation tool configured to apply a patch to a surface, the installation tool comprising:
a frame defining an internal cavity; and a flexible membrane coupled to the frame to divide the internal cavity into a first chamber proximate the surface and a second chamber separated from the surface by the first chamber and the flexible membrane, wherein the flexible membrane is configured to be releasably attached to the patch such that the patch faces the surface, wherein the frame defines first and second vacuum ports into the first and chambers, respectively, such that pressures within the first and second chambers are separately controllable.

2 . An installation tool according to claim 1 further comprising a heat blanket supported by the flexible membrane, wherein the flexible membrane comprises first and second surfaces facing the first and second chambers, respectively, and wherein the first surface of the flexible membrane is releasably attached to the patch and the second surface of the flexible membrane supports the heat blanket.

3 . An installation tool according to claim 1 wherein the flexible membrane comprises a vacuum bag.

4 . An installation tool according to claim 3 wherein the vacuum bag is comprised of an elastomeric silicone material.

5 . An installation tool according to claim 1 further comprising a boot coupled to the frame and configured to conform to a contour of the surface.

6 . An installation tool according to claim 1 further comprising a cover coupled to the frame opposite the surface relative to the flexible membrane.

7 . An installation tool according to claim 6 wherein the cover is at least partially translucent.

8 . A system configured to apply a patch to a surface, the system comprising:
a frame defining an internal cavity; a flexible membrane coupled to the frame to divide the internal cavity into a first chamber proximate the surface and a second chamber separated from the surface by the first chamber and the flexible membrane, wherein the flexible membrane is configured to be releasably attached to the patch that is coated with an adhesive that faces the surface; and a vacuum source in fluid communication with the first and second chambers, wherein the vacuum source is configured to separately control the pressures within the first and second chambers such that the adhesive is degassed while the patch remains spaced from the surface and the flexible membrane is thereafter caused to be stretched such that the patch is urged toward the surface.

9 . A system according to claim 8 wherein the vacuum source is further configured to separately control the pressures within the first and second chambers to draw a vacuum in both the first and second chambers to degas the adhesive.

10 . A system according to claim 9 wherein the vacuum source is further configured to separately control the pressures within the first and second chambers to continue to draw the vacuum in the first chamber while permitting the pressure within the second chamber to be greater than the pressure within the first chamber, thereby causing the flexible membrane to be stretched such that the patch is urged toward the surface and the adhesive is brought into contact with the surface.

11 . A system according to claim 10 wherein the vacuum source is configured to permit the pressure within the second chamber to be greater than the pressure within the first chamber by evacuating the second chamber to atmosphere.

12 . A system according to claim 8 further comprising a heat blanket supported by the flexible membrane, wherein the flexible membrane comprises first and second surfaces facing the first and second chambers, respectively, and wherein the first surface of the flexible membrane is releasably attached to the patch and the second surface of the flexible membrane supports the heat blanket.

13 . An installation tool according to claim 8 wherein the flexible membrane comprises a vacuum bag.

14 . A method of applying a patch to a surface, the method comprising:
dividing an internal cavity within a frame into first and second chambers with a flexible membrane, wherein the first chamber is proximate the surface and the second chamber is separated from the surface by the first chamber and the flexible membrane; releasably attaching the patch to the flexible membrane such that the patch faces the surface, wherein the patch is coated with an adhesive that faces the surface; and controlling pressures within the first and second chambers such that the adhesive is degassed while the patch remains spaced from the surface and the flexible membrane is thereafter caused to be stretched such that the patch is urged toward the surface.

15 . A method according to claim 14 wherein controlling the pressures comprises drawing a vacuum in both the first and second chambers to degas the adhesive.

16 . A method according to claim 15 further comprising heating the adhesive while a vacuum is drawn in both the first and second chambers and the patch remains spaced from the surface to degas the adhesive.

17 . A method according to claim 15 wherein controlling the pressures further comprises continuing to draw the vacuum in the first chamber while permitting the pressure within the second chamber to be greater than the pressure within the first chamber, thereby causing the flexible membrane to be stretched such that the patch is urged toward the surface and the adhesive is brought into contact with the surface.

18 . A method according to claim 17 wherein permitting the pressure within the second chamber to be greater than the pressure within the first chamber comprises evacuating the second chamber to atmosphere.

19 . A method according to claim 14 further comprising heating the adhesive while the patch is urged toward the surface and the adhesive is in contact with the surface.

20 . A method according to claim 19 wherein the adhesive is cured as a result of the heating of the adhesive while the adhesive is in contact with the surface, and wherein controlling the pressures comprises releasing the pressure within the first chamber such that the first chamber is evacuated to atmosphere after the adhesive has cured.

Assignees

• Boeing Co

Inventors

• Perron Daniel J
• Evens Michael W
• Olberg Jeffrey H

Classifications

• B32B2038/0028

  Stretching, elongating · CPC title

• B32B37/1018

  using only vacuum · CPC title

• B32B38/1858 Primary

  using vacuum · CPC title

• B29C73/12

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

• B30B5/02

  wherein the pressing means is in the form of a flexible element, e.g. diaphragm, urged by fluid pressure · CPC title