COMPLETING A FIBER COMPOSITE PART

Abstract

A method of completing a fiber composite part includes the steps of providing a pre-manufactured fiber composite part, the fiber composite part including a structure of fibers embedded in a matrix of a resin, the resin being hardened; inspecting the composite part for portions of the structure of fibers that are insufficiently impregnated by the hardened resin; applying a preparation of a hardenable material to a surface portion where an identified structure portion of the structure of fibers that is insufficiently impregnated is exposed; applying mechanical vibration to the preparation applied to the surface portion to cause material of the preparation to impregnate the structure portion in a flowable state, and causing the material to solidify.

Claims

1. A method of completing a fiber composite part, the method comprising the steps of providing a pre-manufactured fiber composite part, the fiber composite part comprising a structure of fibers embedded in a matrix of a resin, the resin being hardened; inspecting the composite part for portions of the structure of fibers that are insufficiently impregnated by the hardened resin; applying a preparation of a hardenable material to a surface portion where an identified structure portion of the structure of fibers that is insufficiently impregnated is exposed; applying mechanical vibration to the preparation applied to the surface portion to cause material of the preparation to impregnate the structure portion in a flowable state, and causing the material to solidify.

2. The method according to claim 1, wherein the preparation comprises the resin material of which the matrix is made.

3. The method according to claim 1, wherein the preparation is of a curable material.

4. The method according to claim 1, wherein the vibration is a longitudinal vibration.

5. The method according to claim 1, and further comprising the step of laterally confining a flow of the preparation while the mechanical vibration is applied.

6. The method according to claim 5 comprising providing the preparation in a receptacle and pressing the tool, by which the vibrations are applied, towards the surface portion while the preparation or at least a portion thereof is within the receptacle.

7. The method according to claim 6, wherein the receptacle is open towards a distal side.

8. The method according to claim 7, wherein the receptacle is a sleeve.

9. The method according to claim 8, wherein the sleeve is collapsible.

10. The method according to claim 9, wherein during the step of applying the vibration, a tool by which the vibration is applied is moved towards the distal side and wherein a portion of the collapsible sleeve is kept at a constant position relative to a portion of the tool and in contact therewith.

11. The method according to claim 7, wherein the receptacle has a receptacle wall and a plurality of openings facing towards the distal side.

12. The method according to claim 6, wherein the receptacle comprises an open porous structure with the preparation in pores of the open porous structure.

13. The method according to claim 12, wherein the open porous structure is laterally coated by a coating impermeable to the preparation in the flowable state.

14. The method according to claim 12, wherein the open porous structure has an anisotropic porosity, such that it is permeable in longitudinal directions but not permeable or permeable to a substantially lower extent in lateral directions.

15. The method according to claim 1, wherein the step of applying the preparation to the surface portion comprises applying the preparation in a manner that the entire surface portion in which the structure of fibers is exposed is covered by the preparation.

16. The method according to claim 15, wherein a tool, by which the mechanical vibration is applied, laterally extends over the whole defect.

17. The method according to claim 15, wherein a tool, by which the mechanical vibration is applied, is moved laterally over the defect with the preparation in a pressing-iron-like manner or iteratively at different positions.

18. The method according to claim 1, wherein the step of applying the preparation to the surface portion comprises applying the preparation in a manner that only a part of the surface portion in which the structure of fibers is exposed is covered by the preparation, and the method comprises the further step of, after applying the vibration, applying a further preparation to another surface part after the step and of repeating the step of applying the vibration.

19. The method according to claim 1, further comprising the step of choosing one receptacle of different available receptacles, depending on a size and shape of the defect, prior to the step of applying the preparation.

20. The method according to claim 1, further comprising the step of applying a vacuum from a side of the part that is opposed to a side of the surface portion.

21. The method according to claim 1, wherein the mechanical vibration is applied by a sonotrode comprising a laterally projecting distal wing portion.

22. The method according to claim 1, wherein the mechanical vibration is applied by a sonotrode having a distally facing coupling-out face, wherein the coupling-out face is structured.

23. The method according to claim 22, wherein the sonotrode comprises a distally projecting peripheral ridge.

24. The method according to claim 23, wherein the peripheral ridge is interrupted so as to not extend around a full circumference.

25. A method of manufacturing a fiber composite part, the method comprising the steps of placing a structure of fibers in a mold, thereafter injecting a resin in the mold, hardening the resin, and completing the fiber composite part by the method according to claim 1.

