Method of repairing repaired part

Abstract

To quickly perform repair by applying uniform heating while minimizing a thermal impact on a surrounding area of a repaired part.SOLUTION: A method of repairing a repaired part using a repair patch containing resin to repair the repaired part to be repaired includes the steps of: placing the repair patch on the part to be repaired; placing a thermal transfer material over the repair patch; placing a susceptor serving as a heat source on the thermal transfer material; hermetically sealing the repair patch, the thermal transfer material, and the susceptor with a bag film; and evacuating an inside of the bag film and inductively heating the susceptor by a magnetic field to heat the repair patch through the thermal transfer material.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a method for repairing a part to be repaired. [Background technology]

[0002] A conventional method for repairing a part to be repaired is to cover the part to be repaired with a repair patch, heat the repair patch with a heater mat, thermally harden the resin contained in the repair patch, and adhere the repair patch to the part to be repaired (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2014-188995 Summary of the Invention [Problem to be solved by the invention]

[0004] The repair method of Patent Document 1 uses a heater mat to heat the repair patch, but in this case, heat leaks from the heater mat to the area surrounding the repair patch. Therefore, the repair method of Patent Document 1 reduces the efficiency with which the heater mat heats the repair patch, which means it takes time to bond the repair patch to the area to be repaired, lengthening the repair work. Furthermore, if heat leaks from the heater mat to the area surrounding the repair patch, the surrounding area may be unnecessarily heated, potentially causing material degradation due to heat.

[0005] Therefore, an object of the present disclosure is to provide a method for repairing a part to be repaired that can quickly perform repairs by uniform heating while suppressing the thermal impact on the surrounding area of ​​the part to be repaired. [Means for solving the problem]

[0006] The repair method for a repaired part disclosed herein is a method for repairing a repaired part that uses a repair patch containing resin to repair the repaired part that is to be repaired, and includes the steps of placing the repair patch on the repaired part, placing a heat transfer material on the repair patch, placing a susceptor that serves as a heat source on the heat transfer material, hermetically sealing the repair patch, the heat transfer material, and the susceptor with a bag film, and drawing a vacuum inside the bag film and inductively heating the susceptor with a magnetic field, thereby heating the repair patch via the heat transfer material.

[0007] Another method for repairing a part to be repaired disclosed herein is a method for repairing a part to be repaired using a repair patch containing metal, wherein the metal functions as a susceptor, and includes the steps of placing a joint patch containing resin on the part to be repaired, placing the repair patch on the joint patch, hermetically sealing the joint patch and the repair patch with a bag film, and heating the joint patch by drawing a vacuum inside the bag film and inductively heating the metal of the repair patch using a magnetic field. [Effects of the Invention]

[0008] According to the present disclosure, repairs can be performed quickly by uniform heating while suppressing the thermal impact on the surrounding area of ​​the part to be repaired. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is an explanatory diagram of a method for repairing a part to be repaired according to a first embodiment. [Figure 2] FIG. 2 is a flowchart showing the method for repairing a part to be repaired according to the first embodiment. [Figure 3] FIG. 3 is a diagram showing the temperature distribution of the repair patch. [Figure 4] FIG. 4 is an explanatory diagram of a method for repairing a part to be repaired according to the second embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0010] Hereinafter, embodiments of the present disclosure will be described in detail with reference to the drawings. However, this disclosure is not limited to these embodiments. Furthermore, the components in the following embodiments include those that are easily replaceable by those skilled in the art, or those that are substantially identical. Furthermore, the components described below can be combined as appropriate, and when there are multiple embodiments, the respective embodiments can also be combined.

[0011] [First embodiment] The method for repairing a part to be repaired according to the first embodiment is a method for repairing a part to be repaired 4 that is the target of repair using a repair patch 5 containing resin. Specifically, the method for repairing a part to be repaired repairs the part to be repaired 4 using multiple layers of repair patches 5 by repeating the step of hardening one layer of repair patch 5. First, with reference to FIG. 1 , the layered structure relating to the method for repairing the part to be repaired 4 will be described.

[0012] (Method of repairing the part to be repaired) Fig. 1 is an explanatory diagram of a method for repairing a part to be repaired according to a first embodiment. As shown in Fig. 1, in the method for repairing a part to be repaired 4, various components including a repair patch 5 are layered. Specifically, arranged in this order from the side of the part to be repaired 4 are the repair patch 5, a release film (release material) 6, a deaeration cloth (first deaeration member) 7, a heat transfer material 8, a susceptor 9, and a deaeration cloth (second deaeration member) 10. These components are then covered with a bag film 13, and the space between the part to be repaired 4 and the bag film 13 is airtightly sealed with a sealant 12.

