# US 9,434,139 B2 · Structural integrated repair method and system tool device for repairing delaminated composite structures > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,434,139 B2 - Document ID: US9434139B2 - Status: Granted - Kind: B2 - Application number: 14/267,052 - Filed: 2014-05-01 - Published: 2015-11-05 - Granted: 2016-09-06 - Earliest claimed: 2014-05-01 - Assignees: The Boeing Company - Applicants: The Boeing Company - Inventors: Eugene Dan-Jumbo - Web page: https://patentgrep.com/patent/US9434139B2 ## CPC - B32B 37/0023: {around holes, apertures or channels present in at least one layer} - B29C 70/443: {and impregnating by vacuum or injection} - B29C 70/545: {Perforating, cutting or machining during or after moulding} - B29C 70/546: {Measures for feeding or distributing the matrix material in the reinforcing structure} - B29C 73/025: {fed under pressure} - B29C 73/14: using elements composed of two parts joined together after having been placed one on each side of the article - B29C 65/48: using adhesives {, i.e. using supplementary joining material; solvent bonding} - B29C 65/542: {by injection} - B29C 65/544: {by suction} - B29C 66/71: {characterised by the composition of the plastics material of the parts to be joined (welding bar compositions B29C65/125)} - B29C 73/30: for local pressing or local heating - B29C 2793/0045: Perforating - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - 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) ## Abstract A system for repair of damaged holes in composite structures incorporates a repair system tool device having a sleeve sized to be closely received in a hole in a composite structure. The sleeve has a central bore for receiving parent resin and an array of orifices for radial expulsion of the parent resin into the hole. A caul plate seals the central bore and a vacuum bag covering the caul plate is sealed to the surface of the composite structure. Introduction of vacuum in the vacuum bag provides a differential pressure for infusion of resin from the orifices in the sleeve into delaminations extending from the hole. ## Claims ### Claim 1 A system for repair of damaged holes in composite structures, said system comprising: a repair system tool device having a sleeve sized to be closely received in a hole in a composite structure, said sleeve having a central bore for receiving parent resin and a selected array of orifices for radial expulsion of the parent resin into adjacent delaminations in the hole; a caul plate sealing the central bore; a vacuum bag covering the caul plate and sealed to a surface of the composite structure, wherein introduction of vacuum in the vacuum bag provides a differential pressure for infusion of resin from the orifices in the sleeve into delaminations extending from the hole. ### Claim 2 (depends on 1) The system for repair of damaged holes in composite structures as defined in claim 1 wherein the repair system tool device further comprises an upper flange from which the sleeve extends. ### Claim 3 (depends on 2) The system for repair of damaged holes in composite structures as defined in claim 2 further comprising a seal received around the sleeve adjacent the upper flange, said seal engaging a top surface of the structure around the hole. ### Claim 4 (depends on 3) The system for repair of damaged holes in composite structures as defined in claim 3 wherein the central bore of the sleeve is sealed opposite the upper flange. ### Claim 5 (depends on 3) The system for repair of damaged holes in composite structures as defined in claim 3 further comprising a lower flange engaging the sleeve opposite the upper flange and a seal received around the sleeve adjacent the lower flange, said seal engaging a bottom surface of the structure around the hole. ### Claim 6 (depends on 5) The system for repair of damaged holes in composite structures as defined in claim 5 wherein the sleeve incorporates a threaded end received in a mating threaded bore in the lower flange. ### Claim 7 (depends on 1) The system for repair of damaged holes in composite structures as defined in claim 1 wherein each of the orifices in the array of orifices has a diameter of between 0.01 and 0.1 inch. ### Claim 8 (depends on 1) The system for repair of damaged holes in composite structures as defined in claim 1 wherein the sleeve is titanium. ### Claim 9 (depends on 1) The system for repair of damaged holes in composite structures as defined in claim 1 wherein tubes are inserted in orifices in the selected array, said tubes extending beyond an outer surface of the sleeve. ### Claim 10 (depends on 1) The system for repair of damaged holes in composite structures as defined in claim 1 wherein plugs are inserted in orifices other than the selected array. ### Claim 11 A method for repair of damage holes in composite structures, the method comprising: conducting a non-destructive evaluation of a structural composite delaminated hole to assess damage; inserting a repair system tool device sleeve having a plurality of orifices into the damaged delaminated hole; introducing a predetermined amount of parent toughed resin into the sleeve of the repair system tool device through a central bore in the sleeve; installing a caul plate and bagging for application of vacuum; applying vacuum on the bag to urge the caul plate into sealing contact with a top flange maintaining substantially atmospheric pressure in the sleeve while placing a laminate around the hole under vacuum for diffusion of the resin through the orifices in the sleeve; and, forcing the resin into the delaminations in the laminate surrounding the hole by capillary action. ### Claim 12 (depends on 11) The method as defined in claim 11 further comprising treating the sleeve of the repair system tool device with cetyle alcohol lubricant for installation. ### Claim 13 (depends on 11) The method as defined in claim 11 further comprising encircling the sleeve with an upper o-ring seal abutting the top flange. ### Claim 14 (depends on 13) The method as defined in claim 13 further comprising: assembling a lower o-ring seal on the sleeve; engaging a mating flange onto the sleeve; and, tightening the mating flange to avoid leakage of resin. ### Claim 15 (depends on 11) The method as defined in claim 11 further comprising curing a damaged area under vacuum. ### Claim 16 (depends on 15) The method as defined in claim 15 further comprising: unbagging a repaired area; removing the caul plate; and, withdrawing the repair system tool device sleeve from the hole. ### Claim 17 (depends on 16) The method as defined in claim 16 further comprising reaming the hole as repaired to remove excess resin and produce final tolerance hole size. ### Claim 18 (depends on 17) The method as defined in claim 17 further comprising installing a fastener into the repaired hole to continue with production. ### Claim 19 (depends on 11) The method as defined in claim 11 further comprising selecting an array of orifices to align with delaminations identified in the non-destructive evaluation. ### Claim 20 (depends on 19) The method as defined in claim 19 further comprising plugging orifices other than the selected array.