26. A kit of parts for carrying out the method according to claim 1, the kit comprising raw material of a hardenable preparation, a plurality of receptacles for laterally confining a flow of the penetration, and a vibration application tool capable of applying the vibrations to the preparation when the same is within the receptacle.

27. The kit according to claim 26, comprising receptacles of different dimensions to adapt to different shapes and sizes of defects.

28. The kit according to claim 26, comprising vibration application tools of different dimensions to adapt to different shapes and sizes of defects.

29. The kit according to claim 26, wherein the vibration application tool is a sonotrode comprising a laterally projecting distal wing portion.

30. The kit according to claim 26, wherein the vibration application tool is a sonotrode comprising having a distally facing coupling-out face, wherein the coupling-out face is structured.

31. The kit according to claim 26, wherein the vibration application tool is a sonotrode comprising a distally projecting peripheral ridge that does not run around a full periphery of the coupling out-face but is interrupted.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0077] In the following, ways to carry out the invention and embodiments are described referring to drawings. The drawings are schematical. In the drawings, same reference numerals refer to same or analogous elements. The drawings show:

[0078] FIGS. 1a and 1b, in top view and in section, respectively, a defective fiber reinforced composite part;

[0079] FIG. 2 a first example of a method according to the invention;

[0080] FIG. 3 the possibility of vacuum assisting examples of a method according to the invention;

[0081] FIGS. 4a and b, a second example of a method according to the invention during two subsequent stages;

[0082] FIG. 5 a third example of a method according to the invention;

[0083] FIGS. 6-8 different variants of yet an other example;

[0084] FIG. 9 depicts an example of an arrangement with a thermoplastic preparation;

[0085] FIG. 10 depicts a device for applying the vibrations and a mechanical pressing force;

[0086] FIG. 11 a further arrangement for carrying out the method according to the invention;

[0087] FIG. 12 an illustration of the confining effect of the sonic pump;

[0088] FIG. 13 yet another arrangement for carrying out the method according to the invention;

[0089] FIG. 13a an illustration of a breathing effect;

[0090] FIG. 14 a bottom view of an example of a sonotrode for an arrangement as shown in FIG. 13;

[0091] FIG. 15 a bottom view of an alternative example of a sonotrode for an arrangement as shown in FIG. 13;

[0092] FIG. 16 an example of a method of repairing a non-plane fiber reinforced composite part;

[0093] FIGS. 17 and 18 alternative sonotrodes for repairing a non-plane fiber reinforced composite part;

[0094] FIG. 19 an even further arrangement for carrying out the method according to the invention;

[0095] FIG. 20 a bottom view of an alternative example of a sonotrode for an arrangement as shown in FIG. 19;

[0096] FIG. 21 an arrangement allowing for continuous feeding of the preparation;

[0097] FIGS. 22a and 22b the first and second stage, respectively, of a two-stage process; and

[0098] FIGS. 23 and 24 examples of sonotrodes with replaceable foot elements.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0099] FIGS. 1a and 1b show, in top view and in section, a defective fiber composite part 1 hat has a structure of fibers 2 embedded in a matrix of hardened resin 3. For illustration purposes, in all depicted examples, the fiber composite part is assumed to have a general flattish shape, as has for example a car body part, or an aircraft's wall or the like. All examples of the invention are, however, also applicable to parts that are not flattish but have any other shape.

[0100] A defect 4 is constituted by a portion of the part where the structure 2 is insufficiently impregnated by the resin 3 so that the fibers are exposed, and possibly the fibers are not even wetted. Such a defect may be through-going or, as in FIG. 1b, not through-going.

[0101] FIG. 2 shows the defective composite part 1 placed on a non-vibrating support 5. A preparation 10 is applied to the portion of the surface 7 where the structure of fibers is exposed. In the example of FIG. 2, the preparation 10 is a dose of a flowable, curable material, for example of a two-component mix of a resin, e.g. an epoxy or polyester resin or a thermoplastic powder, e.g. a polyamide.

[0102] A sonotrode 6 is used to apply the vibrations while being pressed towards the surface 7. This causes the flowable curable material to interpenetrate the fibers and may additionally accelerate the curing process.

[0103] As in all subsequent embodiments, an optional intermediate protecting layer (not shown), for example of a textile material or a material impervious to the preparation 10 (e.g. PTFE or Silicon films or coated papers and textiles, well known in manufacturing of fiber composite materials), may be used between the sonotrode and the preparationalternatively, the sonotrode may be coated with such a non-adhering material (PTFE, poly-fluoro-chloro polyolefines, a-CH amorphous carbon or diamond like carbon).