[0013] The repair patch 5 is a composite material in which a sheet-like reinforcing fiber is impregnated with a resin. Examples of the reinforcing fiber include carbon fiber and glass fiber, and unidirectional materials, woven fabrics, and nonwoven fabrics are used. Examples of the resin include thermoplastic resins such as PP (polypropylene), PEI (polyetherimide), and PEEK (polyetheretherketone). The repair patch 5 may be in a sheet shape, either circular or rectangular. Note that although a thermoplastic resin is used as the resin in the first embodiment, a thermosetting resin may also be used.

[0014] The release film 6 is a perforated film with a large number of through holes formed in a film having releasability. The film material of the release film 6 may have releasability itself, or the film may be coated with a release agent to impart releasability. The release film 6 has heat resistance higher than the heating temperature applied during repair. Examples of the release film 6 include FEP (fluororesin) film and polyimide film coated with a release agent.

[0015] The deaeration cloth 7 is a thin woven or nonwoven fabric that has a heat resistance higher than the heating temperature applied during repair. The deaeration cloth 7 is, for example, a woven fabric made of glass fiber. The release film 6 and the deaeration cloth 7 may be separate or integrated, and are not particularly limited.

[0016] The heat transfer material 8 is a laminate of multiple flexible metal films. The heat transfer material 8 transfers heat from the susceptor 9 in an in-plane direction perpendicular to the lamination direction, thereby achieving uniform temperature distribution in the in-plane direction and achieving heat equalization. Examples of the metal film include aluminum foil and copper foil. The heat transfer material 8 may be arranged so that the thermal conductivity of the metal film on the repair patch 5 side is higher than the thermal conductivity of the metal film on the susceptor 9 side. Specifically, the heat transfer material 8 may be a laminate of multiple aluminum foils. Alternatively, the heat transfer material 8 may be a laminate of copper foil on the repair patch 5 side and multiple aluminum foils on the susceptor 9 side. Furthermore, the heat transfer material 8 may be a laminate of multiple copper foils. By using the heat transfer material 8 as a laminate, the heat transfer material 8 can be arranged to follow the shape of the repair target portion 4, even if the repair target portion 4 has a curved shape.

[0017] The susceptor 9 is a heat source that is heated by induction heating. The susceptor 9 is made of a conductive material. To increase heating efficiency, the susceptor 9 may also be made of a magnetic material. Examples of conductive materials include aluminum and carbon fiber. Examples of magnetic materials include iron and stainless steel, and the susceptor 9 is made of flexible fiber fabric, metal film, or metal mesh. By providing flexibility to the susceptor 9, the susceptor 9 can be positioned to conform to the shape of the repair target 4, even if the repair target 4 has a curved surface.

[0018] The breathable cloth 10 also functions as a heat insulating material and is made of a thicker woven or nonwoven fabric than the breathable cloth 7. Like the breathable cloth 7, the breathable cloth 10 has a higher heat resistance than the heating temperature applied during repairs. The breathable cloth 10 is, for example, a woven fabric made of glass fiber, and is made by layering multiple layers.

[0019] Next, a method for repairing a part to be repaired will be described with reference to Figures 1 and 2. Figure 2 is a flowchart of a method for repairing a part to be repaired according to a first embodiment. In the method for repairing a part to be repaired 4, first, a pre-process is performed on the part to be repaired 4 before a repair patch 5 is placed (step S1).

[0020] In step S1, the part to be repaired 4 is inspected, the repair range of the part to be repaired 4 is identified, pre-repair machining is performed on the part to be repaired 4, and pre-adhesion processing is performed on the part to be repaired 4. Also in step S1, the number of repair patches 5 to be layered on the part to be repaired 4 is determined.

[0021] In the repair method, after performing step S1, a single layer (1-ply) of repair patch 5 is placed on the portion to be repaired 4 as shown in FIG. 1 (step S2). Note that, although a single layer of repair patch is placed in step S2, more than one layer is sufficient; for example, multiple layers (multiple ply) of repair patch 5 may be placed. Here, in step S2, the repair patch 5 is made of a single ply in order to uniformize the temperature distribution in the layering direction and to reduce the bending rigidity of the repair patch 5 in the layering direction. Therefore, even if more than one ply is used, multiple ply layers may be laminated if the temperature in the layering direction can be uniformized and if the repair patch 5 conforms to the portion to be repaired 4. In the repair method, after performing step S2, a release film 6 is placed on the repair patch 5 (step S3). In the repair method, after performing step S3, an air-wicking cloth 7 is placed on the release film 6 (step S4). The release film 6 and the deaeration cloth 7 placed in steps S3 and S4 have the same size, and their placement areas are larger than those of the repair patch 5, the heat transfer material 8, and the susceptor 9.

