Device and method for rapidly repairing broken hole damage of composite material

Abstract

The invention discloses a device and a method for rapidly repairing composite material broken hole damage. The device is composed of a broken hole rapid plugging module, an integrated rapid repairing bag and an intelligent energy control module. The broken hole blocking and sealing device is used for blocking the back face of a broken hole and composed of a metal pull rod and a silica gel pad. The integrated rapid repairing bag is of a multi-layer flexible structure and is composed of a second stripping film, a sealing rubber ring, a prepreg, demolding cloth, a vacuum film, a heating layer, a heat preservation layer and a fixing adhesive tape, and rapid heating and curing can be achieved. The intelligent energy control module is composed of a miniature power source, a miniature temperature control digital display module and a miniature timer and used for controlling the heating process. The repairing method comprises the five steps of surface cleaning, back face blocking, integrated rapid repairing bag pasting, heating curing and cleaning. The device solves the problems of long composite material broken hole damage repair time, complex device, low efficiency and the like in a battlefield environment, and has the advantages of rapidness, portability and simplicity and convenience in operation.

Description

Technical Field

[0001] This invention belongs to the field of composite material repair technology, specifically relating to a device and method for rapid repair of pore damage in composite materials. Background Technology

[0002] Composite materials, with their advantages of high specific strength, high specific stiffness, and corrosion resistance, have become indispensable materials for core equipment in aerospace, defense equipment, shipboard platforms, armored vehicles, and advanced weapon systems. However, in complex and ever-changing environments such as the battlefield, composite material structures are susceptible to high-speed impacts from projectiles and fragments, resulting in penetrating damage. Such damage severely disrupts the overall force transmission path of the structure, leading to a significant decrease in its compression, shear, and bending properties, directly affecting the equipment's mobility, safety, and mission execution capabilities. Therefore, under forward-looking conditions such as battlefield or field training, how to achieve rapid and effective repair of composite material perforation damage, quickly restore structural integrity and basic functions, and ensure equipment withdrawal from the battlefield or continued mission execution has become a key issue in maintaining the continuous combat capability of the armed forces.

[0003] Currently, the composite material repair technologies widely used in civil aviation and industrial fields mainly include adhesive bonding repair and prepreg autoclave / thermal compression repair. However, these methods are complex, require numerous equipment, are time-consuming, and heavily rely on constant temperature and humidity workshop environments and stable energy supplies, making it difficult to meet the urgent needs of the front lines for rapid, mobile, and efficient support. Among existing technologies, Chinese patent application No. 201610118271.6, "Method and Apparatus for Microwave Non-destructive Testing, Rapid Repair, and Real-time Monitoring of Composite Materials," proposes a method and apparatus for microwave non-destructive testing, rapid repair, and real-time monitoring of composite materials. It uses the same microwave source to achieve heating curing and signal monitoring, and has the function of synchronous monitoring of the repair process. However, this scheme does not specify the curing efficiency, and there is currently a lack of miniature portable microwave equipment suitable for battlefield environments, limiting its application in on-site emergency repairs. Chinese Patent Application No. 201810253703.3, entitled "A Rapid Self-Healing Device and Method for Composite Material Components in the Field," provides a rapid self-healing device and method for composite material components in the field. By integrating the repair equipment into a portable toolbox and utilizing conductive prepreg patches for self-heating, it aims to improve the convenience of field repair. However, this solution still suffers from problems such as low equipment integration, complex operation procedures, long repair cycles, and insufficient overall portability.

[0004] In summary, existing composite material repair technologies generally suffer from common problems such as complex equipment, high energy consumption, cumbersome processes, and long repair cycles, making them unsuitable for resource-constrained and time-sensitive emergency scenarios in battlefields or the field. Therefore, there is an urgent need to develop a highly integrated, portable, easy-to-operate, and rapidly curing composite material pore damage repair device and method to fill the technological gap and meet the practical needs of emergency repairs. Summary of the Invention

[0005] The technical problem this invention aims to solve is to provide a device and method for rapid repair of perforated damage in composite materials. This addresses the issues of complex repair processes, bulky equipment, excessively long repair times, and low efficiency encountered in existing technologies, particularly in harsh environments such as battlefields and the field, when composite material structures (such as armor, bulletproof plates, and helmets) suffer perforated damage. This invention provides an integrated, portable rapid repair device and method that enables rapid and effective on-site repair of perforated damage in composite materials.

[0006] The technical solution of this invention is: A device for rapid repair of pore damage in composite materials includes a rapid pore sealing module, an integrated rapid repair kit, and an intelligent energy control module. It is used to repair materials with pores having a diameter of R1. The rapid pore sealing module is inserted into and seals the back of the pore in the material to be repaired, achieving rapid sealing. The integrated rapid repair kit is attached to the surface of the pore and is heated by the intelligent energy control module, thereby completing the reinforcement and curing repair of the pore.

[0007] The quick hole plugging module includes a metal pull rod and a pre-coated silicone pad. The silicone pad can be quickly positioned and pressed against the back of the hole through threaded connection, and can be conveniently disassembled after plugging. The silicone pad is used to seal and plug the hole from the back. It is made of silicone material with a temperature resistance of ≥150°C. The back side (i.e., the side that fits against the back of the hole) is pre-coated with a high-temperature adhesive layer and covered with a first release film to ensure stable adhesive performance during storage. When in use, the release film can be peeled off to expose the bonding surface. The silicone pad is circular, with a diameter R2 satisfying R1 < R2, and a thickness H1 satisfying 4mm ≤ H1 ≤ 5mm. It can cover the size range of common bullet holes and impact holes, and can provide sufficient compression and resilience to ensure an effective sealing pressure is formed after being tightened outward by the metal pull rod towards the hole. The metal pull rod is T-shaped, composed of a long rod and a short rod that are perpendicular to each other. The length L1 of the long rod satisfies 5cm ≤ L1 ≤ 20cm to meet the operating requirements of different thickness structures; the short rod serves as a handle, with a length L2 satisfying 4cm ≤ L2 ≤ 10cm, which conforms to ergonomics and is convenient for holding and applying a stable tightening force. The overall diameter R4 of the metal pull rod satisfies 1mm ≤ R3 ≤ 2mm. The bottom end of the long rod is provided with external threads, with a thread diameter R5 satisfying 2mm ≤ R2 ≤ 15mm and a thread height H2 satisfying 3mm ≤ H2 ≤ 4mm, which are used to screw into the center of the silicone pad to form a reliable mechanical connection, facilitating the pushing and tightening of the silicone pad to be fixed on the back of the hole.

