REPAIR PATCH, METHOD FOR MOLDING REPAIR PATCH, AND METHOD FOR REPAIRING COMPOSITE MATERIAL

Abstract

A repair patch for a composite material adapted to repair a portion to be repaired of the composite material, the repair patch including: a patch body including a bonding surface to be bonded to the portion to be repaired; and an expected margin disposed at an opposite side to the bonding surface in a thickness direction of the patch body, and being debondable from the patch body. The bonding surface includes an inclined surface inclined outward from the patch body toward the expected margin in the thickness direction of the patch body, and the inclined surface is formed to extend from the patch body onto the expected margin.

Claims

1. A repair patch for a composite material adapted to repair a portion to be repaired of the composite material, the repair patch comprising: a patch body including a bonding surface to be bonded to the portion to be repaired; and an expected margin disposed at an opposite side to the bonding surface in a thickness direction of the patch body, and being debondable from the patch body, wherein the bonding surface includes an inclined surface inclined outward from the patch body toward the expected margin in the thickness direction of the patch body, the inclined surface is formed to extend from the patch body onto the expected margin, and the patch body has a surface bonded to the expected margin, the surface being a boundary surface between the patch body and the expected margin that is debondable.

2. The repair patch according to claim 1, wherein the expected margin is made of a peel ply, and the patch body is made of prepregs.

3. A repair patch for a composite material adapted to repair a portion to be repaired of the composite material, the repair patch comprising: a patch body including a bonding surface to be bonded to the portion to be repaired; an expected margin disposed at an opposite side to the bonding surface in a thickness direction of the patch body, and being debondable from the patch body; and a bonding layer provided between the patch body and the expected margin to bond the patch body and the expected margin, and the bonding layer includes an adhesive agent enabling the expected margin to be debonded from the patch body at the time of debonding, wherein the bonding surface includes an inclined surface inclined outward from the patch body toward the expected margin in the thickness direction of the patch body, and the inclined surface is formed to extend from the patch body onto the expected margin.

4. The repair patch according to claim 1, further comprising a release layer provided in the inclined surface formed in the expected margin, and the release layer enables debonding of an adhesive used in bonding to the portion to be repaired.

5. The repair patch according to claim 1, wherein the boundary surface is the surface orthogonal to the thickness direction, and a taper ratio of an angle formed by the boundary surface and the inclined surface is expressed as L:D where a thickness in the thickness direction of the patch body is D and a length in an in-plane direction along the boundary surface is L, and when the thickness D is 1, the length L is not less than 10.

6. A method for molding a repair patch for a composite material adapted to repair a portion to be repaired of the composite material, the method comprising: a bonding step of integrally bonding, to a laminate including a plurality of reinforcing fiber base materials layered on one another in a thickness direction, an expected margin debondable from the laminate, such that the expected margin is disposed at one side in the thickness direction of the laminate; and a machining step of forming an inclined surface inclined outward from the laminate toward the expected margin in the thickness direction, wherein at the machining step, the inclined surface is formed to extend from the laminate onto the expected margin.

7. A composite material repairing method for repairing a portion to be repaired of a composite material, the composite material repairing method in which the repair patch according to claim 1 is prepared in advance, the composite material repairing method comprising: an adhesive arrangement step of disposing an adhesive in a surface to be bonded of the portion to be repaired; a patch arrangement step of disposing the bonding surface of the repair patch via the adhesive such that the bonding surface is disposed being opposed to the surface to be bonded; a bonding step of bonding the repair patch to the portion to be repaired; and a debonding step of debonding the expected margin of the repair patch from the patch body.

8. A composite material repairing method for repairing a portion to be repaired of a composite material, the composite material repairing method comprising, with a repair kit being prepared in advance, and the repair kit including an expected margin debondable from a laminate including a plurality of reinforcing fiber base materials layered on one another in a thickness direction such that the expected margin is bonded to the laminate to be disposed at one side in the thickness direction of the laminate: a machining step of forming an inclined surface inclined outward from the laminate toward the expected margin in the thickness direction, and forming the inclined surface to extend from the laminate onto the expected margin, to form a bonding surface including the inclined surface; an adhesive arrangement step of disposing an adhesive in a surface to be bonded of the portion to be repaired; a kit arrangement step of disposing the bonding surface of the repair kit machined in the surface to be bonded via the adhesive such that the bonding surface is disposed being opposed to the surface to be bonded; a bonding step of bonding the repair kit to the portion to be repaired; and a debonding step of debonding the expected margin of the repair kit from the laminate.

