Method for Repairing Composite Materials Via Dielectric Barrier Discharge

1 . A method for repairing a composite material, comprising:

applying an epoxy to an area of the composite material in need of repair;

covering the area with an epoxy-filled patch; and

curing the epoxy electromagnetically, thereby repairing the composite material.

2 . The method of claim 1 , wherein the curing step comprises:

exposing the composite material and the epoxy-filled patch to a plasma produced by an electromagnetic applicator;

heating inductively via the plasma the composite material and the epoxy-filled patch; and

transferring heat from the composite material and the epoxy-filled patch to the epoxy contained therein to cure the same.

3 . The method of claim 2 , wherein the electromagnetic applicator is a dielectric barrier discharge applicator.

4 . The method of claim 3 , wherein the dielectric barrier discharge applicator comprises:

a pair of electrodes; and

a dielectric layer and an air gap positioned to separate the electrodes so that current flowing through the pair of electrodes flows through the dielectric layer to generate the plasma.

5 . The method of claim 3 , wherein the dielectric barrier discharge applicator is a hand-held dielectric barrier discharge applicator.

6 . The method of claim 3 , wherein the dielectric barrier discharge applicator does not make physical contact with the composite material during the exposing step.

7 . The method of claim 1 , wherein the composite material is a unidirectional carbon fiber reinforced composite material, a crossweaved carbon fiber reinforced composite material, or a hybrid composite consisting of carbon fibers and carbon nanomaterials.

8 . The method of claim 1 , wherein the epoxy-filled patch is made of a carbon fiber material, a heat-sensitive thermosetting epoxy, or nanomaterials for additional reinforcement.

9 . The method of claim 1 , wherein the area of the composite material in need of repair is repaired in situ.

10 . The method of claim 1 , wherein the composite material in need of repair is a component of a 3-dimensional composite part.

11 . A layup manufacturing process of a composite part, comprising:

applying an epoxy to a first layer of composite material;

laying a second layer of composite material onto the first layer to shape the composite material as a layup, said epoxy disposed between said first layer and said second layer; and

heating the epoxy to cure it to bond the first layer to the second layer in the layup to form the composite part.

12 . The layup manufacturing process of claim 11 , wherein the heating step comprises:

positioning a dielectric barrier discharge applicator proximal to the layup, said dielectric barrier discharge applicator comprising a pair of electrodes with a dielectric layer and air gap positioned therebetween;

heating resistively the composite material in the layup with a plasma produced when an electric current is applied across the pair of electrodes in the dielectric barrier discharge; and

transferring heat from the composite material in the layup to the epoxy to cure the same in the shape of the composite part.

13 . The layup manufacturing process of claim 12 , wherein the dielectric barrier discharge applicator is stationary.

14 . The layup manufacturing process of claim 12 , wherein the dielectric barrier discharge applicator is movable relative to the layup.

15 . The layup manufacturing process of claim 12 , wherein the dielectric barrier discharge applicator is a hand-held dielectric barrier discharge applicator.

16 . The layup manufacturing process of claim 12 , wherein prior to the heating step, the method further comprises:

repeating the applying step and the laying step at least once until the composite material is shaped as the composite part.

17 . The layup manufacturing process of claim 12 , wherein the composite material is a carbon fiber reinforced composite material or a composite material filled with carbon nanotubes, carbon black or chopped fibers.

18 . A system for manufacturing a 3-dimensional composite part, comprising:

a supply of a prepreg composite material stored on a spool;

a supply of an epoxy material;

an extruder configured to dispense the prepreg composite material and the epoxy material; and

a dielectric barrier discharge applicator positioned proximal to the extruder configured to generate a plasma to resistively heat the prepreg composite material and to cure the epoxy material as they are dispensed by the extruder, said 3-dimensional composite part formed thereby.

19 . The system of claim 18 , wherein the prepreg composite material is a carbon fiber reinforced composite material.

20 . The system of claim 18 , wherein the dielectric barrier discharge applicator comprises a pair of electrodes with a dielectric layer and air gap positioned therebetween.