[0008] The integrated rapid repair kit employs a multi-layered flexible stacked design, comprising, from bottom to top, a second release film, a sealing ring, a pre-impregnated body, a release cloth, a vacuum membrane, a heating layer, an insulation layer, and a fixing tape. The rapid-curing resin, fiber reinforcement layer, and pre-impregnated body are composed of the fiber reinforcement layer and the rapid-curing resin. The fiber reinforcement layer, as the main load-bearing structure, is composed of a combination of plain and twill woven carbon fiber cloth stacked (2-20 layers). To provide sufficient strength, its area is at least twice the area of ​​the puncture. To reduce the difficulty of cutting the fiber cloth, the fiber cloth is typically square, and its length L6 should satisfy R1≤L6 to ensure sufficient load transfer. The rapid-curing resin is a nano-reinforced, single-component epoxy latent curing resin that remains stable during storage and is easy to transport. This resin is fully impregnated into the fiber reinforcement layer during manufacturing to form the pre-impregnated body. The rapid-curing resin consists of an E51 epoxy resin matrix, modified amine or imidazole latent curing agents, and carbon nanotubes or graphene nanoreinforcing materials. The mass ratio of the E51 epoxy resin matrix, modified amine or imidazole latent curing agents, and carbon nanotubes or graphene nanoreinforcing materials is 100:25~35:0.5~2. The curing trigger temperature of the modified amine or imidazole latent curing agents is ≥80℃. The addition of nanomaterials aims to simultaneously improve the resin's thermal conductivity, mechanical properties, and interfacial adhesion. This resin system initiates a curing reaction at 80℃, and completes curing in 30~35 minutes when the temperature is maintained at 80℃, or in 10~12 minutes at 120℃. The carbon fiber woven fabric layer and the nano-reinforced rapid-curing resin serve as the main core repair components, providing structural reinforcement after the resin cures, thereby restoring the strength of the material to be repaired. The sealing ring 22 serves as the main sealing and bonding frame of the repair package. It is made of synthetic rubber or butyl tape with a temperature resistance of ≥150℃ and forms the boundary of the core working area in a ring shape (such as a square frame). Its width L4 satisfies 1cm ≤ L4 ≤ 2cm, and its thickness H3 satisfies 2mm ≤ H3 ≤ 10mm. The enclosed inner area is used to accommodate reinforcing material, and the side length L5 of the inner area satisfies L6 + 10mm ≤ L5 ≤ L6 + 20mm. A second release film, made of fluoroplastic, is pre-placed at the bottom of the ring to protect the bonding surface during storage. Its length L3 satisfies L5 + 2L4 + 20mm ≤ L3 ≤ L5 + 2L4 + 30mm. A vacuum film covers and adheres to the sealing ring, forming an upper sealed cavity together with the ring, providing a stable physical constraint environment for the curing process. Its length L8 satisfies L8 = L3. The vacuum membrane, sealing ring, and second release membrane together form a sealing and interface layer, which is used to achieve reliable adhesion and sealing between the repair package and the damaged substrate, prevent resin loss, and isolate the external environment.The heating layer is attached to the outer surface of the vacuum membrane and is made of polyimide electrothermal film. Its thickness H4 meets the requirement of 1mm ≤ H4 ≤ 2mm, and its length L9 meets the requirement of L9 = L5 + 2L4. The maximum heating temperature is 125-150℃, and the operating voltage is DC 1-21V. It is preferably equipped with a Type-C or Type-A universal interface for quick connection to a portable power supply. The insulation layer completely covers the heating layer and is adhered to the vacuum membrane. It uses high-efficiency heat insulation materials such as nano-aerogel, with a thickness H5 meeting the requirement of 3mm ≤ H5 ≤ 20mm, and a length L... 10 Satisfying L9+20mm≤L 10 ≤L9+30mm. Its function is to reduce heat loss, improve heat utilization efficiency, and ensure that heat is concentrated in the core repair layer. The heating layer and insulation layer can provide and maintain the heat required for curing, ensuring efficient and uniform curing process. The release cloth is laid between the fiber reinforcement layer and the vacuum membrane. The material is polyester or nylon with a temperature resistance of ≥150℃. To facilitate removal with the sealing ring after curing, its edge is pasted on the sealing ring, and its length L7 satisfies L7=L5+L4. Its function is to provide an easy-to-peel interface for the repair after curing, thereby obtaining a smooth surface. The fixing tape is pasted on the outer surface of the insulation layer in a cross or other form. It is made of high-temperature resistant flexible material such as Teflon, and its thickness H6 satisfies 0.13mm≤H6≤0.25mm. Its function is to apply auxiliary pressure after attachment to enhance the initial fit of the repair package to complex curved surfaces. All materials of the quick repair package are flexible and can adapt to curved surface structures.

[0009] The intelligent energy control module integrates a miniature power supply, a miniature temperature control display module, and a miniature timer within a lightweight plastic housing. The miniature power supply, with an output voltage of 5-24V, powers the miniature temperature control display module, the miniature timer, and the heating layer. Its capacity ranges from 10,000 to 40,000mAh, ensuring that a single full charge supports multiple complete repair processes. The miniature temperature control display module, also with a driving voltage of 5-24V, monitors and controls the heating temperature. Its temperature sensor is pre-positioned between the heating layer and the vacuum membrane, directly and accurately sensing the actual temperature acting on the repair material and feeding the signal back to the control module. The miniature timer, also with a driving voltage of 5-24V, controls the heating time. Upon reaching a preset time, it automatically or prompts to cut off heating to prevent under-curing or over-curing.

