Method of making and using shape memory polymer composite patches

Abstract

A method of repairing a composite component having a damaged area including: laying a composite patch over the damaged area; activating the shape memory polymer resin to easily and quickly mold said patch to said damaged area; deactivating said shape memory polymer so that said composite patch retains the molded shape; and bonding said composite patch to said damaged part.

What is claimed is: 
     
         1 . A shape memory polymer patch, the shape memory polymer patch comprising:
 at least one layer of fibrous material having two opposed faces;   a shape memory polymer resin; and   an adhesive disposed on at least one face of the fibrous material;   wherein the fibrous material is embedded within the shape memory polymer resin or the fibrous material is impregnated with the shape memory polymer resin.   
     
     
         2 . The shape memory polymer patch of  claim 1 , wherein the fibrous material is embedded within the shape memory polymer resin. 
     
     
         3 . The shape memory polymer patch of  claim 1 , wherein the fibrous material is impregnated with the shape memory polymer resin. 
     
     
         4 . The shape memory polymer patch of  claim 1 , wherein the shape memory polymer resin is a styrene shape memory polymer, a cyanate ester shape memory polymer, a maleamide shape memory polymer, a vinyl ester shape memory polymer, or an epoxy shape memory polymer. 
     
     
         5 . The shape memory polymer patch of  claim 1 , wherein the shape memory polymer is a shape memory polymer alloy. 
     
     
         6 . The shape memory polymer patch of  claim 1 , wherein the shape memory polymer is a thermoset resin. 
     
     
         7 . The shape memory polymer patch of  claim 1 , wherein the adhesive is disposed on both of the two opposed faces of the fibrous material. 
     
     
         8 . The shape memory polymer patch of  claim 1 , wherein the adhesive is operable to be thermally cured. 
     
     
         9 . The shape memory polymer patch of  claim 8 , wherein the adhesive is operable to be thermally cured at a curing temperature at or above the transition temperature of the shape memory polymer resin. 
     
     
         10 . The shape memory polymer patch of  claim 1 , wherein the adhesive is a pressure sensitive adhesive. 
     
     
         11 . The shape memory polymer patch of  claim 1 , wherein the shape memory patch is operable to be activated by heating said shape memory polymer patch above the transition temperature of the shape memory polymer resin. 
     
     
         12 . The shape memory polymer patch of  claim 1 , wherein the shape memory polymer patch is operable to be activated by application of hot air, heat lamps, or inductive heating. 
     
     
         13 . The shape memory polymer patch of  claim 1 , wherein deactivation of the shape memory polymer patch is achieved by reducing the temperature of said shape memory polymer patch below the transition temperature of the shape memory polymer patch. 
     
     
         14 . The shape memory polymer patch of  claim 1 , wherein the shape memory polymer patch further comprises a thermal energy generation means embedded therein. 
     
     
         15 . The shape memory polymer patch of  claim 14 , wherein the shape memory polymer patch is operable to be activated by applying electrical current to said embedded thermal energy generation means. 
     
     
         16 . The shape memory polymer patch of  claim 1 , wherein the shape memory polymer patch further comprises thermally conductive fibers. 
     
     
         17 . The shape memory polymer patch of  claim 1 , wherein the shape memory polymer patch further comprises an electrical conductor. 
     
     
         18 . The shape memory polymer patch of  claim 1 , wherein the shape memory polymer patch is operable to be activated by application of electromagnetic radiation. 
     
     
         19 . The shape memory polymer patch of  claim 18 , wherein the electromagnetic radiation is visible light or ultraviolet light. 
     
     
         20 . The shape memory polymer patch of  claim 1 , wherein the shape memory polymer patch is operable to be deactivated by application of electromagnetic radiation 
     
     
         21 . The shape memory polymer patch of  claim 20 , wherein the electromagnetic radiation is visible light or ultraviolet light. 
     
     
         22 . The shape memory polymer patch of  claim 1 , wherein the shape memory polymer patch further comprises a protective coating layer applied to the face of the fibrous material opposite the adhesive. 
     
     
         23 . The shape memory polymer patch of  claim 1 , wherein the fibrous material is a nanofiber, a spandex, a chopped fiber, a random fiber mat, a fabric, a continuous fiber, or other type of textile fabric. 
     
     
         24 . The shape memory polymer patch of  claim 1 , wherein the fibrous material is a carbon fiber. 
     
     
         25 . The shape memory polymer patch of  claim 1 , wherein the fibrous material is a fiberglass. 
     
     
         26 . The shape memory polymer patch of  claim 1 , wherein the fibrous material is a yarn. 
     
     
         27 . The shape memory polymer patch of  claim 1 , wherein the fibrous material is in the form of a flat weave, a two dimensional weave, or a three-dimensional weave.