US4560428A
Expired / Lapsed
US
⏱️ 0.0 years remaining
System and method for producing cured composites
Assignee: Boeing North American Inc
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Filing: 1984-08-20
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Granted: 1985-12-24
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Expires: 2004-08-20
Abstract
Abstract 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.
Inventors
- 👤 George O. Sherrick
- 👤 Joseph R. Rosenthal
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-30 13:41
CPC Classifications
B; B29; B29C; B29C65/00; B29C65/02; B29C65/34; B29C65/3472; B29C65/3484; B29C65/3492; B29C35/00; B29C35/02; B29C35/0272; B29C65/3404; B29C65/344; B29C65/3444; B29C65/3456; B29C65/3468; B29C65/48; B29C65/4805; B29C65/481; B29C65/4815; B29C65/483; B29C65/4835; B29C65/50; B29C65/5007; B29C65/5014; B29C65/5021; B29C66/00; B29C66/01; B29C66/05; B29C66/10; B29C66/11; B29C66/112; B29C66/1122; B29C66/50; B29C66/51; B29C66/53; B29C66/532; B29C66/5326; B29C66/70; B29C66/71; B29C66/72; B29C66/721; B29C66/7212; B29C66/73; B29C66/739; B29C66/7392; B29C66/7394; B29C66/80; B29C66/81; B29C66/814; B29C66/8145; B29C66/81455; B29C66/90; B29C66/91; B29C66/912; B29C66/9121; B29C66/91221; B29C66/914; B29C66/9141; B29C66/91411; B29C66/91431; B29C66/9161; B29C66/91651; B29C66/91655; B29C73/00; B29C73/04; B29C73/10; C; C09; C09J; C09J5/00; C09J5/06; H; H05; H05B; H05B3/00; H05B3/10; H05B3/12; H05B3/14; H05B3/145; B29C43/00; B29C43/02; B29C43/10; B29C43/12; B29C66/737; B29C66/7375; B29C66/73755; B29C66/73941; B29C66/96; B29C66/961; B29L; B29L2031/00; B29L2031/30; B29L2031/3076; C09J2203/00; C09J2203/35; C09J2301/00; C09J2301/30; C09J2301/314; Y; Y10; Y10S; Y10S428/00; Y10S428/913; Y10T; Y10T428/00; Y10T428/28; Y10T428/2813; Y10T428/2817; Y10T428/2826; Y10T428/30
Claims Analysis
Total Claims: 47
Claim 1
Independent Claim
88 words
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.
Claim 2
Independent Claim
88 words
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.
Claim 3
Dependent Claim
14 words
The system of claim 1, said bonding means comprising a partially cured thermosetting resin.
Claim 4
Dependent Claim
23 words
The system of claim 1, said electrical resistance heating element comprising a layer of graphite fibers impregnated with a partially cured thermosetting resin.
Claim 5
Dependent Claim
15 words
The system of claim 1, said electrical resistance heating element comprising graphite tape or fabric.
Claim 6
Dependent Claim
23 words
The system of claim 1, said electrical resistance heating element comprising a layer of graphite fiber reinforced partially cured epoxy or epoxy-novolac resin.
Claim 7
Dependent Claim
16 words
The system of claim 1, said bonding means comprising a film of a heat curable adhesive.
Claim 8
Dependent Claim
34 words
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.
Claim 9
Independent Claim
98 words
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.
Claim 10
Independent Claim
98 words
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.
Claim 11
Dependent Claim
42 words
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.
Claim 12
Dependent Claim
29 words
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.
Claim 13
Independent Claim
118 words
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.
Claim 14
Independent Claim
118 words
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.
Claim 15
Dependent Claim
21 words
The system of claim 11, said layer of graphite fibers being impregnated with a heat curable thermosetting or a thermoplastic resin.
Claim 16
Dependent Claim
44 words
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.
Claim 17
Dependent Claim
26 words
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.
Claim 18
Dependent Claim
25 words
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.
Claim 19
Dependent Claim
21 words
The system of claim 11, said heating element being configured to provide a series electrical circuit or a parallel electrical circuit.
Claim 20
Independent Claim
129 words
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.
Claim 21
Independent Claim
129 words
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.
Claim 22
Independent Claim
151 words
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.
Claim 23
Independent Claim
151 words
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.
Claim 24
Dependent Claim
87 words
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.
Claim 25
Dependent Claim
87 words
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.
Claim 26
Dependent Claim
117 words
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.
Claim 27
Dependent Claim
117 words
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.
Claim 28
Dependent Claim
22 words
The process of claim 20, said layer comprising graphite fiber reinforced partially cured epoxy or epoxy-novolac resin or polyether ether ketone resin.
Claim 29
Dependent Claim
34 words
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.
Claim 30
Dependent Claim
94 words
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.
Claim 31
Dependent Claim
94 words
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.
Claim 32
Dependent Claim
24 words
The process of claim 23, said layer of graphite fibers being impregnated with a heat curable thermosetting resin or a high temperature thermoplastic resin.
Claim 33
Dependent Claim
46 words
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.
Claim 34
Dependent Claim
16 words
The process of claim 23, said heat curable thermosetting resin being a partially cured epoxy resin.
Claim 35
Dependent Claim
16 words
The process of claim 25, said heat curable thermosetting resin being a partially cured epoxy resin.
Claim 36
Dependent Claim
96 words
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.
Claim 37
Dependent Claim
96 words
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.
Claim 38
Dependent Claim
122 words
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.
Claim 39
Dependent Claim
122 words
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.
Claim 40
Dependent Claim
9 words
The composite produced by the process of claim 19.
Claim 41
Dependent Claim
9 words
The composite produced by the process of claim 20.
Claim 42
Dependent Claim
9 words
The composite produced by the process of claim 28.
Claim 43
Dependent Claim
9 words
The composite produced by the process of claim 29.
Claim 44
Dependent Claim
9 words
The composite produced by the process of claim 23.
Claim 45
Dependent Claim
9 words
The composite produced by the process of claim 24.
Claim 46
Dependent Claim
9 words
The composite produced by the process of claim 25.
Claim 47
Dependent Claim
9 words
The composite produced by the process of claim 27.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1988-12-23 | 1989-06-24 | 1989-12-24 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1992-12-23 | 1993-06-24 | 1993-12-24 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1996-12-23 | 1997-06-24 | 1997-12-24 | $7700.00 | Window Closed / Lapsed |