9. A composite material repairing method for repairing a portion to be repaired of a composite material, the composite material repairing method in which the repair patch according to claim 3 is prepared in advance, the composite material repairing method comprising: an adhesive arrangement step of disposing an adhesive in a surface to be bonded of the portion to be repaired; a patch arrangement step of disposing the bonding surface of the repair patch via the adhesive such that the bonding surface is disposed being opposed to the surface to be bonded; a bonding step of bonding the repair patch to the portion to be repaired; and a debonding step of debonding the expected margin of the repair patch from the patch body.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0023] FIG. 1 is a cross-sectional view schematically illustrating an example of a repair patch according to a first embodiment.

[0024] FIG. 2 is a cross-sectional view schematically illustrating another example of a repair patch according to the first embodiment.

[0025] FIG. 3 is an explanatory diagram illustrating a method for molding the repair patch according to the first embodiment.

[0026] FIG. 4 is an explanatory diagram of an example of a method for repairing a composite material by using the repair patch according to the first embodiment.

[0027] FIG. 5 is an explanatory diagram of another example of a method for repairing a composite material by using the repair patch according to the first embodiment.

[0028] FIG. 6 is a graph on the result of repairing of a portion to be repaired that has been repaired with the repair patch according to the first embodiment.

[0029] FIG. 7 is a cross-sectional view schematically illustrating an example of a repair patch according to a second embodiment of the present invention.

DESCRIPTION OF EMBODIMENTS

[0030] Detailed description of embodiments according to the present invention will be given below with reference to the drawings. Note that the present invention is not limited by the embodiments. In addition, constituent elements in the following embodiments include those that can be replaced easily by a person skilled in the art or those that are substantially the same. Further, the constituent elements described below can be combined as appropriate, and in the case of a plurality of embodiments, the embodiments can be combined with one another.

First Embodiment

[0031] A repair patch 10 according to the present embodiment is a repair material used in repairing a composite material. A method for repairing a composite material by using the repair patch 10 is directed to repairing a defective portion caused by a damage or the like formed in the composite material, and is a method for repairing this portion to be repaired.

[0032] FIGS. 1 and 2 are cross-sectional views schematically illustrating an example of a repair patch according to a first embodiment. FIG. 3 is an explanatory diagram illustrating a method for molding the repair patch according to the first embodiment FIGS. 4 and 5 are explanatory diagrams of an example of a method for repairing a composite material by using the repair patch according to the first embodiment. FIG. 6 is a graph on the result of repairing of a portion to be repaired 5 that has been repaired with the repair patch according to the first embodiment.

[0033] First, the repair patch 10 will be described with reference to FIG. 1. The repair patch 10 is made of a composite material and includes a patch body 11 and an expected margin 12.

[0034] The patch body 11 has a truncated cone shape including a bottom surface 15, a top surface 14, and side surfaces 13a. In the patch body 11, the top surface 14 and the side surfaces 13a is a bonding surface 18 to be bonded to a portion to be repaired, and the bottom surface 15 is an opposite surface to the bonding surface 18.

[0035] The patch body 11 includes a plurality of prepregs as reinforcing fiber base materials laminated on one another in the thickness direction to be temporarily cured (pre-cured). Note that the direction along a plane orthogonal to the thickness direction is the in-plane direction. The prepregs is a material obtained by impregnating reinforcing fibers with a resin. For example, carbon fibers are used as the reinforcing fibers; however, the reinforcing fibers are not limited to carbon fibers. Other fibers of plastic fibers, glass fibers, natural fibers, or metal fibers may be used as the reinforcing fibers. A thermosetting resin is preferable as the resin. Alternatively, a thermoplastic resin may be used. An example of the thermosetting resin includes an epoxy resin. Examples of the thermoplastic resin include polyether ether ketone (PEEK), polyether ketone ketone (PEKK), and polyphenylene sulfide (PPS). Note that the resin is not limited to these resins, and other resins may be used. In addition, a method such as hand lay-up, resin infusion, resin transfer molding (RTM), or the like may be applied other than the molding by using the prepregs.