[0104] The embodiment of FIG. 2 is especially suited for situations where the tendency of the curable material to evade the pressure by the sonotrode 6 is minimal (for example because the material has a high viscosity) and/or can be coped with (for example if the area size of the defect is comparably large compared to its depth).

[0105] FIG. 3 yet depicts an option that exists for all examples. The non-vibrating support 5 is provided with a plurality of suction holes 21 through which a vacuum can be applied.

[0106] FIGS. 4a and 4b show a first example in which the preparation is kept in a receptacle during the step of applying the vibration. The receptacle is a sleeve 12, for example of plastics like polyurethane. At least the distal portion 12.1 of the sleeve is collapsible.

[0107] In the depicted example, the sleeve is attached to the sonotrode 6 along a circumferential region 6.1 thereof so as to close off the contained volume of the preparation 10 towards the upper (proximal) side.

[0108] For the process, the preparation 10 and the arrangement that comprises the sonotrode 6 and the sleeve 12 are placed on the surface 7, with the distal ends of the sleeve in contact with the surface 7. Then the sonotrode 6 is pressed towards the surface 7 while mechanical vibration is coupled into the sonotrode.

[0109] FIG. 4b shows the set-up towards the end of this process, with the sonotrode 6 advanced almost to the surface 7, with the collapsible end 12.1 of the sleeve 12 bulged out and with the preparation 10 impregnating the not previously impregnated portions of the fiber structure 3.

[0110] In a variant, it would be possible to not attach the sleeve to the sonotrode but keep the sonotrode shiftable in a piston-like manner within the sleeve. In this variant, it is advantageous to tightly fit the sleeve to the sonotrode. As a further possibility, such a loose fitting, flexible sleeve would allow to cover the defect and move the sonotrode inside the sleeve. The latter would allow to minimize the emission of resin fumes during the impregnation and curing process, especially if combined with a fume suction unit providing a slight pressure drop inside the sleeve.

[0111] The embodiment of FIG. 5 is distinct from the one of FIGS. 4a and 4b in that the receptacle is not a sleeve but a cushion 23 with a plurality of holes 24 facing towards the surface 7. The cushion 23 does not have any holes facing laterally or proximally but is closed off towards lateral sides and towards the sonotrode. For the process, the sonotrode 6 is pressed against the proximal side of the cusion 23 while mechanical vibration is coupled into the sonotrode 6, so as to press the preparation 10 out of the holes 24 while at the same time the cushion transmits the vibration to the interface to the part 1.

[0112] In FIG. 6, the receptacle is an open porous foam 31 soaked by the preparation 10. In the depicted embodiment, the foam 31 comprises an optional coating 32 impervious to the material of the preparation. The coating may be present at least on the lateral surfaces, in the depicted embodiment it is additionally present on the proximal surface so that the sonotrode does not come into direct contact with the preparation 10.

[0113] The example of FIG. 7 is distinct from the one of FIG. 6 in that the sonotrode 6 does not laterally extend over the entire receptacle but has a smaller lateral extension than the latter. During the step of applying the vibration, the sonotrode is placed at some place on the foam and pressed towards the surface until the foam is compressed underneath the sonotrode and flowable material of the preparation has been pressed into the structure 2 of fibers. Then, the sonotrode is caused to slide sideways over the foam 31 to effectively iron the preparation 10 into the structure. Alternatively, the sonotrode could be placed on one spot after the other so as to force the preparation into the structure 2 of fibers in a step-by-step process.

[0114] The variant of FIG. 8 is distinct from the examples of FIGS. 6 and 7 in that the foam has an anisotropic porosity, with pores oriented approximately perpendicularly to the surface so that the foam is essentially impermeable in lateral directions but well permeable in longitudinal directions.

[0115] Due to this, the receptacle does, in contrast to the previous embodiments, not have any coating.

[0116] In FIG. 8, the sonotrode 6 is shown to not laterally extend over the entire receptacle but to be moved over it. However, it would equally well be possible to use a foam with anisotropic porosity in an arrangement like that of FIG. 6.

[0117] The receptacles of the preparations shown in the previous figures may be available in different shapes and sizes so that an operator may choose a suitable receptacle, depending on the size and shape of the defect.

[0118] For preparing the preparation from a two-component material, for example a two-compartment syringe (one compartment per component) with a mixing head may be used. The mixing head may for example be disposable. It is possible to provide such a mixing head with an interface directly adapted to the used compartment, or to make the compartment one-piece with the mixing head. For example, the mixing head could directly interface with a coating 32 of the previously described kind.

