Bonded structure and bonding-condition detecting method
10145786 ยท 2018-12-04
Assignee
Inventors
- Nozomi SAITO (Tokyo, JP)
- Takayuki Shimizu (Tokyo, JP)
- Toshio ABE (Tokyo, JP)
- Nobuo TAKEDA (Tokyo, JP)
- Shu MINAKUCHI (Tokyo, JP)
- Keigo Uhira (Tokyo, JP)
Cpc classification
B32B2262/106
PERFORMING OPERATIONS; TRANSPORTING
G01D5/35338
PHYSICS
B32B3/08
PERFORMING OPERATIONS; TRANSPORTING
B32B7/12
PERFORMING OPERATIONS; TRANSPORTING
B32B5/26
PERFORMING OPERATIONS; TRANSPORTING
International classification
G01L9/00
PHYSICS
B32B5/26
PERFORMING OPERATIONS; TRANSPORTING
B32B3/08
PERFORMING OPERATIONS; TRANSPORTING
B32B7/12
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A bonded structure includes a first member, a second member, an adhesive that bonds the first member and the second member together, and an optical fiber sandwiched between the first member and the second member. When pressure is applied to the optical fiber only from a predetermined direction, the sectional shape of the optical fiber changes to an elliptical shape, so that birefringence occurs, whereby the shape of the light spectrum changes so as to have multiple peaks. The optical fiber is used as a sensor for detecting the bonding condition between the first member and the second member based on the birefringence.
Claims
1. A bonded structure comprising: a first member; a second member; a first adhesive that bonds the first member and the second member together; and an optical fiber sandwiched between the first member and the second member, wherein a solid object is inserted between the optical fiber and at least one of the first member and the second member, the solid object being formed by hardening a second adhesive, wherein the solid object has a length covering only sensing portions of the optical fiber, wherein at least one of the first member and the second member is hardened before the first member and the second member are bonded together via the first adhesive, and wherein a bonding condition between the first member and the second member is detected based on birefringence of the optical fiber.
2. The bonded structure according to claim 1, wherein the first member and the second member are laminates of carbon fiber composite materials, and wherein the bonding condition between the first member and the second member is detected based on birefringence of the optical fiber in a case where the first member and the second member are bonded together using a pressurizing device.
3. The bonded structure according to claim 2, wherein the first member and the second member sandwiching the first adhesive and the optical fiber are covered with a bag, a pressure inside the bag is set to less than atmospheric pressure, and the bonding condition between the first member and the second member is detected based on birefringence of the optical fiber while a pressure is being applied inside an autoclave.
4. The bonded structure according to claim 1, wherein the solid object is inserted between the optical fiber and the first adhesive.
5. The bonded structure according to claim 1, wherein the optical fiber is bent multiple times.
6. The bonded structure according to claim 1, wherein a light input end of the optical fiber and a light output end of the optical fiber protrude from a same side of the first member or the second member.
7. The bonded structure according to claim 1, wherein a thickness of the solid object is defined such that a total thickness of the optical fiber and the solid object is less than a thickness of a bonding layer formed of the first adhesive.
8. A bonding-condition detecting method comprising: bonding a first member and a second member together using a first adhesive with an optical fiber sandwiched therebetween; and detecting a bonding condition between the first member and the second member based on birefringence of the optical fiber, wherein a solid object is inserted between the optical fiber and at least one of the first member and the second member, the solid object being formed by hardening a second adhesive, wherein the solid object has a length covering only sensing portions of the optical fiber, and wherein at least one of the first member and the second member is hardened before the first member and the second member are bonded together via the first adhesive.
9. The bonding-condition detecting method according to claim 8, wherein the optical fiber is bent multiple times.
10. The bonding-condition detecting method according to claim 8, wherein a light input end of the optical fiber and a light output end of the optical fiber protrude from a same side of the first member or the second member.
Description
BRIEF DESCRIPTION OF DRAWINGS
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DESCRIPTION OF EMBODIMENTS
(15) Now, an embodiment of a bonded structure and a bonding-condition detecting method according to the present invention will be described with reference to the drawings.
(16) [First Embodiment]
(17) Here, a first embodiment of the present invention will be described.
(18)
(19) The bonded structure 10 includes a laminate 12A, a laminate 12B, an adhesive 14 that bonds together the laminate 12A and the laminate 12B, and an optical fiber 16 sandwiched between the laminate 12A and the laminate 12B. The optical fiber 16 is used as a sensor (optical fiber sensor) for detecting the bonding condition between the laminate 12A and the laminate 12B based on birefringence. For example, the optical fiber 16 is a single mode fiber with a cladding diameter of 125 m and a circular cross section.
