JP2017035848A - Repairing method of composite material component and manufacturing method of composite material component - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a technique capable of improving the efficiency of repair work of composite material components.SOLUTION: Provided is a repairing method of a composite material component 10 formed with a fiber-reinforced resin composite material, which includes: a step of forming a recessed part 14 by removing a damaged part 12 of the composite material product 10 as a repairing target; a step of disposing a fiber body 16 made of a woven fabric or a nonwoven fabric along an inner surface of the recessed part 14; a step of covering the recessed part 14 where the fiber body 16 is disposed with a patch 18 formed with the fiber-reinforced resin composite material; and a step of inserting a resin 28 to a gap between the composite material component 10 as the repairing target and the patch and impregnating and curing the resin in the fiber body.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a method for repairing composite parts and a method for manufacturing composite parts, and more particularly, to a method for repairing composite parts formed of fiber-reinforced resin composite materials and a method for manufacturing composite parts.

  For structural members for aircraft and vehicles, composite parts formed of fiber reinforced resin composite materials are used. Such composite material parts may be damaged by impact or the like during assembly of the actual machine or during application to the actual machine. For this reason, repairing the damaged part of a composite material part is performed. Patent Document 1 describes a repair method for a composite material.

JP 2014-1000084

  By the way, as described in Patent Document 1 and the like, the repair method of the composite material part removes the damaged part of the composite material part, and arranges the repair material via the film adhesive in the part from which the damaged part is removed. The film adhesive and the repair material are integrally and simultaneously cured. As the repair material, a semi-cured state in which prepregs are laminated, or an uncured state in which a dry fabric is impregnated with a resin is used. In some cases, the repaired material may be a cured composite material that has been processed according to the shape of the damage removal portion.

  Moreover, the film adhesive is comprised from the base fabric layer which consists of base fabrics, such as a nylon fiber and glass fiber, and the resin layer laminated | stacked on both surfaces of a base fabric layer. Since the film-like adhesive is provided with resin layers on both sides of the base fabric layer, the film-like adhesive is not easily deformed by being restrained by the resin layer, and is not easily adapted to the shape of the part from which the damaged part is removed. For this reason, it takes time to arrange the film adhesive along the shape of the part from which the damaged part has been removed, and there is a possibility that the efficiency of the repair work of the composite material part is lowered.

  Accordingly, an object of the present invention is to provide a composite part repair method and a composite part manufacturing method capable of further improving the efficiency of repair work of composite part.

  A method for repairing a composite material part according to the present invention is a method for repairing a composite material part formed of a fiber reinforced resin composite material, wherein a damaged part of the composite material part to be repaired is removed to form a recess. A step of arranging a fiber body made of a woven fabric or a non-woven fabric along the inner surface of the concave portion, a step of closing the concave portion in which the fibrous body is arranged with a patch formed of a fiber reinforced resin composite material, and the repair target And a step of injecting a resin into a gap between the composite material part and the patch and impregnating and curing the resin in the fibrous body.

  In the method for repairing a composite part according to the present invention, the step of forming the concave portion is characterized in that an inner surface of the concave portion is formed in an uneven shape.

  A method for manufacturing a composite material part according to the present invention is characterized by including a process comprising the above-described repair method for a composite material part.

  According to the above configuration, the fiber body made of woven fabric or non-woven fabric is disposed along the inner surface of the recessed portion from which the damaged portion in the composite material part to be repaired is removed, and the recessed portion in which the fiber body is disposed is closed with the patch, and the composite to be repaired The composite material component is repaired by injecting resin into the gap between the material component and the patch and impregnating and curing the resin in the fibrous body. According to the above configuration, since the fiber body is not provided with the resin layer, the fiber body can be easily deformed and disposed along the inner surface of the concave portion. It becomes possible to improve.

In embodiment of this invention, it is a flowchart which shows the structure of the repair method of a composite material component. In embodiment of this invention, it is a schematic diagram for demonstrating each process of the repair method of a composite material component.

  Embodiments of the present invention will be described below in detail with reference to the drawings. FIG. 1 is a flowchart showing the structure of a method for repairing a composite material part. FIG. 2 is a schematic diagram for explaining each step of the method of repairing the composite material part. The method of repairing a composite material part includes a step of forming a recess (S10), a step of placing a fibrous body (S12), a step of closing with a patch (S14), and a step of impregnating and curing a resin (S16). I have.

  The step of forming the recess (S10) is a step of forming the recess 14 by removing the damaged portion 12 in the composite part 10 to be repaired formed of the fiber reinforced resin composite material.