[0010] The method for rapidly repairing damaged composite materials using the aforementioned rapid repair device for composite material pores includes the following steps: Step 1: Surface Cleaning. Use 80-120 grit sandpaper to sand the area around the hole. The sanded area should be larger than the area covered by the fiber reinforcement layer, and remove the surface paint and contaminants. Then, use a wire brush to lightly scribble a dense, irregular crosshatch pattern in the sanded area. Thoroughly clean the area with a non-woven cloth dampened with anhydrous alcohol, and then wipe it dry with a dry non-woven cloth. Step 2: Backside Sealing. Select a silicone pad with a diameter larger than the puncture diameter and peel off the first release film on its surface. Screw the threaded end of the metal rod into the center of the silicone pad to assemble a quick-sealing module for the puncture. Then, insert the quick-sealing module into the puncture from the front. After the silicone pad has completely passed through the puncture, pull the metal rod outwards from the puncture surface to firmly adhere the edge of the silicone pad to the bottom side of the puncture. After fixing, rotate the metal rod in the opposite direction to separate it from the silicone pad and remove it. Step 3: Attach the integrated quick-repair kit. Peel off the second release film at the bottom of the integrated quick-repair kit, align the exposed sealing ring with the hole in the material to be repaired, and press firmly with your palm to ensure the sealing ring adheres tightly to the surface of the hole. Then, pull the two fixing tapes on the surface of the insulation layer taut and attach them to the surface of the material to be repaired, so that the entire integrated quick-repair kit is firmly fixed to the surface of the hole in the material to be repaired. Step 4: Heating and Curing. Connect the universal plug of the heating layer to the miniature power supply of the intelligent energy control module. Turn on the miniature power supply switch and set the heating temperature of the miniature temperature control digital display module to 120℃. The device starts working, and the heating layer begins to heat. At this time, the viscosity of the fast-curing resin decreases and its fluidity increases due to heat, and the excess fast-curing resin at the bottom of the pre-impregnated body will fill the pores. When the temperature exceeds 80℃, the fast-curing resin begins to react and gradually cure. When the temperature reaches 120℃, the curing speed will accelerate. At this time, start the miniature timer to ensure that the fast-curing resin is completely cured. During this period, the miniature temperature control digital display module maintains 120℃. Step 5: Cleaning. After timing T (T is 10-12 minutes, preferably 10 minutes), the miniature timer will sound an alarm and the power will be turned off. Remove the heating layer and insulation layer. After the repaired area has cooled naturally to room temperature, peel off the vacuum membrane, release cloth, and sealing ring together. At this point, the carbon fiber reinforcement layer and cured resin have formed a strong patch that bonds well with the material to be repaired, and the repair is complete.

[0011] Compared with the prior art, the present invention can achieve the following beneficial effects: 1. The device of the present invention provides rapid and efficient repair. It adopts an integrated rapid repair kit and intelligent energy control module, which can complete resin curing in about 10 minutes, greatly shortening the repair time and meeting emergency needs. 2. The device of this invention has a compact structure, and all components are easy to carry and integrate, making it particularly suitable for use in resource-constrained environments such as the field and battlefield. Furthermore, it is easy to operate, requiring no complex equipment or specialized training; ordinary soldiers or operators can perform the task. 3. The rapid repair kit of this invention is flexible, allowing it to conform well to various curved structures. Simultaneously, the heating and insulation layer is reusable, enhancing the device's versatility. The device is simple to manufacture, has low repair costs, and can be mass-produced. Attached Figure Description

[0012] Figure 1 This is an overall structural diagram of the device of the present invention; Figure 2 This is a structural diagram of the rapid hole-sealing module of the present invention; Figure 3 This is a structural diagram of the integrated rapid repair package of the present invention; Figure 4 This is a schematic diagram of the intelligent energy control module of the present invention; Figure 5 These are comparison images of the repair process before and after in Embodiment 1 of the present invention. Figure 5 (a) is the image before restoration. Figure 5 (b) is the restored image.

[0013] Explanation of reference numerals in the attached figures: 1. Rapid pore sealing module; 2. Integrated rapid repair kit; 3. Intelligent energy control module; 4. Material to be repaired; 11. Metal pull rod; 12. Silicone pad; 121. First release film; 21. Second release film; 22. Sealing ring; 23. Pre-impregnated body; 231. Rapid curing resin; 232. Fiber reinforcement layer; 24. Release cloth; 25. Vacuum membrane; 26. Heating layer; 27. Universal connector; 28. Insulation layer; 29. ​​Fixing tape; 31. Miniature power supply; 32. Miniature temperature control digital display module; 33. Miniature timer; 321. Temperature sensor. Detailed Implementation

[0014] The present invention will be further described below with reference to the accompanying drawings and embodiments. It should be noted that the following embodiments are merely illustrative of certain specific implementations of the method and are not intended to limit the scope of protection of the present invention. Furthermore, any modifications and variations made by those skilled in the art based on the principle of the rapid repair device for composite material pores of the present invention after its disclosure are within the scope defined by the appended claims.

[0015] Figure 1 This is an overall structural diagram of the device of the present invention. (See diagram below.) Figure 1As shown, the device of the present invention consists of a rapid hole plugging module 1, an integrated rapid repair package 2, and an intelligent energy control module 3, and is used to repair a material 4 to be repaired with a hole diameter of R1. Among them, the rapid hole plugging module 1 is inserted and sealed on the back of the hole of the material 4 to be repaired, realizing rapid sealing of the bottom. The integrated rapid repair package 2 is attached to the surface of the hole and is electrically heated by connecting to the intelligent energy control module 3, thereby completing the reinforcement and curing repair of the hole. The material 4 to be repaired is a resin fiber composite material (such as carbon fiber, glass fiber, ultra-high molecular weight polyethylene resin composite material, or a metal matrix or ceramic matrix composite material).

