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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. The repair material is placed in intimate contact with the mold such a mold surface supports the repair material. The resin-additive mixture is introduced into the repair material. A sufficient amount of time elapses for the resin-additive mixture to permeate the repair material such that the resin-additive mixture adheres to the fibers thereby stabilizing the resin-additive mixture and the fibers. After the resin-additive mixture has fully adhered to and secured the fibers, the repair material is removed from the mold. The present invention also provides a method of repairing a damaged section of a non-linear conduit, comprising a number of steps. A repair material is provided with a material structure adapted to engage an interior surface of a non-linear conduit. The material structure is defined by a plurality of fibers such that the repair material is flexible and seamless. A curable resin is introduced into the repair material by either injection or infusion depending on the type of resin utilized. Next, the repair material is placed in the conduit in close proximity to a damaged portion of the conduit. The resin is then cured. Preferably, the material structure is substantially cylindrical to facilitate conformity with the non-linear conduit. However, the material structure is flexible and can be formed by braiding, knitting, stitch-bonding, or needle-punching the fibers. Repair materials fabricated from any of these techniques offer exceptional ability to conform to irregular conduit geometries. The fibers can be electrically conductive fibers, for example carbon fibers, and in order to cure the resin, an electric current can be caused to flow through the conductive fibers to resistively heat the repair material. Alternatively, the fibers can be a combination of electrically conductive fibers and non-conductive fibers.

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First Claim