[0036] Specifically, the patch body 11 is the patch body 11 having a truncated cone shape obtained by machining a plate-shaped laminate including a plurality of prepregs laminated on one another and temporarily cured (pre-curing).

[0037] The bonding surface 18 includes the top surface 14 and the side surfaces 13a. In the bonding surface 18, at the cross section illustrated in FIG. 1 cut in the thickness direction of the patch body 11 along the central axis of the patch body 11 having a truncated cone shape, the side surfaces 13a are located at both sides in the in-plane direction between which the top surface 14 is interposed. Each of the side surfaces 13a is a surface linearly inclined with respect to the thickness direction. That is, in the cross section illustrated in FIG. 1, the side surfaces 13a at both the sides are inclined outward from the patch body 11 toward the expected margin 12 in the thickness direction. Note that each of the side surfaces 13a is a portion of an inclined surface 13 formed extending from the patch body 11 onto the expected margin 12.

[0038] The bottom surface 15 is a boundary surface between the patch body 11 and the expected margin 12 and is a surface extending in the in-plane direction. The patch body 11 has a corner portion (an edge portion) formed by the bottom surface 15 and each of the side surfaces 13a. Here, the inclined surface 13 including the side surface 13a has a predetermined taper ratio. When a thickness in the thickness direction of the patch body 11 is D and a length in the in-plane direction along the boundary surface is L, the taper ratio is expressed as L:D. The taper ratio of the inclined surface 13 in the first embodiment is such that when the thickness D is 1, the length L is not less than 10, and specifically, when the thickness D is 1, the length L is 30.

[0039] According to the taper ratio, as a ratio of the length L to the thickness D is larger, the recovery in strength of a portion to be repaired with the patch body 11 of the repair patch 10 can further be improved. Accordingly, the corner portion formed by the bottom surface 15 and the side surface 13a of the patch body 11 preferably has a more acute angle. On the other hand, when the corner portion of the patch body 11 is acute, fiber meandering easily occurs at the corner portion. Thus, the expected margin 12 described below is provided in the first embodiment.

[0040] The expected margin 12 is provided at the opposite side to the bonding surface 18 of the patch body 11 in the thickness direction, that is, is provided at the bottom surface 15 side of the patch body 11. The expected margin 12 is bonded to the patch body 11 and is debondable from the patch body 11. The expected margin 12 is made of, for example, a peel ply. In the repair patch 10 illustrated in FIG. 1, a peel ply is applied as the expected margin 12, and thus the expected margin 12 is integrally bonded to the patch body 11. Note that the expected margin 12 is not particularly limited to a peel ply, and any material may be used as the expected margin as long as the material is a material to be bonded to the patch body 11 and to be debondable form the patch body 11.

[0041] The expected margin 12 includes inclined surfaces 13b continuously formed with the side surfaces 13a of the patch body 11 to which the expected margin 12 is bonded. Each of the inclined surfaces 13b is a surface linearly inclined with respect to the thickness direction, and the inclined surfaces 13b are formed at both sides in the in-plane direction in the cross section illustrated in FIG. 1. That is, in the cross section illustrated in FIG. 1, the inclined surfaces 13b at both the sides are inclined outward from the patch body 11 toward the expected margin 12 in the thickness direction. Each of the inclined surfaces 13b is a portion of the inclined surface 13 formed extending from the patch body 11 onto the expected margin 12.

[0042] Next, another example of a repair patch 20 will be described with reference to FIG. 2. The repair patch 20 includes a patch body 11, an expected margin 12, and a bonding layer 23 provided between the patch body 11 and the expected margin 12. Note that the patch body 11 and the expected margin 12 are the same as those of the repair patch 10 illustrated in FIG. 1 and thus will not be described.

[0043] The bonding layer 23 bonds the patch body 11 and the expected margin 12. The bonding layer 23 bonds the expected margin 12 to the patch body 11, and the expected margin 12 is debondable from the patch body 11. The bonding layer 23 includes an adhesive agent. For example, a fluororesin-based adhesive agent or an acrylic resin-based adhesive agent is applied as the adhesive agent. In a case where the bonding layer 23 is provided, the patch body 11 and the expected margin 12 can be molded separately. Accordingly, the expected margin 12 is not limited to a peel ply, and any material may be applied.

