# US 2013/0152389 A1 · Rotor blade repair structure and method > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2013/0152389 A1 - Document ID: US20130152389A1 - Status: Published application - Kind: A1 - Application number: 13/328,361 - Filed: 2011-12-16 - Published: 2013-06-20 - Earliest claimed: 2011-12-16 - Assignees: Sikorsky Aircraft Corporation - Inventors: Marcus D. Cappelli; Wonsub Kim; Joshua Mancher - Web page: https://patentgrep.com/patent/US20130152389A1 ## CPC - B29C 73/10: using patches sealing on the surface of the article (B29C73/14 takes precedence) - Y10T 29/49318: Repairing or disassembling - Y10T 29/49732: by attaching repair preform, e.g., remaking, restoring, or patching - Y10T 29/49734: and removing damaged material - 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) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A method of repairing a damaged portion of a rotor blade includes filling the damaged portion with a filler material. A pre-cured patch assembly is applied over the damaged portion, the patch assembly including one or more laminate packs positionable at least one of an upper rotor blade surface and a lower rotor blade surface and one or more overwrap plies positionable over the upper rotor blade surface and the lower blade surface. A repair structure for a damaged portion of a rotor blade includes a volume of fill material disposed at the damaged portion. ## Claims ### Claim 1 A method of repairing a damaged portion of a rotor blade comprising: filling the damaged portion with a filler material; and applying a patch assembly over the damaged portion, the patch assembly including: a precured laminate pack positionable at least one of an upper rotor blade surface and a lower rotor blade surface; and one or more precured overwrap plies positionable over the upper rotor blade surface and the lower blade surface. ### Claim 2 (depends on 1) The method of claim 1, further comprising removing material from the damaged portion. ### Claim 3 (depends on 2) The method of claim 2, wherein the material is removed from the damaged portion in a segmented arc shape. ### Claim 4 (depends on 1) The method of claim 1, wherein the filler material comprises a mixture of adhesive and one of a fiberglass powder or whisker. ### Claim 5 (depends on 1) The method of claim 1, wherein the laminate pack comprises a plurality of plies. ### Claim 6 (depends on 5) The method of claim 5, wherein the plurality of plies comprise plies of two or more materials. ### Claim 7 (depends on 6) The method of claim 6, wherein the two or more materials include woven fiber glass/epoxy prepreg fabric, Kevlar or carbon fiber tape. ### Claim 8 (depends on 1) The method of claim 1, wherein the one or more overwrap plies comprise one or more plies of woven fiber glass/epoxy prepreg, Kevlar, or carbon fiber tape. ### Claim 9 (depends on 1) The method of claim 1, further comprising affixing the patch assembly to the rotor blade via adhesive. ### Claim 10 (depends on 1) The method of claim 1, wherein the damaged portion is at a trailing edge of the rotor blade. ### Claim 11 (depends on 10) The method of claim 10, further comprising conforming the patch assembly over the trailing edge. ### Claim 12 (depends on 1) The method of claim 1, further comprising installing the patch assembly as a unitary element. ### Claim 13 A repair structure for a damaged portion of a rotor blade comprising: a volume of fill material disposed at the damaged portion; one or more precured laminate packs located over the fill material at least one of an upper rotor blade surface and a lower rotor blade surface; and one or more precured overwrap plies affixed over the precured laminate pack over the upper rotor blade surface and the lower blade surface. ### Claim 14 (depends on 13) The repair structure of claim 13, wherein the fill material comprises a mixture of adhesive and one of a fiberglass powder or whisker. ### Claim 15 (depends on 13) The repair structure of claim 13, wherein the one or more laminate packs comprises a plurality of plies. ### Claim 16 (depends on 15) The repair structure of claim 15, wherein the plurality of plies comprise plies of two or more materials. ### Claim 17 (depends on 13) The repair structure of claim 13, wherein the one or more laminate packs are disposed at both the upper rotor blade surface and the lower rotor blade surface. ### Claim 18 (depends on 13) The repair structure of claim 13, wherein the one or more overwrap plies are affixed to the rotor blade via adhesive. ### Claim 19 (depends on 13) The repair structure of claim 13, wherein the damaged portion is at a trailing edge of the rotor blade. ### Claim 20 (depends on 13) The repair structure of claim 13, wherein the one or more overwrap plies are wrapped over the trailing edge. ### Claim 21 (depends on 13) The repair structure of claim 13, further comprising one or more underwrap plies located between the one or more laminate packs and at least one of an upper rotor blade surface and a lower rotor blade surface. ### Claim 22 (depends on 13) The repair structure of claim 13, wherein at least a portion of damaged material is removed from the rotor blade. ### Claim 23 (depends on 22) The method of claim 22, wherein the damaged material is removed in a segmented-arc shape.