[0016] Figure 2 is the structural diagram of the rapid hole plugging module 1. As Figure 2 shown, this module mainly consists of a metal pull rod 11 and a silicone pad 12. The silicone pad 12 is quickly positioned and pressed at the bottom of the hole through threaded connection, and can be easily disassembled from the silicone pad 12 after the bottom is sealed. The silicone pad 12 is used to seal and plug the hole from the bottom of the hole, and is made of a silicone material with a temperature resistance of ≥150°C. The side of the silicone pad 12 that fits the bottom of the hole is pre-coated with a high-temperature resistant adhesive layer, and a first release film 121 is covered on the surface of the high-temperature resistant adhesive layer to ensure stable adhesive performance during storage. When in use, the first release film 121 is peeled off to expose the bonding surface. The surface area of the silicone pad 12 that fits the bottom of the hole covers the area of the bottom of the hole. The shape of the silicone pad 12 is preferably a disc shape, with a diameter R2 satisfying R1 < R2, where R1 is the hole diameter, and a thickness H1 satisfying 4 mm ≤ H1 ≤ 5 mm, which can cover the common bullet hole and impact hole size ranges, and can provide sufficient compression and resilience to ensure effective sealing pressure is formed after being tightened outward by the metal pull rod 11. The metal pull rod 11 is in a T shape, consisting of a long rod 111 and a short rod 112 that are perpendicular to each other. The length L1 of the long rod 111 satisfies 5 cm ≤ L1 ≤ 20 cm to meet the operation requirements of reaching the bottom of holes with different depths; the short rod 112 is used as a handle, and its length L2 satisfies 4 cm ≤ L2 ≤ 10 cm, which conforms to ergonomics and is convenient for holding and applying a stable tightening force. The diameter R4 of the long rod 111 satisfies 1 mm ≤ R4 ≤ 2 mm, and the diameter of the short rod 112 is equal to R4. The bottom end of the long rod 111 is provided with an external thread, with a thread diameter R5 satisfying 2 mm ≤ R2 ≤ 15 mm and a thread height H2 satisfying 3 mm ≤ H2 ≤ 4 mm, which is used to screw into the center of the silicone pad 12 to form a reliable mechanical connection, facilitating the pushing and tightening fixation of the silicone pad at the bottom of the hole.

[0017] Figure 3 is the structural diagram of the integrated rapid repair package 2. All materials of the integrated rapid repair package 2 are flexible and can adapt to curved surface structures. As Figure 3As shown, the integrated rapid repair kit 2 adopts a multi-layer flexible stacked design, which includes, from bottom to top, a second release film 21, a sealing ring 22, a pre-impregnated body 23, a release cloth 24, a vacuum film 25, a heating layer 26, a heat insulation layer 28, and a fixing tape 29.

[0018] The pre-impregnated body 23 is formed by completely impregnating the fiber reinforcement layer 232 with a fast-curing resin 231. The fiber reinforcement layer 232, as the main load-bearing structure, is composed of alternating layers of woven carbon fiber cloth. The carbon fiber cloth is stacked in such a way that one layer of plain woven carbon fiber cloth is stacked on top of one layer of twill woven carbon fiber cloth, with 2 to 20 layers stacked alternately. To provide sufficient strength, the surface area of ​​the fiber reinforcement layer 232 is greater than or equal to twice the area of ​​the perforation. To reduce the difficulty of cutting the fiber cloth, the carbon fiber cloth is usually square, and its side length L6 should satisfy R1≤L6 to ensure sufficient load transfer.

[0019] Rapid-curing resin 231 is a nano-reinforced, single-component, latent epoxy curing resin that remains stable during storage and is easy to transport. Rapid-curing resin 231 completely impregnates fiber reinforcement layer 232, leaving a 1-2 mm thick excess resin layer at the bottom of fiber reinforcement layer 232 to form a pre-impregnated body 23. Rapid-curing resin 231 consists of an E51 epoxy resin matrix, a curing agent, and nano-reinforcing materials, with a mass ratio of 100:30:1. The curing agent is a modified amine or imidazole latent curing agent with a curing trigger temperature ≥80℃; the nano-reinforcing materials are carbon nanotubes or graphene nano-reinforcing materials. The addition of nano-reinforcing materials aims to simultaneously improve the thermal conductivity, mechanical properties, and interfacial adhesion of rapid-curing resin 231. The curing initiation temperature of the rapid-curing resin 231 is 80℃. Below this temperature, no curing reaction will occur; excessively high temperatures can cause a burst effect. If the curing temperature is maintained at 80℃, complete curing will occur in 30 minutes; or at 120℃, complete curing will be achieved in 10 minutes. During heating, the rapid-curing resin 231 permeates the bottom of the fiber reinforcement layer 232 and flows towards the pores to fill them. The pre-impregnated body 23, composed of the fiber reinforcement layer 232 and the rapid-curing resin 231, forms a patch on the pore surface after the rapid-curing resin 231 has cured, providing structural reinforcement to the pores and restoring the strength of the material to be repaired.

[0020] The sealing ring 22, serving as the main sealing and bonding frame of the quick-repair kit 2, is made of synthetic rubber or butyl tape, possessing flexibility and requiring a temperature resistance ≥150℃. It forms the boundary of the pre-impregnated body 23 in a square frame form. The width L4 of the sealing ring 22 satisfies 1cm ≤ L4 ≤ 2cm, and the thickness H3 satisfies 2mm ≤ H3 ≤ 10mm. The enclosed internal area accommodates the pre-impregnated body 23, and the side length L5 of the internal area satisfies L6 + 10mm ≤ L5 ≤ L6 + 20mm. A second release film 21 is attached to the lower surface of the sealing ring 22 (the surface furthest from the fiber reinforcement layer 232).

