Below water-line hull repair system using composite patch heated by ferromagnetic heating device

A water vessel repair system, the water vessel repair system comprising:

• a patch assembly comprising (i) a first flexible outer layer, (ii) a second flexible outer layer and (iii) an inner layer of composite material sealed between the first flexible outer layer and the second flexible outer layer;
• wherein the first flexible outer layer and the second flexible outer layer are joined together at a perimeter region of the patch assembly;
• wherein, when the inner layer is heated and then cures, the composite material transforms from an uncured state, where the inner layer is flexible, to a cured state, where the inner layer has a fixed shape;
• an electric heating element disposed between the inner layer and the first flexible outer layer, wherein, when the electric heating element is electrically operated, the electric heating element generates heat at the inner layer;
• wherein, with the composite material in the uncured state, and with the patch assembly positioned at a damaged area of a hull of a water vessel, an outer surface of the patch assembly engages the hull at and around the damaged area and the inner layer flexes to conform to a shape of the hull;
• wherein, with the patch assembly engaging the hull, and with the inner layer flexed to conform to the shape of the hull, electrically operating the electric heating element heats the inner layer, and wherein, after the electric heating element heats the inner layer and the inner layer cures, the composite material is in the cured state, where the inner layer has the fixed shape that is conformed to the shape of the hull;
• and
• wherein, with the fixed shape of the inner layer conformed to the shape of the hull, and with the inner layer removed from between the first flexible outer layer and the second flexible outer layer, the inner layer is configured to be attached to the hull at and around the damaged area.

A method for repairing a damaged water vessel, the method comprising:

• providing a patch assembly comprising (i) a first flexible outer layer, (ii) a second flexible outer layer and (iii) an inner layer of composite material sealed between the first flexible outer layer and the second flexible outer layer;
• wherein the first flexible outer layer and the second flexible outer layer are joined together at a perimeter region of the patch assembly;
• wherein, when the inner layer is heated and then cures, the composite material transforms from an uncured state, where the inner layer is flexible, to a cured state, where a shape of the inner layer is fixed;
• wherein a first ferromagnetic heating element is disposed between the inner layer and the first flexible outer layer and a second ferromagnetic heating element is disposed between the inner layer and the second flexible outer layer, and wherein, when the first ferromagnetic heating element and the second ferromagnetic heating element are electrically operated, the first ferromagnetic heating element and the second ferromagnetic heating element generate heat at the inner layer;
• wherein a first vacuum membrane is disposed between the first ferromagnetic heating element and the first flexible outer layer and a second vacuum membrane is disposed between the second ferromagnetic heating element and the second flexible outer layer, and wherein the first vacuum membrane and the second vacuum membrane apply vacuum pressure between the inner layer and the first ferromagnetic heating element and the second ferromagnetic heating element;
• wherein the first ferromagnetic heating element and the second ferromagnetic heating element each comprise an electrically conductive material and a ferromagnetic material, and wherein, when the first ferromagnetic heating element and the second ferromagnetic heating element are electrically operated, the electrically conductive materials are electrically charged to create a magnetic field at the respective ferromagnetic heating elements and the respective ferromagnetic materials generate heat responsive to the created magnetic fields;
• with the composite material in the uncured state, positioning the patch assembly at a damaged area of a hull of a water vessel so that an outer surface of the patch assembly engages the hull at and around the damaged area and the inner layer flexes to conform to a shape of the hull, and wherein the damaged area of the hull is at least partially submerged under water;
• with the patch assembly engaging the hull and with the inner layer flexed to conform to the shape of the hull, electrically operating the first ferromagnetic heating element and the second ferromagnetic heating element to heat the inner layer, wherein, after the first ferromagnetic heating element and the second ferromagnetic heating element heat the inner layer and the inner layer cures, the composite material is in the cured state, where the shape of the inner layer is fixed relative to the shape of the hull;
• and
• with the shape of the inner layer fixed relative to the shape of the hull, attaching the inner layer to the hull at and around the damaged area.