(20) The adhesive 14 is formed, for example, as a bonding layer. Although there is no particular limitation as to the kind of the adhesive 14, for example, an epoxy-resin-based adhesive can be used.
(21) Before the laminates 12 A and 12B are bonded together via the adhesive 14, at least one of them is hardened.
(22) Furthermore, although the planar shapes of the laminates 12A and 12B shown in
(23) The optical fiber 16 shown in
(24) Furthermore, although the optical fiber 16 shown in
(25) Furthermore, as shown in
(26) The laminates 12A and 12B are bonded together by applying a pressure to them with the adhesive 14 sandwiched therebetween. When the pressure is applied to the laminates 12A and 12B, a pressure is also applied to the optical fiber 16.
(27) When the pressure is not applied to the optical fiber 16, the light spectrum has only one peak, as shown in
(28) That is, when the laminates 12A and 12B are bonded together by suitably applying a pressure, a pressure is applied to the optical fiber 16 from both directions associated with the laminate 12A and the laminate 12B, and the light spectrum of the optical fiber 16 exhibits multiple peaks due to birefringence. By using the optical fiber 16 as a pressure sensor as described above, it becomes possible to detect the bonding condition between the laminates 12A and 12B.
(29) In the first embodiment, in which bonded members are the laminates 12A and 12B of carbon fiber composite materials, when the laminates 12A and 12B are bonded together by using a pressurizing device (e.g., an autoclave in the first embodiment), the bonding condition is detected based on birefringence of the optical fiber 16. Thus, in the first embodiment, it is possible to determine whether members are bonded together appropriately when bonding together the laminates 12A and 12B of carbon fiber composite materials as members.
(30) Next, test results for the first embodiment will be described by using
(31)
(32)
(33) As shown in
(34) In
(35) Then, the temperature was raised in the next step. Referring to
(36) While the temperature was being raised, the peak of the light spectrum converged back to one. This is because the viscosity of the adhesive 14 decreased due to the temperature rise, so that the non-axisymmetric pressure applied to the optical fiber 16 only from a predetermined direction decreased, whereby the deformation of the sectional shape of the optical fiber 16 was alleviated. Even when the pressure applied to the optical fiber 16 decreased, a pressure required for bonding was maintained at the laminates 12A and 12B.
(37) Then, the adhesive 14 was hardened after the temperature rise, whereby the laminates 12A and 12B were bonded together.
(38) On the other hand,
(39) As shown in
(40) Furthermore, even during the temperature rise, the shape of the light spectrum did not change except that the peak position shifted to the higher frequency side.
(41) This indicates that, with the hydrostatic pressure, a sufficient pressure required for bonding was not applied to the laminates 12A and 12B due to the occurrence of voids, etc. in the adhesive 14.
(42) The results shown in
(43) In the conventional manufacturing process, the bag is vacuum-pumped and is maintained in that state until shaping is finished or is vacuum-pumped and is opened to the atmosphere when the pressure becomes 1 atm or higher. Furthermore, the autoclave is opened to the atmosphere when the adhesive 14 is hardened, cooling is started, and the temperature becomes 60 C. or lower.
(44) On the other hand, in the test for the first embodiment, shown in
(45) Accordingly, a pressure is applied continuously to the laminates 12A and 12B until the adhesive 14 is hardened, so that the laminates 12A and 12B are bonded together more reliably.
(46) Furthermore, it was confirmed that when cooling was started with a certain pressure applied, the sectional shape of the optical fiber 16 again changed to an elliptical shape, which resulted in birefringence. In accordance with this phenomenon, multiple (two) peaks again appeared in the light spectrum. By utilizing this phenomenon, it is possible to combine multiple bonded structures 10, for example, for use as a structural member of an airplane, and to detect the detachment status between the laminates 12A and 12B in real time by measuring the light spectrum even while the airplane is in flight. This is because when the laminates 12A and 12B become detached from each other, the change in the sectional shape of the optical fiber 16 is alleviated, so that the light spectrum exhibits only one peak.
(47) [Second Embodiment]
(48) Now, a second embodiment of the present invention will be described.
(49)
(50) As shown in
(51) The example shown in
(52) A solid element 30 is inserted between the optical fiber 16_2 and the laminate 12B. Furthermore, a solid element 30 is inserted between the optical fiber 16_3 and the adhesive 14.
(53) For example, the solid elements 30 are made of hardened adhesive, and examples thereof include chemical setting, thermosetting, and thermoplastic adhesives.
