System and method for repairing a composite structure
AssigneeTextron Innovations Inc.
InventorsSuvankar Mishra, Vance Newton Cribb, III
Life of this patent
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Abstract
A method of repairing a composite structure includes providing an assembled composite structure comprising a substantially rigid outer component, wherein the composite structure comprises a void space at least partially bounded by the outer component. The method further includes forming an injection hole through the outer component to provide a path between the void space and space external to the composite structure. The method further includes injecting foam into the void space through the injection hole while the foam is in a substantially unexpanded state and expanding the foam within the void space.
Claims21
A method of repairing a composite structure, comprising:
- providing an assembled composite structure comprising a first outer component, a second outer component, and a void space between the first outer component and the second outer component;
- forming an injection hole through the first outer component to provide a path between the void space and space external to the composite structure;
- injecting foam into the void space through the injection hole while the foam is in a substantially unexpanded state;
- and
- expanding the foam within the void space, wherein upon expansion, the foam contacts an expanded adhesive that is disposed between a spar and the void space.
A method of repairing a rotor blade, comprising:
- providing a rotor blade comprising a void space between a spar of the rotor blade and a honeycomb structure of the rotor blade, the void space extending from an upper skin of the rotor blade to a lower skin of the rotor blade;
- forming an injection hole through at least one of the upper skin and the lower skin;
- and
- injecting foam into the void space via the injection hole;
- wherein an expanded adhesive is disposed between the spar and the void space.
A method of repairing a composite structure, comprising:
- providing an assembled composite structure comprising a first outer component, a second outer component, and a void space between the first outer component and the second outer component;
- forming an injection hole through the first outer component to provide a path between the void space and space external to the composite structure;
- injecting foam into the void space through the injection hole while the foam is in a substantially unexpanded state;
- expanding the foam within the void space, wherein upon expansion, the foam at least one of (1) contacts an innermost wall of at least one of the first outer component and second outer component and (2) contacts an expanded adhesive that is disposed between a spar and the void space;
- prior to forming the injection hole, performing a nondestructive evaluation of the composite structure to identify the void space;
- applying masking tape to the composite structure around an area of the first outer component identified as being associated with the identified void space;
- vacuum cleaning the void space;
- and
- removing paint from the area of the first outer component;
- wherein the forming the injection hole is conducted after applying the masking tape.
Dependencies are inferred from the claim text.