[0022] In the repair method, after performing step S4, the heat transfer material 8 is placed on the breathable cloth 7 (step S5). In the repair method, after performing step S5, the susceptor 9 is placed on the heat transfer material 8 (step S6). In the repair method, after performing step S6, the heat insulating breathable cloth 10 is placed on the susceptor 9 (step S7). Then, in the repair method, after performing step S7, the repair patch 5, release film 6, breathable cloth 7, heat transfer material 8, susceptor 9, and breathable cloth 10 are covered with a bag film 13, and a sealant 12 is placed between the repair target portion 4 and the bag film 13 to airtightly seal the inside of the bag film 13 (step S8).

[0023] In the repair method, after step S8 is performed, the inside of the bag film 13 is evacuated through the vacuum port 15 in contact with the degassing cloth 10, while a magnetic field is applied by the magnetic field coil 25 to inductively heat the susceptor 9, thereby performing vacuum forming (step S9). In step S9, the susceptor 9 is heated, and heat from the susceptor 9 is input to the repair patch 5 via the heat transfer material 8. At this time, the heat transfer material 8 transfers the heat transferred from the susceptor 9 in the in-plane direction, thereby making the temperature distribution in the in-plane direction uniform. The heated repair patch 5 is then bonded to the repair target portion 4. Also, in step S9, the magnetic field coil 25 is arranged to generate eddy currents in the plane of the susceptor 9. That is, the magnetic field coil 25 is arranged above the susceptor 9, and applies a magnetic field so that the direction of the magnetic field it forms is perpendicular to the in-plane direction of the susceptor 9, thereby inductively heating the susceptor 9.

[0024] In the repair method, after executing step S9, debugging is performed to open the inside of the bag film 13 to the atmosphere (step S10). In the repair method, after executing step S10, it is determined whether the number of layers of the repair patches 5 (number of plies) determined in step S1 has been reached (step S11). In the repair method, if it is determined in step S11 that the number of layers of the repair patches 5 has been reached (step S11: Yes), the repair method for the repaired portion 4 is terminated. Note that in the repair method, after laminating the repair patches 5 on the repaired portion 4, post-processing such as inspection and painting may be performed if necessary. On the other hand, in the repair method, if it is determined in step S11 that the number of layers of the repair patches 5 has not been reached (step S11: No), steps S2 to S11 are repeatedly executed until the number of layers is reached. Note that when steps S2 to S11 are repeatedly executed, the release film 6 to the bag film 13 may be attached and detached as a single unit.

[0025] Next, the temperature distribution of the repair patch will be described with reference to Fig. 3. Fig. 3 is a diagram relating to the temperature distribution of the repair patch. Fig. 3 illustrates the temperature distribution of the repair patch 5 heated by induction heating in the conventional manner (in a form in which the heat transfer material 8 is not installed) and the temperature distribution of the repair patch 5 heated by induction heating in the repair method of this embodiment. As shown in Fig. 3, it was confirmed that the temperature distribution of the repair patch 5 in the repair method of this embodiment is more uniform than the temperature distribution of the repair patch 5 in the conventional manner.

[0026] [Second embodiment] Next, a second embodiment will be described with reference to Fig. 4. Fig. 4 is an explanatory diagram of a method for repairing a part to be repaired according to the second embodiment. In the second embodiment, to avoid redundant description, only parts different from the first embodiment will be described, and parts having the same configuration as the first embodiment will be described using the same reference numerals.

[0027] (Method of repairing the part to be repaired) The method for repairing the repair target portion 4 in the second embodiment uses a repair patch 22 containing metal instead of the repair patch 5 of the first embodiment. Specifically, in the method for repairing the repair target portion 4, a joint patch 21, a repair patch 22, a release film 6, and a deaeration cloth 10 are arranged in this order from the side of the repair target portion 4. Note that the release film 6 and the deaeration cloth 10 are the same as in the first embodiment, and therefore will not be described here.

[0028] The joining patch 21 joins the repair patch 22 to the repair target portion 4. The joining patch 21 contains a resin, and examples of the resin that can be used include a thermoplastic resin such as a resin film, and a thermosetting resin such as a film adhesive.

[0029] The repair patch 22 is a metal film and functions as a susceptor, that is, the repair patch 22 becomes a heat source that is heated by induction heating.

