# US 2022/0194629 A1 · Systems and Methods for Thrust Reverser Corrosion Damage Repair

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 2022/0194629 A1
- Document ID: US20220194629A1
- Status: Published application
- Kind: A1
- Application number: 17/500,119
- Filed: 2021-10-13
- Published: 2022-06-23
- Earliest claimed: 2020-12-23
- Assignees: Nextant Aerospace
- Applicants: Nextant Aerospace
- Inventors: Mark O'Donnell
- Web page: https://patentgrep.com/patent/US20220194629A1

## CPC

- B64F 5/40: Maintaining or repairing aircraft
- B23P 6/00: Restoring or reconditioning objects (straightening or restoring form of sheet metal, metal rods, metal tubes, metal profiles, or specific articles made therefrom B21D1/00, B21D3/00; repairing defective or damaged objects by casting techniques B22D19/10)
- B23P 6/04: Repairing fractures or cracked metal parts or products, e.g. castings
- F05B 2230/80: Repairing, retrofitting or upgrading methods
- F05D 2230/80: Repairing, retrofitting or upgrading methods
- Y10T 29/49318: Repairing or disassembling
- B64F: GROUND OR AIRCRAFT-CARRIER-DECK INSTALLATIONS SPECIALLY ADAPTED FOR USE IN CONNECTION WITH AIRCRAFT; DESIGNING, MANUFACTURING, ASSEMBLING, CLEANING, MAINTAINING OR REPAIRING AIRCRAFT, NOT OTHERWISE PROVIDED FOR; HANDLING, TRANSPORTING, TESTING OR INSPECTING AIRCRAFT COMPONENTS, NOT OTHERWISE PROVIDED FOR
- B23P: METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS (arrangements for copying or controlling B23Q)
- F05B: INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
- F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

Systems and methods for repairing corrosion damage of a part of a thrust reverser assembly. The method includes removing the part having an inner surface and an outer surface. The method also includes removing an outer skin from the inner surface and the outer surface of the part. The method further includes installing a ply of synthetic fiber material onto an area of the inner surface or the outer surface of the part. The method also includes installing one or more doublers onto the ply of synthetic fiber material and heat curing layers of film adhesive. The method further includes applying an edge seal to gaps between the one or more doublers and the inner surface or outer surface of the part. The method also includes installing the outer skin to the inner surface and the outer surface of the part and installing the part to the thrust reverser assembly.

## Claims

### Claim 1

A method for repairing corrosion damage of a part of a thrust reverser assembly, the part comprising an inner surface and an outer surface, the method comprising:
removing an outer skin from the inner surface and the outer surface of the part;
installing a ply of synthetic fiber material onto an area of the inner surface or the outer surface of the part, wherein the area comprises corrosion damage,
wherein the ply of synthetic fiber material is sandwiched between a layer of film adhesive on each side of the ply of synthetic fiber material;
installing one or more doublers onto the ply of synthetic fiber material;
heat curing the layers of film adhesive;
applying an edge seal to a plurality of gaps between the one or more doublers and the inner surface or outer surface of the part; and
installing the outer skin to the inner surface and the outer surface of the part.

### Claim 2 (depends on 1)

The method of claim 1, wherein the part is one of an upper door assembly or a lower door assembly.

### Claim 3 (depends on 1)

The method of claim 1, further comprising:
removing the part of the thrust reverser assembly prior to removing the outer skin; and
installing the part to the thrust reverser assembly after installing the outer skin.

### Claim 4 (depends on 1)

The method of claim 1, wherein the one or more doublers are installed using rivets.

### Claim 5 (depends on 1)

The method of claim 1, wherein heat curing the layers of film adhesive comprises:
ramping up a temperature of the film adhesive up to 250 degrees F.;
dwelling at the temperature of 250 degrees F. for an hour;
ramping down the temperature of the film adhesive to a room temperature.

### Claim 6 (depends on 1)

The method of claim 1, wherein the edge seal comprises a resin.

### Claim 7 (depends on 6)

The method of claim 6, further comprising heat curing the edge seal resin.

### Claim 8 (depends on 7)

The method of claim 7, further comprising sanding an excess of edge seal resin.

### Claim 9 (depends on 1)

The method of claim 1, further comprising painting a topcoat to the inner surface and the outer surface of the part.

### Claim 10 (depends on 1)

The method of claim 1, further comprising:
clamping the one or more doublers onto the part;
identifying a plurality of locations for doubler holes; and
reaming the plurality of locations for doubler holes.