[0119] FIG. 9 shows an example where the preparation 41 is not of a resin but is thermoplastic. In this, the material of the preparation is not flowable initially but becomes flowable after the mechanical energy has started impinging on it and the thermoplastic material is liquefied at least in parts.

[0120] An example of a material that can be transformed from a solid state to a flowable state by mechanical energy is Poly(methyl methacrylate) (PMMA).

[0121] There may be situations where the defect 4 is too large for a single preparation. Then the above-described processin any one of the shown embodimentsis applied firstly for one section of the defect and then is repeated at an other section until the full defect is repaired.

[0122] FIG. 10 depicts a device 51 for applying the vibration. The device 51 may be a handheld ultrasonic device. It comprises a casing 52 and a vibration generating unit 53 inside the casing, the vibration generating unit being slideable into proximal directions against the force of at least one spring 54. The sonotrode 6 is coupled to the vibration generating unit 53. The vibration generating unit may for example comprise a piezoelectric transducer block (not explicitly shown in the figure).

[0123] The vibration generating unit comprises a unit contact 56, and the casing comprises a casing contact 57. The device is configured so that the vibrations can only be switched on if the contacts 56, 57 contact each other (additionally, it may optionally be required, that the operator operates a manual switch (not shown). The contacts 56, 57 are arranged so that the contact each other only when the vibration generating unit 53 is displaced relative to the casing 52 by a certain minimal displacement, and when the vibration generating unit is not displaced too far. Therefore, the device will only operate if the sonotrode 6 is pressed against the preparation/the surface by a certain minimal pressing force and if the pressing force does not exceed a certain upper limit.

[0124] A similar principle could be applied by other means, such as light barriers, toggle switches etc. It would also be possible make an arrangement by which the device only defines an upper limit or only defines a lower limit for the pressing force.

[0125] In the arrangement of FIG. 11, the sonotrode 6 is of the kind having a laterally projecting wing portion 63 that is formed by a disc portion of the sonotrode, which disc portion is attached to a shaft portion 62 (which in the depicted embodiment can be viewed as a neck portion). The shaft portion 62 is held by a sonotrode main body 61. The main body 61, the shaft portion 62 and the disc portion are together of one piece.

[0126] When the sonotrode is subject to vibrations in axial directions (the axis in this is the proximodistal axis 20) about which the sonotrode may but does not need to be rotationally symmetric, this will cause bending vibrations of the wing portion 63 (see arrows). It has been observed that this causes an advantageous pumping effect on the preparation, which instead of being sprayed into various directions, as can be the case for plain sonotrodes without any lateral confinement, is efficiently confined and pumped into the structure of fibers 2 of the defect 4.

[0127] The fact that the bending vibrations of the wing portion 63 do cause a confinement could be verified by using the sonotrode of FIG. 11 with the distal end facing upwardly and with a preparation 10 placed on top of it. This is illustrated in FIG. 12. After the vibrations were switched on, the preparation was confined on the surface of the sonotrode and did not flow sideways, nor was there a substantial amount of preparation liquid being sprayed away.

[0128] FIG. 13 illustrates an other example. The sonotrode 6 comprises a peripheral ridge 65. The peripheral ridge 65 may extend around a full circumference, as illustrated in FIG. 14, or it may be interrupted to leave discrete ridge portions 65.1, 65.2, 65.3 with channels 68 to an outside between them, as shown in FIG. 15.

[0129] It was observed that the sonotrode designs of FIGS. 13-15 yielded a considerably improved infiltration of the structure of fibers by the preparation 10 compared to a plain sonotrode (sonotrode with a flat distal end and with purely axial vibrations) without any additional means for confinement.

[0130] A first possible explanation for this improved behavior is a simple partial confinement of the preparation by the peripheral ridge 15 as shown in FIG. 13. This confinement effect may especially contribute to the effect in the embodiment of FIG. 14.

[0131] However, especially, and somewhat surprisingly, designs like the one of FIG. 15 with channels 68 between a confined volume 67 and an outside yielded excellent results, in many cases even superior to the results achieved by a design like in FIG. 14. It was observed that when the sonotrode was held against the surface of the fiber composite part 1 while the vibrations acted, preparation initially displaced laterally to an exterior were sucked into the volume 67 and efficiently pressed into the structure of fibers.