(54) A chemical setting adhesive is an adhesive whose hardening response progresses, for example, when two liquids, namely, a main agent and a hardening agent, are mixed together. An example thereof is EA9394 from Henkel.
(55) A thermosetting adhesive is an adhesive whose hardening response progresses when heat is applied to the adhesive from outside. An example thereof is FM300-2 from Cytec.
(56) A thermoplastic adhesive is an adhesive whose hardening response progresses when a polymerization reaction occurs due to heat applied to the adhesive and then heat is dissipated. An example thereof is PPS resin (Poly Phenylene Sulfide Resin).
(57) Furthermore, as the solid elements 30, shims such as unhardened prepregs used to adjust the gaps at the bonding regions may be used.
(58) In the second embodiment, as an example of the solid elements 30, an element formed by hardening FM300-2 from Cytec, mentioned above, was used. In the second embodiment, as an example, FM300-2 from Cytec was also used as the adhesive 14.
(59) Since the solid elements 30 are formed by hardening an adhesive of the same kind as the adhesive 14 as described above, so that the solid elements 30 and the adhesive 14 are integrated (assimilated) in the bonding process of the bonded structure 10, the solid elements 30 do not become impurities in the bonded structure 10, and the strength in the vicinity of the regions where the solid elements 30 are inserted is not reduced.
(60) Furthermore, the choice among chemical setting, thermosetting, thermoplastic, and other types of adhesive for use as the solid elements 30 is determined suitably in accordance with the shape of the solid elements 30, the kind of the adhesive 14 used, etc.
(61) Furthermore, for example, the size of the solid elements 30 is a plate shape of 20 mm5 mm, and their lengthwise direction is aligned with the directions of the optical fibers 16. The solid elements 30 need not be inserted in association with the entire optical fibers 16, and it suffices to insert the solid elements 30 in regions associated with sensing portions of the optical fibers 16. The shape of the solid elements 30 need not be a rectangular shape and may be a square shape, a polygonal shape other than a rectangular shape, a circular shape, etc. Furthermore, the thickness of the solid elements 30 is chosen such that the total thickness of the optical fibers 16 and the solid elements 30 is less than the thickness of the bonding layer formed of the adhesive 14.
(62)
(63) First, to form the bonded structure 10, the laminate 12A, the adhesive 14, the optical fibers 16, and the laminate 12B are stacked in that order (
(64) Then, the laminated assembly is covered with a bag 40 (
(65) Then, the interior of the bag 40 is vacuum-pumped to set the internal pressure to less than the atmospheric pressure (
(66) Then, a predetermined pressure is applied from the outside of the bag 40 (autoclave pressurization) (
(67) Then, heat is applied at a predetermined temperature from the outside of the bag 40 (autoclave heating) (
(68) Then, after cooling for a predetermined period, the hardening of the adhesive 14 is finished, whereby the bonded structure 10 is formed (
(69)
(70) In
(71) Furthermore, there were no significant differences among the temperatures measured by the temperature sensors 30 associated with the optical fibers 16_1, 16_2, and 16_3, and the temperatures changed substantially the same over time.
(72) Region A in
(73) Region B corresponds to the case where the vacuum interior of the bag 40 was opened, whereby the non-axisymmetric strains of the optical fibers 16_2 and 16_3 were eliminated. Region B was provided experimentally in order to measure the non-axisymmetric strains of the optical fibers 16_2 and 16_3, and the above operation is not performed in the actual initial pressurizing process.
(74) Region C corresponds to the case where the vacuum pumping of the interior of the bag 40 was resumed, in which the amounts of non-axisymmetric strains of the optical fibers 16_2 and 16_3 increased, similarly to region A.
(75) For both regions A and C, the sensitivity of the optical fiber 16_3, in association with which the solid element 30 was inserted in the gap with the adhesive 14, was higher than the sensitivity of the optical fiber 16_2, in association with which the solid element 30 was inserted in the gap with the laminate 12B.
(76) Therefore, it is preferred to insert the solid elements 30 between the optical fibers 16 and the adhesive 14. This makes it possible to determine more accurately whether members are bonded together appropriately even during the bonding process of the bonded structure 10 in which the laminates 12A and 12B have not yet been bonded together or are being bonded together.
(77) Region D corresponds to the case where autoclave pressurization was performed (
(78) Region E corresponds to the case where the pressure was removed, at which time the pressure decreased to 1 atm and the non-axisymmetric strains of the optical fibers 16_2 and 16_3 were eliminated. Region E was provided experimentally in order to measure the non-axisymmetric strains of the optical fibers 16_2 and 16_3, and the above operation is not performed in the actual initial pressurizing process.