[0044] Next, a method for molding the repair patch 10 of FIG. 1 will be described with reference to FIG. 3. In the method for molding the repair patch 10, a laminate 30 temporarily cured is machined, and thus the repair patch 10 is formed. Note that, in the molding method of FIG. 3, description will be given by applying the repair patch 10 of FIG. 1; however, the same can apply to the repair patch 20 of FIG. 2.

[0045] As illustrated in FIG. 3, the laminate 30 including a plurality of reinforcing fiber base materials layered on one another in the thickness direction, and the expected margin 12 are integrally bonded to form a repair kit 40 (step S11: bonding step). The repair kit 40 is the repair patch 10 obtained before machining. The laminate 30 has a plate shape, and the expected margin 12 also has a plate shape. At the bonding step S11, the expected margin 12 is bonded to a surface of the laminate 30 that is the bottom surface 15 side of the patch body 11. At the bonding step S11, during the temporary curing of the laminate 30, the expected margin 12 may temporarily be cured at the same time and thus may be bonded to the laminate body 30. Alternatively, the laminate body 30 and the expected margin are separately and temporarily cured and then may be bonded together. The way to bond the laminate body and the expected margin is not particularly limited.

[0046] Subsequently, the repair kit 40 temporarily cured is machined to form the inclined surfaces 13 inclined outward from the laminate 30 toward the expected margin 12 in the thickness direction (step S12: machining step). At the machining step S12, the inclined surfaces 13 are formed extending from the laminate body 30 onto the expected margin 12. Thus, the repair kit 40 is formed as the repair patch 10. That is, at the machining step S12, the side surfaces 13a of the patch body 11 of the repair patch 10 are formed, and the inclined surfaces 13b are formed in the expected margin 12.

[0047] Next, an example of a method for repairing a composite material including a portion to be repaired by using the repair patch 10 described above will be described with reference to FIG. 4. Note that similarly, in the method for repairing in FIG. 4, description will be given by applying the repair patch 10 of FIG. 1; however, the same can apply to the repair patch 20 of FIG. 2.

[0048] In the method for repairing a composite material, the repair patch 10 described above and a resin sheet 28 as an adhesive are used. The resin sheet 28 is a material obtained by forming a resin in a sheet shape, and the resin sheet 28 is a material that can be bonded to a resin used in the repair patch 10. Note that the resin sheet 28 may be the same as or different from the resin used in the repair patch 10 and is not particularly limited. In addition, a plurality of repair patches 10 having different diameters are prepared, and the repair patches 10 are appropriately selected and used depending on the shape (size) of a counterbore 6 described below to be formed.

[0049] First, a defective portion formed in the composite material is machined by cutting or the like to form the counterbore 6 having the shape illustrated in FIG. 4 (step S21). In the counterbore 6, an opening has a circular shape and a bottom surface is formed in a circular shape smaller than the opening. In addition, side surfaces of the counterbore 6 are surfaces inclined outward from the bottom surface toward the opening. In the counterbore 6, the bottom surface and the side surfaces is a surface to be bonded to which the repair patch 10 is to be bonded.

[0050] Subsequently, the resin sheet 28 is disposed in an inner surface including the bottom surface and the side surfaces of the counterbore 6 formed as a recess (step S22: adhesive arrangement step). Specifically, at the adhesive arrangement step S22, the resin sheet 28 is disposed being in contact with the inner surface of the counterbore 6 to cover the surfaces.

[0051] Next, the repair patch 10 is disposed on the resin sheet 28 while the bonding surface 18 of the repair patch 10 is disposed being opposed to the inner surface that is the surface to be bonded of the counterbore 6 (step S23: patch arrangement step). Note that, at the patch arrangement step S23, marking is applied to a surface of the expected margin 12 of the repair patch 10, and marking is applied to a surface of the composite material that is the portion to be repaired 5. Thus, the repair patch 10 may be disposed in the counterbore 6 to be appropriately positioned with respect to the counterbore 6.