[0132] A possible explanation for this effect is that due to the deviation from a plain sonotrode design due to the ridge 15, vibration modes different from purely axial (longitudinal) vibrations are excited in the sonotrode. Possible vibrations may include Bessel vibrations on the distal end side. Especially, such possible additional vibration modes will cause the volume 67 to be non-constant but to be subject to a breathing effect. This is very schematically (and exaggeratedly) illustrated in FIG. 13a as well as by the simple double arrows in FIG. 15. More complex vibration modes may exist in addition.

[0133] As illustrated in FIGS. 16-18, the fiber composite part 1 to be completed (repaired) does not need to be essentially flat, as shown in the other figures for illustration purposes, but can have other shapes, including bent, folded etc. The shapes of the sonotrodes 6or of replaceable foot portions thereofmay be accordingly adapted to match the surface curvatures of the defect areas in the parts. FIGS. 16-18 illustrate examples of sonotrodes 6 based on the principles of FIG. 13 (FIG. 16) and FIG. 11 (FIGS. 17, 18), respectively, but this also applies to other sonotrode principles, with or without separate confinement means.

[0134] FIGS. 19 and 20 illustrates an even further sonotrode design principle. The sonotrode has a plurality of pockets 69 at the distal end. Optional channels 68 may connect the pockets to the outside for an improved pumping effect. In addition or as an alternative inner channels 70 may connect the pockets to each other. The embodiments of FIGS. 13-15 may be viewed as special case of the principle of FIGS. 19 and 20, with the volume 67 constituting a single pocket.

[0135] FIG. 21 shows an arrangement that makes possible that the step of applying a preparation 10 to the surface portion is not necessarily carried out only before the step of applying the mechanical vibration. Rather, in this arrangement at least parts of the preparation 10 may be applied continuously or step-wise while the mechanical vibration acts or between intervals of the mechanical vibration acting. To this end, the sonotrode has a channel 71 leading to the distal end face. In principle, the preparation could be introduced directly through the channel 71. However, in practice then preparation material in the channel may absorb mechanical vibration energy, and this may lead to an at least partial hardening while the preparation is still in the channel. While there exist situations where this is desired, often it is not. Therefore, in the depicted embodiment the arrangement further comprises a tube 80 with a smaller diameter than the inner diameter of the channel 71. While the vibrations act, the tube will be self-centered in the channel 71 so that there is only minimal contact between the sonotrode 6 and the tube, and consequently the tube will be vibrationally de-coupled from the sonotrode to a large extent. This solution also features the advantage that even if preparation material remains in the tube and hardens therein after the process, only the tube being a minimal cost element needs to be disposed of after the process.

[0136] With respect to FIGS. 22a and 22b, very schematically an embodiment of the invention as a two-step process is illustrated. The Figure shows the example of a sonotrode and configuration according to FIG. 11, however, the two step-process may be carried out also for any other configuration, with or without separate confinement means.

[0137] The two-step process may be, depending on parameters like the sonotrode design, the preparation composition, the size of the defect and others, advantageous in situations where the fiber composite part after the process needs to have a smooth surface.

[0138] In a first step, shown in FIG. 22a, the vibrations act to drive the material of the preparation 10 into the structure of fibers to impregnate the structure portion in a flowable state. The mechanical vibrations in this first step stop, however, before the material hardens. Then, a separation foil 90 with a smooth surface (FIG. 22b) is put on the top of the completed spot, and again mechanical vibrations act until the surface is smoothed out and the preparation material has hardened at least to some extent.

[0139] The sonotrode 6 used in the second step may be the sonotrode also used in the first step. Alternatively, a different sonotrode may be used in the second step, or the sonotrode may be provided with a different replaceable foot for the second step. An exchange of the sonotrode or a foot portion thereof for the second step may especially be advantageous in embodiments in which the sonotrode has a non-smooth distal end face, for example by having a ridge of the hereinbefore described kind.

[0140] FIGS. 23 and 24 yet schematically illustrate sonotrodes 6 with replaceable foot portions 75. The foot portion 75 may be snapped (FIG. 23) or screwed (FIG. 24; thread 76) on the main body 61 of the sonotrode, or otherwise connected (for example by a press fit, etc.) thereto. Preferably, the connection is reversible. The foot portion 75 may be of a same material as the main body 61 or may be of a different material, for example of a low-cost material if the foot portion is designed to be disposable. In an embodiment, the foot portion is of PEEK or an other, not-melting, low adhesion Polymer like PTFE, while the main body is metallic.

[0141] Foot portions with different dimensions and shapes of distal end faces may exist.