[0021] The second release film 21 is square and made of fluoroplastic release film. It covers the lower surface of the sealing ring 22 and is used to protect the bonding surface of the pre-impregnated body 23 and the sealing ring 22 during storage. Its side length L3 satisfies L5+2L4+20mm≤L3≤L5+2L4+30mm.

[0022] The vacuum membrane 25 is square and covers and adheres to the sealing ring 22, forming a sealed cavity together with the sealing ring 22 to enclose the pre-impregnated body 23 and the release cloth 24. This provides a stable physical constraint environment for the curing process of the fast-curing resin 231. The side length L8 of the vacuum membrane 25 satisfies L8=L3. The vacuum membrane 25, the sealing ring 22, and the second release membrane 21 together form a sealing and interface layer, used to achieve reliable adhesion and sealing between the repair package 2 and the material to be repaired 4, preventing the loss of the fast-curing resin 231 and isolating it from the external environment.

[0023] The heating layer 26 is square and attached to the upper surface of the vacuum membrane 25. It is made of polyimide electrothermal film material with a thickness H4 that satisfies 1mm≤H4≤2mm. Its side length L9=L5+2L4. The heating temperature range is 125~150℃ and the working voltage is DC 1~21V. It is preferably equipped with a Type-C or Type-A universal interface 27 to achieve quick connection with a portable power supply.

[0024] The insulation layer 28 is square, completely covering the upper surface of the heating layer 26, with the excess portion adhered to the vacuum membrane 25. It uses heat-insulating materials (such as nano-aerogel, aluminum foil insulation cotton, etc.), with a thickness H5 satisfying 3mm ≤ H5 ≤ 20mm, and a side length L. 10 Satisfying L9+20mm≤L 10 ≤L9+30mm. Its function is to reduce heat loss, improve heat utilization efficiency, and ensure that heat is concentrated in the pre-impregnated body 23. The heating layer 26 and the insulation layer 28 can provide and maintain the heat required for curing, ensuring that the curing process is efficient and uniform.

[0025] A release liner 24 is laid between the fiber reinforcement layer 232 and the vacuum membrane 25. It is made of polyester or nylon with a temperature resistance of ≥150℃, and its edges are adhered to the sealing ring 22. Its length L7 satisfies L7=L5+L4. Its function is to provide an easy-to-peel interface for the prepreg 23 after the rapid-curing resin 23 has cured, thus ensuring a smooth surface for the prepreg 23 and facilitating the removal of the vacuum membrane 25 and sealing ring 22 from the prepreg 23 after the rapid-curing resin 231 has cured.

[0026] The fixing tape 29 is attached to the outer surface of the insulation layer 28 in a crisscross or other manner. It is made of high-temperature resistant flexible material such as Teflon, and its thickness H6 meets the requirement of 0.13mm≤H6≤0.25mm. Its function is to apply auxiliary pressure after attachment to enhance the initial adhesion between the quick repair package 2 and the complex curved surface of the material to be repaired 4.

[0027] Figure 4 This is a schematic diagram of the intelligent energy control module 3. The intelligent energy control module 3 consists of a micro power supply 31, a micro temperature control digital display module 32, and a micro timer 33 integrated into a lightweight plastic casing. The micro power supply 31 has an output voltage of 5~24V, which powers the micro temperature control digital display module 32, the micro timer 33, and the heating layer 26. Its capacity is 10000~40000mAh, ensuring that a single full charge can support multiple complete repair processes. The micro temperature control digital display module 32 has a driving voltage of 5~24V and is used to monitor and control the heating temperature. When the temperature reaches the set value, it controls the heating temperature of the heating layer 26 to be maintained at the set value. The micro temperature control digital display module 32 contains a temperature sensor 321, which is placed between the heating layer 26 and the vacuum membrane 25 before the material to be repaired 4 is repaired. This allows it to directly and accurately sense the actual temperature acting on the material to be repaired and feed the temperature signal back to the micro temperature control digital display module 32. The driving voltage of the micro timer 33 is 5~24V, which is used to control the heating time. After the set time is reached, it can automatically or prompt to cut off the heating power supply to prevent over-curing.

[0028] The invention will be further illustrated below with examples of composite material repair.

[0029] Example 1: This embodiment provides an apparatus and method for rapid repair of puncture damage in composite materials, specifically for repairing a puncture of approximately 8 mm in diameter (R1) on a carbon fiber composite plate. The silicone pad 12 of the rapid puncture sealing module 1 is made of high-temperature resistant silicone, with a diameter (R2) of 12 mm and a thickness (H1) of 4.5 mm. The metal pull rod 11 is made of solid stainless steel; the long rod 111 has a length (L1) of 8 cm, the short rod 112 has a length (L2) of 4 cm, a diameter (R4) of 1.5 mm, a bottom thread diameter (R5) of 6 mm, and a thread height (H2) of 3.5 mm. The second release film 21 in the integrated rapid repair package 2 is made of polyethylene terephthalate silicone oil film, with a side length (L3) of 13 cm. The sealing ring 22 is made of synthetic rubber, with a width (L4) of 1.5 cm, a thickness (H3) of 5 mm, and the inner area enclosed by the adhesive ring has a side length (L5) of 8 cm. The fiber reinforcement layer 232 consists of a combination of one plain weave and one twill weave carbon fiber layer. The plain weave fibers are arranged on the twill fiber cloth, and the side length L6 = 6cm is used to ensure sufficient repair strength. The rapid-curing resin 231 is a single-component epoxy latent curing resin reinforced with carbon nanotubes, composed of E51 epoxy resin matrix, modified amine latent curing agent HAA-1021, and carboxylated carbon nanotubes, with a mass ratio of 100:30:1. The rapid-curing resin 231 can be fully cured at 120℃ for 10 minutes. The release cloth 24 is made of polyester material with a side length L7 = 7.5cm. The vacuum membrane 25 has a side length L8 = 13cm. The heating layer 26 is made of polyimide, with a side length L9 = 11cm and a thickness H4 = 2mm. It has a maximum heating temperature of 135℃, uses 12V DC power, and has a Type-C interface 27. The insulation layer 28 is made of nano-aerogel, with a side length L... 10 =10cm, thickness H5=5mm. The fixing tape 29 is made of Teflon, two strips, length L 11 =12cm, width L 12 =20mm, thickness H6=0.2mm. The micro power supply 31 in the intelligent energy control module 3 is a lithium battery with an output voltage of 12V and a capacity of 20000mAh; the micro temperature control digital display module 32 adopts W3230, its driving voltage is 12V, and its temperature sensor 321 is placed between the heating layer 27 and the vacuum film 26; the micro timer 33 is integrated into the micro temperature control digital display module 32W3230.

