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System and method for producing a composite, particularly applicable for repairing damage to a structural component, wherein an electrical resistance heating element basically in the form of a layer of conductive carbon or graphite, e.g., in fiber form, becomes bonded to and forms a part of the cure

System and method for producing a composite, particularly applicable for repairing damage to a structural component, wherein an electrical resistance heating element basically in the form of a layer of conductive carbon or graphite, e.g., in fiber form, becomes bonded to and forms a part of the cured composite. In the repair of a parent structure, a patch comprising a heat curable resinous material is applied to the parent structure, and a heat bondable adhesive film is positioned between the parent structure and the patch. An electrical resistance heating element in the form of a layer of graphite fibers is provided in contact with, or forming a part of, the patch, the heating element being capable of bonding the patch to the parent structure upon heating the adhesive bond to a predetermined temperature, to form a unitary structure comprised of the damaged parent structure, the patch and the heating element.

대표청구항 ▼

1. A system for producing a composite which comprises a parent component, an electrical resistance heating element comprising a layer of graphite fibers impregnated with a partially cured thermosetting resin or a high temperature thermoplastic resin, means capable of bonding said heating elemen

1. A system for producing a composite which comprises a parent component, an electrical resistance heating element comprising a layer of graphite fibers impregnated with a partially cured thermosetting resin or a high temperature thermoplastic resin, means capable of bonding said heating element to said parent component to produce a composite upon heating said bonding means to a predetermined temperature, said bonding means comprising a film of a heat bondable material interposed between said parent component and said heating element, and electrical power means connected to said heating element. 2. The system of claim 1, said bonding means comprising a partially cured thermosetting resin. 3. The system of claim 1, said electrical resistance heating element comprising a layer of graphite fibers impregnated with a partially cured thermosetting resin. 4. The system of claim 1, said electrical resistance heating element comprising graphite tape or fabric. 5. The system of claim 1, said electrical resistance heating element comprising a layer of graphite fiber reinforced partially cured epoxy or epoxy-novolac resin. 6. The system of claim 1, said bonding means comprising a film of a heat curable adhesive. 7. The system of claim 1, said electrical resistance heating element comprising a layer of graphite fiber reinforced partially cured epoxy or epoxy-novolac resin, said bonding means comprising a film of a heat curable adhesive. 8. A system for producing a composite which comprises, a parent component, a first layer of graphite fibers impregnated with a heat bondable thermosetting resin, a film of heat curable adhesive positioned between said component and said first layer, a second layer of graphite fibers positioned on said first layer, and electrical connections to said second layer of graphite fibers, whereby said second layer functions as a resistance heating element so that when electrical current is passed therethrough, and the temperature raised to a predetermined value, said layers become integrally bonded through said adhesive film to said parent component. 9. The system of claim 8, wherein said parent component is a cured resin component, said first layer comprises a graphite fiber reinforced partially cured epoxy or epoxy-novolac resin, and said second layer is an electrical resistance element comprising graphite tape or fabric. 10. The system of claim 8, including means for applying pressure to the assembly for bonding said heating element to said component during resistance heating to said predetermined temperature value. 11. A system for repairing a damaged structural component which comprises, a parent structural component to be repaired, a patch to be bonded to said component, said patch positioned on the surface of said parent structure, said patch including an electrical resistance heating element in the form of a layer of graphite fibers, a film of a heat bondable adhesive between said patch and said parent component, said adhesive film capable of bonding said patch to said parent component upon heating said adhesive film to a predetermined temperature, and electrical connections to said electrical resistance heating element, whereby upon heating said film to a predetermined temperature, said patch becomes integrally bonded to said parent component to form a composite. 12. The system of claim 11, said layer of graphite fibers being impregnated with a heat curable thermosetting or a thermoplastic resin. 13. The system of claim 11, said patch further including a layer of graphite fibers impregnated with a heat curable thermosetting resin or a thermoplastic resin, said last-mentioned layer being in contact with said electrical resistance heating element and in contact with said adhesive film. 14. The system of claim 12, said heat curable thermosetting resin being a partially cured epoxy resin, and said thermoplastic resin being a high temperature thermoplastic resin. 15. The system of claim 13, said heat curable thermosetting resin being partially cured epoxy resin, and said thermoplastic resin being a high temperature thermoplastic resin. 16. The system of claim 11, said heating element being configured to provide a series electrical circuit or a parallel electrical circuit. 17. A system for producing a composite which comprises a parent component, a first layer of graphite fibers impregnated with a heat bondable thermosetting resin, a film of heat curable adhesive positioned between said component and said first layer, a second layer of graphite fibers positioned on said first layer, electrical connections to said second layer of graphite fibers, whereby said second layer functions as a resistance heating element so that when electrical current is passed therethrough, and the temperature raised to a predetermined value, said layers become integrally bonded through said adhesive film to said parent components, and a bagging material positioned over said resistance heating element, for applying pressure to the assembly for bonding said heating element to said component during resistance heating to said predetermined temperature value. 