[0052] Subsequently, the repair patch 10 and the resin of the resin sheet 28 are melted, and thus the repair patch 10 is bonded to the counterbore 6 (step S24: bonding step). Note that at the bonding step S24, although not illustrated, the repair patch 10 and the resin sheet 28 are hermetically sealed by using a bag film or the like, and while the inside of the sealed space is evacuated, the repair patch 10 and the resin sheet 28 are heated and are completely cured.

[0053] After the curing, the expected margin 12 of the repair patch 10 is debonded from the patch body 11 (step S25: debonding step). At the debonding step S25, the expected margin 12 is peeled from the patch body 11, and thus the bottom surface 15 of the patch body 11 is exposed. Then, a finishing process is performed on a surface of the composite material 1 that is a portion to be repaired and on the bottom surface 15 of the patch body 11 (step S26), and thus the portion to be repaired 5 is repaired.

[0054] Next, another example of a method for repairing a composite material including a portion to be repaired by using a repair kit 40 that is the repair patch 10 obtained before machining, will be described with reference to FIG. 5. Note that similarly, in the method for repairing of FIG. 5, description will be given by applying the repair patch 10 of FIG. 1; however, the same can apply to the repair patch 20 of FIG. 2. Note that in the method for repairing a composite material of FIG. 5, description of portions similar to those in the method for repairing of FIG. 4 will be omitted, and the same steps as the steps in the method for repairing of FIG. 4 will be described with the same reference signs.

[0055] First, a defective portion formed in a composite material is machined by cutting or the like to form the counterbore 6 having the shape illustrated in FIG. 4 (step S21). Subsequently, the resin sheet 28 is disposed in the inner surface including the bottom surface and the side surfaces of the counterbore 6 formed as a recess (step S22: adhesive arrangement step).

[0056] The repair kit 40 including the laminate 30 and the expected margin 12 integrally bonded is prepared before or after steps S21 and S22 (step S31). Subsequently, the repair kit 40 is machined in the same manner as at step S12 to form the inclined surfaces 13 inclined outward from the laminate 30 toward the expected margin 12 in the thickness direction, and thus the repair kit 40 is formed as the repair patch 10 (step S32).

[0057] Next, the repair patch 10 is disposed on the resin sheet 28 while the bonding surface 18 of the repair patch 10 is opposed to the inner surface that is a surface to be bonded of the counterbore 6 (step S23: patch arrangement step). Subsequently, the repair patch 10 and the resin of the resin sheet 28 are melted, and thus the repair patch 10 is bonded to the counterbore 6 (step S24: bonding step). After the bonding, the expected margin 12 of the repair patch 10 is debonded from the patch body 11 (step S25: debonding step). Then, a finishing process is performed on the surface of the composite material 1 that is a portion to be repaired and the bottom surface 15 of the patch body 11 (step S26), and thus the portion to be repaired 5 is repaired.

[0058] Next, the result of repairing of the portion to be repaired 5 that has been repaired with the repair patch 10, 20 will be described with reference to FIG. 6. Fracture strain is indicated on the vertical axis in FIG. 6. Note that, in the related art, fiber meandering has occurred at a corner portion (an edge portion) of a repair patch used for repairing a portion to be repaired. When fracture strain in the related art is compared with fracture strain in the first embodiment, it is confirmed that the fracture strain in the first embodiment is greater than the fracture strain in the related art. That is, it is confirmed that the portion to be repaired 5 is repaired with the repair patch 10, 20 of the first embodiment, and thus the recovery in strength is great, as compared with the related art.

[0059] As described above, according to the first embodiment, even in a case where the edge side (outer side) of the patch body 11 has a small thickness, the thickness can be increased by the expected margin 12. Accordingly, when the side surfaces 13a are formed in the patch body 11, the inclined surfaces 13 can be formed while strength is secured by the expected margin 12. Accordingly, the occurrence of fiber meandering in an end portion at the edge side of the patch body 11 can be suppressed. In addition, the end portion at the edge side of the patch body 11 can be protected by the expected margin 12.

[0060] In addition, according to the first embodiment, in the repair patch 10 of FIG. 1, the expected margin 12 is a peel ply, and thus the expected margin 12 can be peeled easily from the patch body 11.