[0030] The repair method steps are as follows: Step 1: Surface Cleaning. Use 100-grit sandpaper to sand an area of ​​approximately 10cm x 10cm around the approximately 8mm R1 hole in the material to be repaired (4) to remove surface paint and contaminants. Then, use a wire brush to lightly create a dense, irregular crisscross pattern within the sanded area. Thoroughly clean the area with a non-woven cloth dampened with anhydrous alcohol, then wipe it dry with a dry non-woven cloth. Step 2: Backside sealing. Select a silicone pad 12 with a diameter R2 = 12mm from Example 1, and peel off the first release film 121 on its surface. Screw the threaded end of the metal pull rod 11 into the center of the silicone pad 12 to assemble a quick-sealing module 1 for the puncture. Then, insert the quick-sealing module 1 into the puncture surface. After the silicone pad 12 has completely passed through the puncture, pull the metal pull rod 11 outward from the puncture surface to firmly adhere the edge of the silicone pad 12 to the bottom side of the puncture. After fixing, rotate the metal pull rod 11 in the opposite direction to separate it from the silicone pad 12 and remove it. Step 3: Attach the integrated quick repair kit 2. Peel off the second release film 21 at the bottom of the integrated quick repair kit 2, align the exposed sealing ring 22 with and cover the surface of the hole in the material 4 to be repaired, and press firmly with your palm to ensure that the sealing ring 22 is tightly attached to the surface of the hole in the material 4 to be repaired. Then, pull the two fixing tapes 29 on the surface of the insulation layer 28 taut and stick them to the surface of the material 4 to be repaired, so that the entire integrated quick repair kit 2 is firmly fixed to the surface of the hole in the material 4 to be repaired; Step 4: Heating and Curing. Connect the Type-C plug 28 of the heating layer 27 to the micro power supply 31 of the intelligent energy control module 3. Turn on the power switch of the micro power supply 31 and set the heating temperature of the micro temperature control digital display module 32 to 120℃. The device starts working, and the heating layer 26 begins to heat. At this time, the viscosity of the fast-curing resin 231 decreases and its fluidity increases when heated, and the excess fast-curing resin 231 at the bottom of the pre-impregnated body fills the pores. When the temperature exceeds 80℃, the fast-curing resin 231 begins to react and gradually cures. When the temperature reaches 120℃, the curing speed will accelerate. At this time, start the micro timer 33 and start timing for 10 minutes to allow the fast-curing resin 231 to cure completely. During this period, the micro temperature control digital display module 32 maintains 120℃. Step 5: Cleaning. After 10 minutes, the micro timer 33 will sound an alarm and the power will be turned off. Remove the heating layer 26 and the insulation layer 28. Allow the repair area to cool naturally to room temperature, then peel off the vacuum membrane 25, the release cloth 24, and the sealing ring 22. At this point, the fiber reinforcement layer 232 and the cured resin 231 have formed a strong patch that bonds well with the material to be repaired 4, and the repair is complete.

[0031] The before-and-after repair effects of Example 1 and the above five steps are as follows: Figure 5 As shown, before repair Figure 5 As shown in (a), there is an 8mm hole in the carbon fiber composite plate. After repair, it looks like... Figure 5 As shown in (b), the approximately 8mm hole on the carbon fiber composite board is covered by a black patch formed by the fiber reinforcement layer 232 and the cured resin 231, and the repaired surface is relatively smooth.

[0032] Example 2: The difference between Example 2 and Example 1 is that the repair target is a hole in a curved composite material cabin, with an R1 of approximately 8 mm. The fiber reinforcement layer 232 in the integrated rapid repair kit 2 is increased to four layers (two sets are set, with one layer of plain weave carbon fiber cloth stacked on top of one layer of twill weave carbon fiber cloth), with a side length L6 = 8 cm, to accommodate higher strength requirements. Correspondingly, the internal area formed by the sealing ring 22 has a side length L5 = 10 cm, the release film 21 has a side length L3 = 14 cm, the vacuum film 25 has a side length L8 = 14 cm, and the heating layer 13 has a side length L9 = 13 cm. The repair method is the same as in Example 1. Due to the flexible design of the repair kit, it can fit well against the curved surface of the cabin during the pasting process, and the repair effect is similar to... Figure 5 Similarly, the difference lies in that the final patch is designed to fit the curved shape of the composite material being repaired.

