Abstract: An apparatus and method for repairing the juncture or intersection of a first conduit and a second conduit is disclosed. The apparatus includes a main body for transporting and positioning a repair material impregnated with at heat curable resin system or matrix. An inflation device carried within the main body positions and compresses the repair material against the intersection. This includes a portion of the interior of the second conduit and flange portion in the first conduit. The inflation device includes conductive fibers that are electrically conductively heated to effect curing of the resin in the repair material.

Abstract: The apparatus of the present invention is generally characterized by a heating/inflation module having pressurizable interior and an attached heat curable pre-preg. In particular, an elastomeric, seamless composite is provided that includes a heating element disposed within a thermoset resin matrix. The composite adapted to maintain a consistent temperature profile and an internal air pressure. A first end piece is attached to a first end of the composite and has an air port for communication with a compressed air source, a vacuum port for communication with a vacuum supply source and at least one electrical cable port for communication with a power supply source. A second end piece attached to a second end of the composite. The apparatus further includes a pre-preg removably attached to an outer surface of the composite. The pre-preg includes a structural fiber matrix supporting a heat curable resin.

Abstract: The present invention provides a method for producing a repair material for use in repairing an interface area between two intersecting conduits. According to one aspect of the invention, a mold is provided having similar dimensions to an interface area. The interface area is defined by a first conduit and a flange connecting the first conduit to a second conduit. A repair material is provided having a material structure, the material structure defined by an arrangement of fibers such that the material structure has similar dimensions to the interface area. The arrangement of fibers further allowing the repair material to be flexible and seamless. A resin is provided, the resin having a resin viscosity. An additive is provided, the additive is adapted to increase the resin viscosity. The additive is mixed with the resin to form a resin-additive mixture whereby the resin viscosity is increased after a time delay.

Abstract: An apparatus and method for repairing the juncture or intersection of a first conduit and a second conduit is disclosed. The apparatus includes a main body for transporting and positioning a repair material impregnated with a heat curable resin system or matrix. An inflation device and caul plates carried by the main body position and compress the repair material against the intersection. This includes a portion of the interior of the second conduit and flange portion in the first conduit. The inflation device and caul plates include conductive fibers that are electrically resistively heated to effect curing of the resin in the repair material. Additionally, a method and liner apparatus for the in-situ repair of conduits having large diameters is disclosed. The liner comprising a plurality of discrete heating zones, where each zone impregnated with a curable resin. Each zone further having a fiber architecture, where the fiber architecture has a plurality of conductive fibers.

Abstract: A composite substrate for a fiber reinforced plastic part comprising a first outer thermoplastic sheet, an intermediate conductive layer or layers, and a second inner thermoplastic sheet. The composite substrate formed by electrically resistively heating the conductive layer or layers to melt the thermoplastic sheets, and applying pressure to consolidate the layers into a rigid substrate. The conductive layer or layers formed of a conductive fiber mat or tape. Additionally, a method is disclosed comprising providing a conductive filament impregnated with a resin; running the conductive filament through an electrical contact, the electrical contact connected to a supply of electric power; and, winding the filament to a mandrel including a second electrical contact connected to said supply of power. Electricity is then induced through the filament from the first contact to the second contact to resistively heat the filament and cure the resin.