[0061] In addition, according to the first embodiment, in the repair patch 20 of FIG. 2, the bonding layer 23 is provided between the patch body 11 and the expected margin 12. Thus, the patch body 11 and the expected margin 12 can be bonded via the bonding layer 23, while the expected margin 12 can be debonded from the patch body 11 at the time of debonding.

[0062] In addition, according to the first embodiment, the taper ratio L:D of the inclined surface 13 is defined such that when the thickness D is 1, the length L is not less than 10. Thus, the shape of the patch body 11 can be a shape suitable for recovering the strength of the portion to be repaired 5. In addition, even in such a shape, the occurrence of fiber meandering in the end portion at the edge side of the patch body 11 can be suppressed.

[0063] Additionally, according to the first embodiment, the inclined surfaces 13 can be formed in the patch body 11 while strength can be secured by the expected margin 12. Accordingly, the occurrence of fiber meandering in the end portion at the edge side of the patch body 11 can be suppressed. Accordingly, the repair patch 10 having an appropriate shape can be molded.

[0064] In addition, according to the first embodiment, in the method for repairing illustrated in FIG. 4, the patch body 11 can be bonded to the portion to be repaired 5 in a state where the end portion at the edge side of the patch body 11 is protected. Accordingly, the patch body 11 can be bonded to the portion to be repaired 5 while the occurrence of fiber meandering in the end portion at the edge side of the patch body 11 is suppressed.

[0065] In addition, according to the first embodiment, in the method for repairing illustrated in FIG. 5, depending on the shape of the portion to be repaired 5, the bonding surface 18 including the inclined surfaces 13 of the repair kit 40 can be machined. Accordingly, the bonding surface 18 conforming to the shape of the portion to be repaired 5 can be formed. In addition, the inclined surfaces 13 can be formed in the laminate 30 while strength is secured by the expected margin 12. Accordingly, the occurrence of fiber meandering in the end portion at the edge side of the laminate 30 can be suppressed.

[0066] Note that in the first embodiment, the expected margin 12 is peeled from the patch body 11, and thus the expected margin 12 is debonded from the patch body 11; however, for example, the expected margin 12 may be transformed by using a solvent or the like to be easily debonded.

[0067] In addition, in the first embodiment, the patch body 11 has a truncated cone shape, but the shape of the patch body 11 is not particularly limited to such a shape. The patch body 11 may have any shape as long as the patch body 11 includes the inclined surfaces 13.

Second Embodiment

[0068] Next, a repair patch 50 according to a second embodiment will be described with reference to FIG. 7. FIG. 7 is a cross-sectional view schematically illustrating an example of the repair patch according to the second embodiment. In the second embodiment, to avoid redundant description, the difference from the first embodiment will be described, and a part including the same configuration as the configuration in the first embodiment will be described with the same reference numerals assigned.

[0069] The repair patch 50 of the second embodiment further includes a release layer 51 in the repair patch 10 of the first embodiment. The release layer 51 is provided in an inclined surface 13b of an expected margin 12. The release layer 51 is, for example, an adhesive tape using a fluororesin such as Teflon (registered trademark). At the time of bonding the repair patch 50 to a counterbore 6, the release layer 51 suppresses attachment of a melted resin of a resin sheet 28 to the expected margin 12 and bonding of the expected margin 12 to a portion to be repaired 5.

[0070] As described above, according to the second embodiment, bonding of the expected margin 12 to the portion to be repaired 5 can be suppressed by the release layer 51. Note that the release layer 51 is not limited to the adhesive tape described above and may be formed by applying a fluororesin.

REFERENCE SIGNS LIST

[0071] 5 Portion to be repaired

[0072] 6 Counterbore

[0073] 10 Repair patch

[0074] 11 Patch body

[0075] 12 Expected margin

[0076] 13 Inclined surface of repair patch

[0077] 13a Side surface of patch body

[0078] 13b Inclined surface of expected margin

[0079] 14 Top surface

[0080] 15 Bottom surface

[0081] 18 Bonding surface

[0082] 20 Repair patch

[0083] 23 Bonding layer

[0084] 28 Resin sheet

[0085] 30 Laminate

[0086] 40 Repair kit

[0087] 50 Repair patch

[0088] 51 Release layer