[0033] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A device for rapid repair of pore damage in composite materials, characterized in that... The device for rapid repair of pore damage in composite materials consists of a pore rapid sealing module (1), an integrated rapid repair package (2), and an intelligent energy control module (3). The pore rapid sealing module (1) is inserted into and sealed on the back of the pore in the material to be repaired (4). The integrated rapid repair package (2) is attached to the surface of the pore and connected to the intelligent energy control module (3) for heating to complete the reinforcement and curing repair of the pore. The rapid hole sealing module (1) consists of a metal pull rod (11) and a silicone pad (12). The silicone pad (12) is quickly positioned and pressed at the bottom of the hole through a threaded connection. After sealing the bottom, it can be removed from the silicone pad (12). All materials of the integrated rapid repair kit (2) are flexible and adaptable to curved structures. It adopts a multi-layer flexible stacked design, which includes, from bottom to top, a second release film (21), a sealing ring (22), a pre-impregnated body (23), a release cloth (24), a vacuum film (25), a heating layer (26), a heat insulation layer (28), and a fixing tape (29). The pre-impregnated body (23) is made by completely impregnating the fiber reinforcement layer (232) with a rapid curing resin (231). The rapid curing resin (231) is a nano-reinforced single-component epoxy latent curing resin. The rapid curing resin (231) is composed of an E51 epoxy resin matrix, a curing agent, and nano-reinforcing materials. During the heating process, the rapid curing resin (231) penetrates the bottom of the fiber reinforcement layer (232) and flows to the hole to fill it. After curing, it forms a patch on the surface of the hole. The interior enclosed by the sealing ring (22) The area contains the prepreg (23), and the lower surface is covered with a second release film (21); the vacuum film (25) covers and is pasted on the sealing ring (22), together with the sealing ring (22) forming a sealed cavity that wraps the prepreg (23) and the release cloth (24), preventing the rapid curing resin (231) from leaking out and isolating the external environment; the heating layer (26) is attached to the upper surface of the vacuum film (25) and is made of polyimide electrothermal film material; the heat insulation layer (28) covers the upper surface of the heating layer (26) and is made of heat insulation material, with the excess part pasted on the vacuum film (25); the heating layer (26) and the heat insulation layer (28) provide and maintain the heat energy required for curing; the release cloth (24) is laid between the fiber reinforcement layer (232) and the vacuum film (25), and its edge is pasted on the sealing ring (22); the fixing tape (29) is pasted on the outer surface of the heat insulation layer (28); The intelligent energy control module (3) consists of a micro power supply (31), a micro temperature control digital display module (32) and a micro timer (33); the micro temperature control digital display module (32) monitors and controls the heating temperature, and when the temperature reaches the set value, it controls the heating temperature of the heating layer (26) to be maintained at the set value; the temperature sensor (321) in the micro temperature control digital display module (32) is arranged between the heating layer (26) and the vacuum membrane (25) before the material to be repaired (4) is repaired, and senses the temperature acting on the pre-impregnated body (23).

2. The device for rapid repair of pore damage in composite materials as described in claim 1, characterized in that... The silicone pad (12) is made of a silicone material with a temperature resistance of ≥ 150°C. A high-temperature resistant adhesive layer is pre-coated on the side of the silicone pad (12) that fits the bottom of the perforation, and a first release film (121) is covered on the surface of the high-temperature resistant adhesive layer; the surface area of the silicone pad (12) that fits the bottom of the perforation covers the area of the bottom of the perforation, and the thickness H1 of the silicone pad (12) satisfies the formation of a sealing pressure after being tightened outward by the metal pull rod (11) towards the outside of the perforation; the metal pull rod (11) is T-shaped and consists of a long rod (111) and a short rod (112) that are perpendicular to each other; the short rod (112) serves as a handle and conforms to ergonomics; the bottom end of the long rod (111) is provided with an external thread for screwing into the center of the silicone pad (12) to push the silicone pad and tighten it and fix it at the bottom of the perforation.

3. The device for rapid repair of pore damage in composite materials as described in claim 2, characterized in that... The shape of the silicone pad (12) is disc-shaped, and the diameter R2 satisfies R1 < R2, where R1 is the diameter of the perforation, and the thickness H1 satisfies 4 mm ≤ H1 ≤ 5 mm; the length L1 of the long rod (111) satisfies 5 cm ≤ L1 ≤ 20 cm; the length L2 of the short rod (112) satisfies 4 cm ≤ L2 ≤ 10 cm, the diameter R4 of the long rod (111) satisfies 1 mm ≤ R4 ≤ 2 mm, and the diameter of the short rod (112) is equal to R4; the thread diameter R5 of the external thread provided at the bottom end of the long rod (111) satisfies 2 mm ≤ R2 ≤ 15 mm, and the thread height H2 satisfies 3 mm ≤ H2 ≤ 4 mm.

4. The device for rapid repair of pore damage in composite materials as described in claim 1, characterized in that... The fiber reinforced layer (232) serves as the main load-bearing structure and is formed by alternately stacking woven carbon fiber cloth. The stacking method of the carbon fiber cloth is that one layer of plain weave carbon fiber cloth is stacked on one layer of twill weave carbon fiber cloth, and they are alternately stacked 2 to 20 layers. The surface area of the fiber reinforced layer (232) is greater than or equal to 2 times the area of the perforation. The carbon fiber cloth is square, and its side length L6 satisfies R1 ≤ L6; the fast-curing resin (231) leaves a surplus resin layer with a thickness of 1 to 2 mm at the bottom of the fiber reinforced layer (232); the mass ratio of the E51 epoxy resin matrix, curing agent, and nano-enhancing material in the fast-curing resin (231) is: 100: 25 - 35: 0.5 - 2. The curing agent is a modified amine or imidazole latent curing agent, and the curing trigger temperature ≥ 80°C; the nano-enhancing material is a carbon nanotube or graphene nano-enhancing material; The curing starting temperature of the fast-curing resin (231) is 80°C.

