Patent ID: 8382924
Filing Date: 2013-02-26
Classification: B29C,B32B,Y10T

Abstract:
1. A method for fabricating a repair laminate for a composite part having an exposed surface, comprising: preparing a damaged surface on the exposed surface of the composite part for fabricating the repair laminate thereon; applying a release film to the damaged surface; applying a first ply stack to the release film, the first ply stack consists of a first plurality of uncured plies, the first ply stack being applied onto the release film so as to substantially conform to the contouring of the damaged surface; and wherein the first ply stack contacts the release film in contact with the damaged surface; compacting the first plurality of uncured plies; applying a second ply stack to the first ply stack, the second ply stack consists of a second plurality of uncured plies, the second ply stack being applied so as to substantially match the contouring of the damaged surface, the second ply stack being applied directly on the compacted first plurality of uncured plies; compacting the second plurality of uncured plies; removing the release film and the first and second ply stacks from the composite part; applying bonding material to the exposed surface; applying an uncured ply stack assembly comprising the first and second ply stacks to the bonding material on the exposed surface; and curing the uncured ply stack assembly and bonding material; wherein the first ply stack is compacted prior to the second ply stack being applied and subsequently compacted; and wherein the temperature during compacting is below a curing temperature.