[0030] The repair method for the part to be repaired 4 includes a step of placing a joint patch 21 on the part to be repaired 4, and a step of placing a repair patch 22 on the joint patch 21. The repair method for the part to be repaired 4 then includes a step of placing a release film 6 on the repair patch 22, and then placing a heat-insulating deaeration cloth 10 on the release film 6. After this, the repair method for the part to be repaired 4 includes a step of covering the joint patch 21, the repair patch 22, the release film 6, and the deaeration cloth 10 with a bag film 13, and placing a sealant 12 between the part to be repaired 4 and the bag film 13 to airtightly seal the inside of the bag film 13.

[0031] In this repair method, the inside of the bag film 13 is evacuated through the vacuum port 15 in contact with the degassing cloth 10, while the magnetic field coil 25 applies a magnetic field to the repair patch 22 to induce heating, thereby performing vacuum forming. Similar to the first embodiment, the magnetic field coil 25 in the second embodiment is positioned to generate eddy currents within the repair patch 22. That is, the magnetic field coil 25 is positioned above the repair patch 22 and applies a magnetic field so that the direction of the magnetic field it generates is perpendicular to the in-plane direction of the repair patch 22, thereby inductively heating the repair patch 22. When the repair patch 22 is heated, heat from the repair patch 22 is transferred to the joining patch 21. Since the repair patch 22 is a metal film, heat is transferred in the in-plane direction, thereby achieving a uniform temperature distribution in the in-plane direction. If the repair patch 22 is thin and its heat transfer function is insufficient, the repair method for the repaired portion 4 in the first embodiment may be applied. In this case, the repair patch 5 in the first embodiment is replaced with the joining patch 21 and the repair patch 22.

[0032] As described above, the repair method for the repair target portion 4 described in the first and second embodiments can be understood, for example, as follows.

[0033] The first aspect of the repair method for a repaired portion 4 involves repairing the repaired portion 4 to be repaired using a repair patch 5 containing resin, and includes the steps of: step S2 of placing the repair patch 5 on the repaired portion 4; step S5 of placing a heat transfer material 8 on the repair patch 5; step S6 of placing a susceptor 9, which serves as a heat source, on the heat transfer material 8; step S8 of hermetically sealing the repair patch 5, the heat transfer material 8, and the susceptor 9 with a bag film 13; and step S9 of evacuating the bag film 13 and inductively heating the susceptor 9 using a magnetic field, thereby heating the repair patch 5 via the heat transfer material 8.

[0034] According to this configuration, by heating the susceptor 9 by induction heating, the repair patch 5 can be quickly heated via the heat transfer material 8. Furthermore, because heat is input from the susceptor 9 to the repair patch 5 via the heat transfer material 8, heat leakage to areas surrounding the repair patch 5 can be suppressed, and the thermal impact on the surroundings of the repaired portion 4 can be suppressed. Furthermore, by heating the repair patch 5 via the heat transfer material 8, the repair patch 5 can be heated uniformly. This allows for quick repairs through uniform heating while suppressing the thermal impact on the surroundings of the repaired portion 4.

[0035] As a second aspect, in the method for repairing the portion to be repaired 4 according to the first aspect, the repair patch 5 is a composite material in which reinforcing fibers are impregnated with the resin.

[0036] According to this configuration, the repair target portion 4 to which the repair patch 5 is joined can be made strong.

[0037] As a third aspect, in the method for repairing the portion to be repaired 4 according to the first or second aspect, the susceptor 9 is a flexible metal film or metal mesh.

[0038] According to this configuration, even if the repair target portion 4 has a curved surface, the susceptor 9 can be arranged to follow the shape of the repair target portion 4.

[0039] As a fourth aspect, in the method for repairing the portion to be repaired 4 according to any one of the first to third aspects, the heat transfer material 8 is a laminated body in which a plurality of flexible metal films are stacked.

[0040] According to this configuration, even if the repair target portion 4 has a curved shape, the bending rigidity of the heat transfer material 8 can be reduced, and the heat transfer material 8 can be arranged to follow the shape of the repair target portion 4. Furthermore, by stacking multiple metal films, the heat transferred from the susceptor 9 can be transferred in the in-plane direction, making the temperature distribution uniform.

[0041] As a fifth aspect, in the repair method for the repaired portion 4 relating to the fourth aspect, the heat transfer material 8 has a higher thermal conductivity of the metal film on the repair patch 5 side than the thermal conductivity of the metal film on the susceptor 9 side.

[0042] According to this configuration, heat transfer on the repair patch 5 side can be improved, and therefore, efficient heat uniformity can be achieved.