  The composite material part 10 to be repaired is formed of a fiber reinforced resin composite material. The fiber reinforced resin composite material is composed of a reinforced fiber and a matrix resin. Examples of the reinforcing fibers include organic fibers such as PAN-based and pitch-based carbon fibers and aramid fibers, and ceramic fibers such as glass fibers and silicon carbide (SiC) fibers. As the matrix resin, for example, a thermosetting resin or a thermoplastic resin such as an epoxy resin, a bismaleimide resin, a polyimide resin, a polyester resin, or a phenol resin is used. Moreover, a unidirectional reinforcing material (UD material), a two-way reinforcing material (2D material), a three-way reinforcing material (3D material), etc. can be used for the fiber reinforced resin composite material.

  Composite material parts are applied to structural members for aircraft and vehicles (for example, automobiles), for example. When the composite material part receives an impact or the like during assembly of the actual machine or application to the actual machine, damage may occur on the surface or inside of the composite material part. FIG. 2A is a diagram illustrating the configuration of the composite material part 10 to be repaired. The composite part 10 to be repaired includes a damaged portion 12 in which damage such as surface cracks, delamination, and in-layer cracks has occurred. The damaged portion 12 can be detected by a visual inspection or the like, a nondestructive inspection such as an ultrasonic flaw inspection or a radiographic inspection.

  First, the damaged portion 12 in the composite material part 10 to be repaired is removed to form the recess 14. FIG. 2B is a diagram illustrating a state in which the concave portion 14 is formed in the composite material part 10 to be repaired. The damaged portion 12 is removed by hand processing using a grinder or the like, or processing by a processing machine such as an NC processing machine. For example, when the composite material part 10 to be repaired is a large composite material part that is difficult to be placed on a processing machine such as an NC processing machine, the damaged portion 12 is removed by manual processing. The shape of the inner surface of the recess 14 may be a smooth flat surface or curved surface such as a scarf processed surface, or may be uneven such as a manually processed surface.

  The step of arranging the fibrous body (S12) is a step of arranging the fibrous body 16 made of a woven fabric or a non-woven fabric along the inner surface of the concave portion. FIG. 2C is a diagram illustrating a state in which the fiber body 16 is disposed along the inner surface of the recess 14.

  The fibrous body 16 has a function of ensuring the thickness of an adhesive layer formed by impregnating and curing the resin in the fibrous body 16 in a step of impregnating and curing resin (described later) (S16). The fiber body 16 is composed of a woven fabric or a non-woven fabric. Since these fiber bodies 16 have gaps between the fibers, it is possible to impregnate the resin.

  The fiber body 16 is composed of a single piece of woven fabric or non-woven fabric. Unlike the film adhesive, the fiber body 16 does not have a resin layer on both sides of the fiber body 16, and is not easily restricted by the resin layer. Is possible. For this reason, the fiber body 16 can be easily adapted along the inner surface of the recess 14, and the fiber body 16 can be easily disposed along the inner surface of the recess 14. In addition, by removing the damaged portion 12 by hand, the fiber body 16 can be easily arranged along the unevenness of the inner surface of the recess 14 even when the inner surface of the recess 14 is uneven. Furthermore, since the fibrous body 16 is easily adapted to the inner surface of the recess 14, the adhesive layer can be more uniformly formed along the inner surface of the recess 14 in a step of impregnating and curing a resin described later (S 16).

  The fibrous body 16 may be a woven or non-woven fabric made of PAN-based or pitch-based carbon fiber, organic fiber such as aramid fiber, ceramic fiber such as glass fiber or silicon carbide (SiC) fiber, or the like. As for the form of the woven fabric, plain weave, satin weave, twill weave and the like can be used. In general, a woven fabric or a non-woven fabric that is commercially available for a fiber reinforced resin composite material (FRP) can be applied to the fibrous body 16. For the fiber body 16, for example, FRP cloth “WF350 100 BS6” (thickness 0.33 mm) manufactured by Nittobo Co., Ltd. can be used.

  The step of closing with the patch (S14) is a step of closing the concave portion 14 in which the fiber body 16 is disposed with the patch 18 formed of a fiber reinforced resin composite material. FIG. 2 (d) is a diagram showing a state where the concave portion 14 in which the fiber body 16 is arranged is closed with a patch 18.

