Abstract: A method for reworking an electrically conductive layer of a composite skin is disclosed in which a patch replaces the altered section of the electrically conductive layer. The method is performed by removing a portion of the electrically conductive layer to reveal the underlying composite skin. A patch is formed, having an electrically conductive section coupled to an adhesive having a low dielectric breakdown strength, and is then introduced over the underlying composite skin such that the adhesive layer covers the underlying composite skin and overlaps an unremoved portion of the electrically conductive layer. The patch is applied such that the electrically conductive section within the patch covers the adhesive layer and overlaps the unremoved section of the electrically conductive layer. The adhesive layer preferably has a low dielectric breakdown strength, so that electricity from lightning which strikes the composite skin may be conducted through the adhesive.

Abstract: A method for reworking an electrically conductive layer of a composite skin is disclosed in which a patch replaces the altered section of the electrically conductive layer. The method is performed by removing a portion of the electrically conductive layer to reveal the underlying composite skin. A patch is formed, having an electrically conductive section coupled to an adhesive having a low dielectric breakdown strength, and is then introduced over the underlying composite skin such that the adhesive layer covers the underlying composite skin and overlaps an unremoved portion of the electrically conductive layer. The patch is applied such that the electrically conductive section within the patch covers the adhesive layer and overlaps the unremoved section of the electrically conductive layer. The adhesive layer preferably has a low dielectric breakdown strength, so that electricity from lightning which strikes the composite skin may be conducted through the adhesive.

Abstract: A method for reestablishing the electrical continuity of an electrically conductive layer of a composite aircraft wing damaged by a lightning strike or other mechanical event is disclosed in which a copper patch replaced the damaged section of the electrically conductive layer contained. The repair is performed by first removing any surfacers, fasteners, and damaged electrically conductive layer to expose a portion of the underlying composite skin. A copper patch having a copper foil section coupled to an unsupported film adhesive is then introduced onto an underlying composite skin opening contained within an undamaged section of a copper foil grid and covered with resin-impregnated fiberglass material. The film adhesive and resin-impregnated fiberglass material are then cured and fasteners are then reinserted within the fiberglass material, copper patch and underlying composite skin. The surface of the composite wing is then reprimed and repainted to complete the repair.