5. The device for rapid repair of pore damage in composite materials as described in claim 1, characterized in that... The sealing ring (22) serves as the main sealing and bonding frame of the quick repair package 2. It is made of synthetic rubber or butyl tape and is required to withstand temperatures ≥150℃. It forms the boundary of the pre-impregnated body (23) in the form of a square frame. The width L4 of the sealing ring (22) satisfies 1cm≤L4≤2cm, the thickness H3 satisfies 2mm≤H3≤10mm, and the side length L5 of the inner area satisfies L6+10mm≤L5≤L6+20mm. L6 is the side length of the fiber reinforcement layer (232). The second release film (21) is square and made of fluoroplastic release film. It is used to protect the pre-impregnated body (23) and the sealing ring (232) during storage. 2) The bonding surface has a side length L3 that satisfies L5+2L4+20mm≤L3≤L5+2L4+30mm; the vacuum membrane (25) is square with a side length L8 that satisfies L8=L3; the release cloth (24) is made of polyester or nylon with a temperature resistance of ≥150℃ and a length L7 that satisfies L7=L5+L4. Its function is to provide an easy-to-peel interface for the pre-impregnated body (23) after the rapid curing resin (231) has cured, so that the surface of the pre-impregnated body (23) is flat, and at the same time, it is convenient to remove the vacuum membrane (25) and the sealing ring (22) from the pre-impregnated body (23) after the rapid curing resin (231) has cured.

6. The device for rapid repair of pore damage in composite materials as described in claim 1, characterized in that... The heating layer (26) is square, with a thickness H4 satisfying 1mm≤H4≤2mm, and its side length L9=L5+2L4. The heating temperature range is 125~150℃, and the working voltage is DC 1~21V. It is equipped with a Type-C or Type-A universal interface (27). L5 is the side length of the inner area of ​​the sealing ring (22). The heat insulation layer (28) is square, and the heat insulation material used is nano aerogel or aluminum foil insulation cotton. The thickness H5 satisfies 3mm≤H5≤20mm, and the side length L9=L5+2L4 is 2mm. 10 Satisfying L9+20mm≤L 10 ≤L9+30mm; The fixing tape (29) is pasted on the outer surface of the insulation layer (28) in a cross shape. It is made of high temperature resistant flexible material such as Teflon, and the thickness H6 meets 0.13mm≤H6≤0.25mm. Its function is to apply auxiliary pressure after pasting to enhance the initial fit between the integrated quick repair package (2) and the complex curved surface of the material to be repaired (4).

7. The device for rapid repair of pore damage in composite materials as described in claim 1, characterized in that... The micro power supply (31), micro temperature control digital display module (32), and micro timer (33) are integrated into a lightweight plastic shell. The output voltage of the micro power supply (31) is 5~24V, which powers the micro temperature control digital display module (32), micro timer (33), and heating layer (26). Its capacity is 10000~40000mAh, which ensures that it can support multiple complete repair processes after being fully charged once. The driving voltage of the micro temperature control digital display module (32) is 5~24V. The temperature sensor (321) of the micro temperature control digital display module (32) senses the actual temperature acting on the material to be repaired (4) and feeds back the temperature signal to the micro temperature control digital display module (32). The driving voltage of the micro timer (33) is 5~24V, which is used to control the heating time. After the set time is reached, the heating power supply is automatically or prompted to be cut off to prevent over-curing.

8. A method for repairing pores using the device for rapid repair of pore damage in composite materials as described in claim 1, characterized in that... Includes the following steps: The first step is to clean the surface around the hole in the material to be repaired (4); Step 2, back sealing: Select a silicone pad (12) with a diameter larger than the diameter of the hole, peel off the first release film (121) on its surface, screw the threaded end of the metal rod (11) into the center of the silicone pad (12) to assemble a quick hole sealing module (1), and then insert the quick hole sealing module (1) into the front of the hole. After the silicone pad (12) has completely passed through the hole, pull the metal rod (11) to the outside of the hole surface so that the edge of the silicone pad (12) is firmly attached to the bottom side of the hole. After fixing, rotate the metal rod (11) in the opposite direction to separate it from the silicone pad (12) and take it out. The third step is to attach the integrated quick repair kit (2); peel off the second peeling film (21) at the bottom of the integrated quick repair kit (2), align the exposed sealing ring (22) with and cover the surface of the hole in the material to be repaired (4), press it firmly with your palm to ensure that the sealing ring (22) is tightly attached to the surface of the hole in the material to be repaired (4); then pull the two fixing tapes (29) on the surface of the insulation layer (28) tight and stick them to the surface of the material to be repaired (4) respectively, so that the entire integrated quick repair kit (2) is firmly fixed to the surface of the hole in the material to be repaired (4); Step 4, heating and curing; connect the plug (27) of the heating layer (26) to the micro power supply (31) of the intelligent energy control module (3); turn on the power switch of the micro power supply (31) and set the heating temperature of the micro temperature control digital display module (32) to 120°C; the device starts working and the heating layer (26) starts heating; at this time, the viscosity of the fast curing resin (231) decreases when heated and its fluidity increases, and the excess fast curing resin (231) at the bottom of the pre-impregnated body (23) fills the pores; when the temperature exceeds 80°C, the fast curing resin (231) begins to react and gradually cures; when the temperature reaches 120°C, the curing speed accelerates, and the micro timer (33) is started to start timing, so that the fast curing resin (231) is completely cured; during this period, the micro temperature control digital display module (32) is maintained at 120°C; Step 5, cleaning; after a timer of T minutes, the micro timer (33) will issue a prompt and turn off the power, where T is 10~12 minutes; remove the heating layer (26) and the insulation layer (28); wait for the repair area to cool naturally to room temperature, and then peel off the vacuum membrane (25), the release cloth (24) and the sealing ring (22); at this time, the fiber reinforcement layer (232) and the cured resin 231 have formed a strong patch, which is well bonded to the material to be repaired (4), and the repair is completed.

9. The method for repairing holes as described in claim 8, characterized in that... The surface cleaning method described in the first step is as follows: use 80-120 grit coarse sandpaper to sand the area around the hole. The sanded area should be larger than the area covered by the fiber reinforcement layer, and remove the surface paint layer and contaminants. Next, use a wire brush to gently create a dense, irregular cross pattern in the polished area; thoroughly clean the area with a non-woven cloth soaked in anhydrous alcohol, and then wipe it dry with a dry non-woven cloth.

10. The method for repairing holes as described in claim 8, characterized in that... The T mentioned in step 5 is 10 minutes.

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