  The patch 18 is a repair material formed of a fiber reinforced resin composite material. As the fiber reinforced resin composite material that forms the patch 18, a material that has been cured and molded in advance is used. Thereby, the patch 18 can satisfy the required mechanical strength and the like, and the quality is improved. For forming the patch 18, a general method for molding a fiber-reinforced resin composite material can be used. In such a molding method, for example, a method of laying up a prepreg and then curing and molding with an autoclave or the like, or putting a preform formed of a woven fabric into a mold and impregnating the preform with a resin and curing the preform. An RTM (Resin Transfer Molding) method or the like can be applied.

  The patch 18 is formed by machining into substantially the same shape as the recess 14 so that the patch 18 can be fitted into the recess 14 in which the fiber body 16 is disposed after the fiber reinforced resin composite material is molded. Further, the patch 18 may be formed by being molded in substantially the same shape as the recess 14 so that the patch 18 can be fitted into the recess 14 in which the fiber body 16 is disposed.

  The patch 18 is preferably formed of a fiber reinforced resin composite material having the same configuration as the composite material part 10 to be repaired. More specifically, the patch 18 and the composite part 10 to be repaired are preferably formed of a fiber reinforced resin composite material having the same reinforcing fiber, matrix resin, and reinforcing method. For example, when the reinforcing fiber of the fiber reinforced resin composite material forming the composite part 10 to be repaired is made of carbon fiber, the matrix resin is made of epoxy resin, and the reinforcing method is two-way reinforcement (2D material), The configuration of the fiber-reinforced resin composite material forming the patch 18 is preferably the same as this. Thereby, the mechanical strength characteristic of the patch 18 and the mechanical strength characteristic of the composite material part 10 to be repaired can be substantially equalized. Further, delamination or the like due to a difference in thermal expansion or the like between the patch 18 and the composite material part 10 to be repaired can be suppressed.

  The step of impregnating and curing the resin (S16) is a step of injecting the resin into the gap between the composite material component 10 to be repaired and the patch 18 and impregnating and curing the fiber 16 with the resin. FIG.2 (e) is a figure which shows the impregnation method of resin. An adhesive layer formed by impregnating and curing the resin in the fibrous body 16 by injecting resin into the gap between the composite material part 10 to be repaired and the patch 18 and impregnating and curing the resin in the fibrous body 16 And the patch 18 is bonded to the composite part 10 to be repaired.

  The resin impregnation method will be described in more detail. A portion of the composite material part 10 to be repaired covered with the patch 18 is covered with the vacuum back film 20. The periphery of the vacuum back film 20 is attached to the composite material part 10 to be repaired with a sealant 22 in order to prevent leakage. The vacuum back film 20 is formed of a resin film such as a nylon resin film or a polyimide resin film. In addition, in order to prevent the resin from adhering to the surface of the composite material part 10 to be repaired or the surface of the patch 18, a release film (not shown) made of a peel ply made of nylon fiber or a perforated fluorine film or the like. May be provided.

  An evacuation port 24 for evacuating is provided in the vicinity of the portion closed by the patch 18. The vacuum exhaust port 24 is configured by a vacuum drawing base or the like. A vacuum pump (not shown) is connected to the vacuum exhaust port 24.

  The resin injection port 26 is provided in the vicinity of the portion blocked by the patch 18. The resin injection port 26 is connected to a resin tank (not shown) that stores a liquid resin for impregnation. The resin tank (not shown) may be provided with heating means such as a heater in order to warm the liquid resin for impregnation and reduce the viscosity. It is preferable that the resin injection port 26 is provided at a position facing the vacuum exhaust port 24 across the portion blocked by the patch 18. As a result, air can easily escape from the gap between the composite material part 10 to be repaired and the patch 18, so that voids are formed in the adhesive layer formed by impregnating and curing the fiber body 16 with resin. Is suppressed.

  A vacuum is evacuated from the vacuum exhaust port 24, and the portion closed by the patch 18 covered with the vacuum back film 20 is decompressed. As a result, the gap between the composite material part 10 to be repaired and the patch 18 is exhausted and decompressed. Even when the gap between the composite material part 10 to be repaired and the patch 18 is reduced in pressure, the fiber body 16 is disposed along the inner surface of the recess 14, so that a space for forming an adhesive layer is secured. Is done. While evacuating from the vacuum exhaust port 24, liquid resin for impregnation is injected from the resin injection port 26. The injected resin enters through the gap between the composite material part 10 to be repaired and the patch 18 and is impregnated into the fiber body 16.