18. A system for repairing a damaged structural component which comprises, a parent structural component to be repaired, a patch to be bonded to said component, said patch positioned on the surface of said parent structure, said patch including an electrical resistance heating element in the form of a layer of graphite fibers, a film of a heat bondable adhesive between said patch and said parent component, said adhesive film capable of bonding said patch to said parent component upon heating said adhesive film to a predetermined temperature, electrical connections to said electrical resistance heating element, whereby upon heating said film to a predetermined temperature, said patch becomes integrally bonded to said parent component to form a composite, plate means positioned over the assembly, and vacuum bagging over said plate means for applying pressure to said assembly for bonding said patch to said parent component during resistance heating to said predetermined temperature. 19. A process for producing a composite, which comprises, placing a parent component of said composite in contiguous relation with an electrical resistance heating element comprising a layer of graphite fibers impregnated with a heat curable thermosetting resin or a high temperature thermoplastic resin, placing a film of heat bondable material between said resistance heating element and said component, and passing an electric current through said resistance element and heating said bondable film to a predetermined temperature, thereby causing said heating element to become bonded to said component. 20. A process for producing a composite, which comprises, placing a parent component of said composite in contiguous relation with an electrical resistance heating element comprising a layer of graphite fibers, placing a film of heat bondable material between said resistance heating element and said component, placing an additional layer of graphite fibers impregnated with a heat bondable thermosetting resin or a high temperature thermoplastic resin, between said electrical resistance heating element and said heat bondable film, and passing an electric current through said resistance element and heating said bondable film to a predetermined temperature, whereby said resistance heating element and said additional layer become bonded to said component upon passage of electrical current through said heating element. 21. The process of claim 20, said layer comprising graphite fiber reinforced partially cured epoxy or epoxy-novolac resin or polyether ether ketone resin. 22. The process of claim 20, said parent component being a cured resin component, said electrical resistance element comprising graphite tape or fabric, and said additional layer comprising graphite fiber reinforced partially cured epoxy resin. 23. A process for repairing a damaged structural component which comprises, placing a patch on the surface of said structural component, said patch including an electric resistance heating element in the form of a layer of graphite fibers, incorporating an adhesive film of a heat curable thermosetting resin between said patch and said structural component, passing an electric current through said resistance heating element and heating said heat curable thermosetting resin to a predetermined temperature, thereby causing said patch and said heating element to be integrally bonded to said structural component to form a composite. 24. The process of claim 23, said layer of graphite fibers being impregnated with a heat curable thermosetting resin or a high temperature thermoplastic resin. 25. The process of claim 23, said patch further including a layer of graphite fibers impregnated with a heat curable thermosetting resin or a high temperature thermoplastic resin, said last-mentioned layer being in contact with said electrical resistance heating element and in contact with said adhesive film. 26. The process of claim 23, said heat curable thermosetting resin being a partially cured epoxy resin. 27. The process of claim 25, said heat curable thermosetting resin being a partially cured epoxy resin. 28. A process for producing a composite, which comprises, placing a parent component of said composite in contiguous relation with an electrical resistance heating element comprising a layer of graphite fibers, placing a film of heat bondable material between said resistance heating element and said component, vacuum bagging the assembly, passing an electric current through said resistance element and heating said bondable film to a predetermined temperature, thereby causing said heating element to become bonded to said component, and applying pressure to the assembly during passage of electric current through said heating element and during said bonding. 29. A process for repairing a damaged structural component which comprises, placing a patch on the surface of said structural component, said patch including an electric resistance heating element in the form of a layer of graphite fibers, incorporating an adhesive film of a heat curable thermosetting resin between said patch and said structural component, vacuum bagging the assembly of said structural component and said patch, passing an electric current through said resistance heating element and heating said heat curable thermosetting resin to a predetermined temperature, thereby causing said patch and said heating element to be integrally bonded to said structural component to form a composite, and applying pressure to said assembly during passage of an electric current through said resistance heating element. 30. The composite produced by the process of claim 19. 31. The composite produced by the process of claim 20. 32. The composite produced by the process of claim 28. 33. The composite produced by the process of claim 29. 34. The composite produced by the process of claim 23. 35. The composite produced by the process of claim 24. 36. The composite produced by the process of claim 25. 37. The composite produced by the process of claim 27.