(79) Region F corresponds to the case where the autoclave pressurization was resumed, at which time the amounts of non-axisymmetric strains of the optical fibers 16_2 and 16_3 increased, similarly to region D.
(80) The amounts of non-axisymmetric strains of the optical fibers 16_2 and 16_3 increased as the pressure was applied. However, when heating was started, the adhesive 14 gradually softened, so that the stress applied to the optical fibers 16_2 and 16_3 was alleviated, whereby the amounts of non-axisymmetric strains gradually decreased.
(81) Changes in the amount of non-axisymmetric strain of the optical fiber 16_1, in association with which no solid element 30 was inserted, were smaller compared with those of the optical fibers 16_2 and 16_3.
(82) The reason is that, since no solid element 30 was inserted in association with the optical fiber 16_1, when a pressure was applied, the optical fiber 16_1 entered the adhesive 14 instead of a stress being applied thereto, so that the shape of the optical fiber 16_1 did not change. On the other hand, the optical fibers 16_2 and 16_3, in association with which the solid elements 30 were inserted, were hindered from entering the adhesive 14 by the solid elements 30. Thus, a stress was applied to the optical fibers 16_2 and 16_3, and the shapes thereof changed, which resulted in changes in the amounts of non-axisymmetric strains. This made it possible to determine whether members are bonded together appropriately even during the bonding process of the bonded structure 10.
(83) Furthermore, the test results shown in
(84) Therefore, it is preferred to insert the solid elements 30 between the optical fibers 16 and the adhesive 14. Accordingly, in the second embodiment, it is possible to more accurately determine whether members are bonded together appropriately even during the bonding process of the bonded structure 10 in which the laminates 12A and 12B have not yet been bonded together or are being bonded together.
(85)
(86) In
(87) It is to be noted that although the amounts of non-axisymmetric strains of the optical fibers 16_2 and 16_3 increased and decreased even before heating was started (from 0 to just after 100 minutes), the increases and decreases were attributable to large variations in the light spectrum due to vacuum pumping, pressurizing, etc. of the bag 40, which resulted in incorrect calculation of the non-axisymmetric strains.
(88) As shown in
(89) The reason for this is as follows. Since the adhesive 14 softened when heated, the optical fiber 16_1 entered the adhesive 14 instead of a stress being applied thereto. On the other hand, the optical fibers 16_2 and 16_3 were hindered from entering the adhesive 14 by the solid elements 30, so that a stress was applied to the optical fibers 16_2 and 16_3, whereby the shapes thereof changed.
(90) However, the adhesive 14 further softened as the temperature rose, and the stress applied to the optical fibers 16_2 and 16_3 was alleviated, so that the amounts of non-axisymmetric strains gradually decreased.
(91) As for the optical fiber 16_1, in association with which no solid element 30 was inserted, there was no significant change in the amount of non-axisymmetric strain even when the temperature rose.
(92) When heating was finished, the temperature fell, and cooling was started, the adhesive 14 hardened, and the stress applied to the optical fibers 16_1, 16_2, and 16_3 increased. Accordingly, the amounts of non-axisymmetric strains of the optical fibers 16_1, 16_2, and 16_3 increased.
(93)
(94)
(95) As described hereinabove, in the bonded structure 10 according to the second embodiment, the solid element 30 is inserted between the optical fiber 16 and at least one of the laminate 12A and the laminate 12B.
(96) Accordingly, with the bonded structure 10 according to the second embodiment, it is possible to determine whether members are bonded together appropriately even when the laminates 12A and 12B have not yet been bonded together or are being bonded together.
(97) Although the present invention has been described in the context of the above-described embodiments, the technical scope of the present invention is not limited to the scopes of the above-described embodiments. It is possible to make various modifications and improvements to the above-described embodiments without departing from the scope of the invention, and the modes involving such modifications and improvements are also included in the technical scope of the present invention.
(98) For example, although the above embodiments have been described in the context of examples where the bonded members are the laminates 12A and 12B of carbon fiber composite materials, without limitation thereto, according to the present invention, for example, the bonded members may be fiber-reinforced resin-based composite materials reinforced with glass fibers, etc. or metallic materials such as aluminum alloys.
(99) TABLE-US-00001 {Reference Signs List} 10 Bonded structure 12A Laminate 12B Laminate 14 Adhesive 16 Optical fiber 30 Solid element