  As the resin for impregnation, for example, a thermosetting resin or a thermoplastic resin such as an epoxy resin, a bismaleimide resin, a polyimide resin, or a polyester resin is used. The resin for impregnation may contain a curing agent, an accelerator, a viscosity modifier and the like. As the impregnation resin, it is preferable to use a low-viscosity resin in order to facilitate the impregnation. Commercially available resins such as jER825 and jER801, which are epoxy resins manufactured by Mitsubishi Chemical Corporation, can be used as the resin for impregnation.

  As the resin for impregnation, it is preferable from the viewpoint of adhesiveness to use the same type of resin as the matrix resin of the fiber reinforced resin composite material forming the composite material part 10 or the patch 18 to be repaired. For example, when an epoxy resin is used for the matrix resin of the fiber reinforced resin composite material forming the composite material part 10 or the patch 18 to be repaired, it is preferable to use an epoxy resin as the resin for impregnation.

  Next, the resin impregnated in the fibrous body 16 is cured by heating in a heating furnace or the like. If the composite material part 10 is a large product that does not enter the heating furnace, it may be locally heated by an infrared heater, a rubber heater, or the like. The curing conditions differ depending on the resin used for impregnation. In the case of an epoxy resin, the curing conditions are, for example, a curing temperature of 120 ° C. to 200 ° C., and a curing time of 1 hour to 3 hours.

  FIG. 2F is a diagram illustrating a state after the fiber body 16 is impregnated and cured with resin. An adhesive layer 28 in which the resin impregnated in the fiber body 16 is cured is formed between the composite material part 10 to be repaired and the patch 18. The composite part 10 to be repaired and the patch 18 are bonded and integrated by the adhesive layer 28. In addition, since the adhesive layer 28 is formed between the composite material component 10 to be repaired and the patch 18 with substantially the same thickness, variations in adhesive strength and the like are suppressed, and the adhesiveness is improved. In this way, the repair of the composite material part 10 to be repaired is completed.

  In addition, the manufacturing method of a composite material part may include a process including a repair method (S10 to S16) of the composite material part in the above configuration. Even when the composite material part is damaged by impact or the like, the composite material part manufacturing method includes a process comprising the composite material part repair method (S10 to S16) in the above configuration, so that the composite material part is easily manufactured. It becomes possible.

  According to the method for repairing a composite material component in the above configuration, a damaged portion of the composite material component to be repaired is removed to form a recess, and a fiber body made of a woven fabric or a nonwoven fabric is disposed along the inner surface of the recess A step of closing the concave portion in which the fiber body is disposed with a patch formed of a fiber reinforced resin composite material, and injecting resin into a gap between the composite material component to be repaired and the patch, And the step of impregnating and curing the resin, the fiber body can be easily deformed to fit into the inner surface of the recess, and the fiber body can be easily disposed along the inner surface of the recess. Thereby, the efficiency of the repair work of the composite material part is further improved.

  According to the method for repairing a composite material component in the above configuration, even when the inner surface of the recess becomes uneven due to removal of the damaged portion by manual processing, the fiber body can be easily arranged along the inner surface of the recess. Therefore, the efficiency of repair work for composite parts is further improved. Further, even when the inner surface of the concave portion is uneven, the fibrous body can be adapted and disposed along the inner surface of the concave portion, so that the thickness of the adhesive layer formed by impregnating and curing the resin to the fibrous body is substantially It becomes uniform, and the adhesion between the composite material part to be repaired and the patch is improved.

  According to the composite material manufacturing method, since the composite material component repair method in the above configuration is provided, even if the composite material is damaged due to impact or the like, it can be repaired. It is possible to efficiently perform the manufacturing work.

10 Composite parts to be repaired,
12 Damaged part,
14 recess,
16 Fiber body,
18 patches,
20 vacuum back film,
22 sealant,
24 vacuum exhaust port,
26 resin inlet,
28 Adhesive layer.

Claims (3)

A method of repairing a composite part formed of a fiber reinforced resin composite material,
Removing the damaged part of the composite part to be repaired and forming a recess;
A step of arranging a fibrous body made of a woven fabric or a non-woven fabric along the inner surface of the concave portion;
A step of closing the concave portion in which the fibrous body is disposed with a patch formed of a fiber reinforced resin composite material;
Injecting resin into the gap between the composite part to be repaired and the patch, and impregnating and curing the resin in the fibrous body;
A method for repairing a composite material part comprising: A method for repairing a composite part according to claim 1,
The method of repairing a composite material part, wherein the step of forming the recess includes forming an inner surface of the recess in an uneven shape.   A method for manufacturing a composite part, comprising a step comprising the method for repairing a composite part according to claim 1.

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