# US 11,898,062 B2 · Method for repairing surface defect with a fast curing patch > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,898,062 B2 - Document ID: US11898062B2 - Status: Granted - Kind: B2 - Application number: 17/466,149 - Filed: 2021-09-03 - Published: 2022-03-10 - Granted: 2024-02-13 - Earliest claimed: 2020-09-09 - Assignees: Illinois Tool Works Inc. - Applicants: Illinois Tool Works Inc. - Inventors: Mehdi Habibpour; Matt James Lertola; Carlton G. Seaboldt; Grant Shouldice - Web page: https://patentgrep.com/patent/US11898062B2 ## CPC - C09D 7/70: {characterised by shape, e.g. fibres, flakes or microspheres} - B29B 11/14: characterised by structure or composition - B29C 49/071: {Preforms or parisons characterised by their configuration, e.g. geometry, dimensions or physical properties} - B29C 73/06: using plugs sealing in the hole - B29C 73/10: using patches sealing on the surface of the article (B29C73/14 takes precedence) - B33Y 10/00: Processes of additive manufacturing - B33Y 80/00: Products made by additive manufacturing - C08L 67/06: Unsaturated polyesters - C09D 5/002: {Priming paints (C09D5/08 takes precedence)} - C09D 7/61: inorganic - C09D 167/00: Coating compositions based on polyesters obtained by reactions forming a carboxylic ester link in the main chain (based on polyester-amides C09D177/12; based on polyester-imides C09D179/08); Coating compositions based on derivatives of such polymers - B29C 35/0805: {using electromagnetic radiation} - B29C 2035/0827: {using UV radiation} - B29C 2035/0833: {using actinic light} - B29C 2073/262: {for polishing, roughening, buffing or sanding the area to be repaired} - B29C 2949/0715: the preform having one end closed - C08K 2003/265: {Calcium, strontium or barium carbonate} - C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D) - B29B: PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06) - C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09) ## Abstract A method of repairing a surface defect with a patch is provided. A fibrous substrate is impregnated with a formulation that includes a polyester resin, a crosslinking agent, a solvent, and a particulate filler. The fibrous substrate is contacted with the surface defect. The formulation is exposed to actinic radiation to induce cure of the formulation to form the patch to repair the surface defect. A kit is also provided that includes a bottle containing the formulation. A sheet of fibrous support material is also provided that is adapted to receive the formulation therethrough. Instructions for repairing a surface defect by the aforementioned method are also provided as part of the kit. 3D printing of an article to fit in the surface defect is also disclosed. ## Claims ### Claim 1 A method of repairing a surface defect in a substrate with a patch comprising: impregnating a fibrous support with an uncured formulation comprising: a polyester resin, a crosslinking agent, a solvent, and a particulate filler, the uncured formulation having a viscosity sufficient to impregnate the fibrous support while also being retained on the fibrous support to form a matrix surrounding the fibrous support; contacting the fibrous support with the surface defect; placing an article into the surface defect to underlie the fibrous support prior to the contacting; and exposing the uncured formulation to actinic radiation to induce cure of the formulation to form the patch to repair the surface defect. ### Claim 2 (depends on 1) The method of claim 1 further comprising sanding the patch to form a smooth surface. ### Claim 3 (depends on 2) The method of claim 2 further comprising applying an overlayer of a primer or paint on the smooth surface. ### Claim 4 (depends on 1) The method of claim 1 wherein the actinic radiation is emission from an ultraviolet light emitting diode. ### Claim 5 (depends on 1) The method of claim 1 wherein the uncured formulation has a viscosity of between 4,000 and 28,000 Centistokes at standard temperature and pressure. ### Claim 6 (depends on 1) The method of claim 1 wherein the exposing is from 1 to 5 minutes. ### Claim 7 (depends on 1) The method of claim 1 wherein the fibrous support is fiberglass, carbon, polyester, aramid, nylon, natural fibers, or a combination thereof. ### Claim 8 (depends on 1) The method of claim 1 wherein the particulate filler comprises microspheroids having a longest linear dimension of between 20 and 100 microns. ### Claim 9 (depends on 1) The method of claim 1 wherein the particulate filler comprises talc. ### Claim 10 (depends on 1) The method of claim 1 further comprising applying a dent puller fastener or suction to the article to remove a dent from the substrate after the exposing. ### Claim 11 (depends on 1) The method of claim 1 wherein the article is formed by scanning the surface defect to create scan data and three dimensional printing the article based on the scan data. ### Claim 12 (depends on 1) The method of claim 1 wherein the impregnating is done with a three dimensional printer. ### Claim 13 (depends on 1) A kit comprising: a bottle containing a formulation comprising: a polyester resin, a crosslinking agent, a solvent, and a particulate filler; a sheet of fibrous support material; and instructions for repairing the surface defect by the method of claim 1. ### Claim 14 (depends on 13) The kit of claim 13 further comprising a light emitting diode light source emitting ultraviolet wavelengths upon being energized. ### Claim 15 (depends on 13) The kit of claim 13 further comprising a three dimensional printer or instructions how to form the article complementary to the surface defect. ### Claim 16 A method of repairing a surface defect in a substrate with a patch comprising: impregnating a fibrous support with a formulation comprising: a polyester resin, a crosslinking agent, a solvent, and a particulate filler; contacting the fibrous support with the surface defect; placing an article into the surface defect to underlie the fibrous support prior to the contacting; and exposing the formulation to actinic radiation to induce cure of the formulation to form the patch to repair the surface defect. ### Claim 17 A method of repairing a surface defect in a substrate with a patch comprising: impregnating a fibrous support with a formulation comprising: a polyester resin, a crosslinking agent, a solvent, and a particulate filler; contacting the fibrous support with the surface defect; and exposing the formulation to actinic radiation to induce cure of the formulation to form the patch to repair the surface defect; wherein the impregnating is done with a three dimensional printer.