Hot Patch Bonding Equipment

Figure 14.16
Simply stated, a hot patch bonding machine performs two functions:
1.

It applies atmospheric pressure by means of a vacuum pump.

2.

It applies heat, usually in the form of a heat blanket.

Hot patch bonding makes use of heat blankets which have electrical coils bonded into a rubber
pad or blanket. The heat blankets can heat up quickly, unless they have a monitoring unit to
control the rate of temperature rise and to set the temperature.
If the shape of the part to be cured is sharply contoured, instead of using a heat blanket with the
hot bonding machine, in some instances a heat gun may be used. A tent of bagging film is
attached to the part to hold the heat in around the part. The heat gun is monitored with a
thermocouple and the controller of the hot bonding unit.
The monitor or controller is a device which will maintain a constant temperature, or will change
the temperature at a specific rate. In working with composites, the temperature must be
controlled both at a constant and at a specific rate of change. It is critical to perform these
functions with a minimum of effort and maximum of efficiency in order to achieve professional
results. The simplest function the controller will do is to maintain a specified temperature for the
repair. The specified temperature is called the set point of the repair and when the controller is
working in this mode it is called a set point controller.
Another function the controller may be able to perform is the ramp and soak. The controller
allows the temperature to slowly rise at a specific rate, then hold the temperature constant, and
then allows a slow decline of temperature at a specific rate.
Recording the temperatures of the curing process can be accomplished using hot bonding units
which are equipped with a temperature recording unit. Such controllers may use a recorder that
is included in the control unit, or as a separate unit. In any case, some manufacturers require
that permanent records of the cure cycle be included in the log of the aircraft repairs.

Warning
Dont become dependent on the recording record as an assurance that the part was repaired
correctly. There are many aspects of a repair that need close monitoring. Just because the
repair was cured at the proper temperature does not mean that the repair is airworthy
To use a controller, a thermocouple is placed beside the repaired area under a heat blanket and
under the bagging film to sense what temperature is being delivered to the part. The
thermocouple sends the temperature information to the controller. The controller adds heat or
stops heating depending on how the controller is set.
To initially apply heat at the final cure temperature will not allow the resins enough time to flow
properly before they go through their curing process. This may result in a resin rich area. For
example, if 250F is the final cure temperature and the controller applies heat, it will reach the
250F mark as soon as it possibly can (usually within 30 seconds). The resin and catalyst
mixtures need time to slowly start their chemical reaction before the final cure temperature is
reached.
It is also important not to turn off the heat and allow the part to cool too quickly because
composites gain much of their strength during the cooling down process which will also prevent
the part from becoming brittle. A slow rate of temperature rise and decline is desirable, but can
usually be achieved only if a monitor or controller is available.