[0043] As a sixth aspect, in a method for repairing a part to be repaired 4 relating to any one of the first to fifth aspects, step S1 of determining the number of layers of the repair patch 5 to be superimposed on the part to be repaired 4 is further executed, and the steps from step S2 of placing the repair patch 5 to step S9 of heating the repair patch are repeated the number of times equal to the determined number of layers.

[0044] With this configuration, the repair patches 5 can be stacked one layer at a time, thereby suppressing residual stress generated inside. Furthermore, by placing the repair patches 5 one layer at a time on the repair target 4 and then performing the thermal repair, the heating time for each step can be shortened. This reduces the total repair time and suppresses the thermal impact on the surrounding area of ​​the repair target 4. Furthermore, because the bending rigidity of the repair patches 5 in the stacking direction can be reduced, it becomes possible to place the repair patches 5 following the shape of the repair target 4, even if the repair target 4 has a curved shape.

[0045] As a seventh aspect, in the method for repairing the repaired portion 4 relating to any one of the first to sixth aspects, steps S3 and S4 are further executed in which a release material (release film 6) is placed between the repair patch 5 and the heat transfer material 8, and a first deaeration member (deaeration cloth 7) is placed between the release material and the heat transfer material 8.

[0046] According to this configuration, the member containing the release agent placed on the repair patch 5 can be suitably peeled off.

[0047] As an eighth aspect, in the method for repairing the repair target portion 4 relating to any one of the first to seventh aspects, a step S7 is further performed in which a second degassing member (degassing cloth 10) that functions as an insulating material is placed on the susceptor 9.

[0048] According to this configuration, the second degassing member can suppress heat radiation from the susceptor 9, and the repair patch 5 can be heated efficiently.

[0049] A ninth aspect of the repair method for a part to be repaired (4) is a method for repairing a part to be repaired (4) using a repair patch (22) containing metal, in which the metal functions as a susceptor, and the method includes the steps of placing a joint patch (21) containing resin on the part to be repaired (4), placing the repair patch (22) on the joint patch (21), hermetically sealing the joint patch (21) and the repair patch (22) with a bag film (13), and evacuating the bag film (13) and heating the joint patch (21) by inductively heating the metal of the repair patch (22) using a magnetic field.

[0050] With this configuration, the repair patch 22 is heated by induction heating, thereby quickly heating the bonding patch 21. Furthermore, because heat is input from the repair patch 22 to the bonding patch 21, heat leakage to the surrounding area of ​​the repair patch 22 is suppressed, thereby suppressing the thermal impact on the surrounding area of ​​the repaired portion 4. Furthermore, because the repair patch 22 is a metal film, the bonding patch 21 can be heated uniformly. This allows for quick repairs through uniform heating while suppressing the thermal impact on the surrounding area of ​​the repaired portion 4.

[0051] The method for repairing the portion to be repaired 4 according to the tenth aspect further includes a step of placing a release material (release film 6) on the repair patch 22.

[0052] According to this configuration, the member containing the release agent placed on the repair patch 22 can be suitably peeled off. [Explanation of symbols]

[0053] 4 Part to be repaired 5 Repair Patches 6 Release film 7. Vacuum cloth 8 Heat Transfer Materials 9 Susceptor 10. Vacuum cloth 12. Sealant 13 Bag Film 15 Vacuum port

Claims

1. A method for repairing a part to be repaired, comprising the steps of: repairing the part to be repaired using a repair patch containing a resin, placing the repair patch on the part to be repaired; placing a thermal transfer material over the repair patch; placing a susceptor serving as a heat source on the heat transfer material; hermetically sealing the repair patch, the heat transfer material, and the susceptor with a bag film; a step of drawing a vacuum inside the bag film and inductively heating the susceptor using a magnetic field to heat the repair patch via the heat transfer material.

2. 2. The method for repairing a part to be repaired according to claim 1, wherein the repair patch is a composite material in which reinforcing fibers are impregnated with the resin.

3. 2. The method for repairing a part to be repaired according to claim 1, wherein the susceptor is a flexible metal film or metal mesh.

4. 2. The method for repairing a part to be repaired according to claim 1, wherein the heat transfer material is a laminate of a plurality of flexible metal films.

5. 5. The method for repairing a part to be repaired according to claim 4, wherein the thermal conductivity of the metal film on the repair patch side of the heat transfer material is higher than the thermal conductivity of the metal film on the susceptor side.

6. A step of determining the number of repair patches to be laminated on the repaired portion is further performed; 2. The method for repairing a part to be repaired according to claim 1, further comprising repeating steps from the step of placing the repair patch to the step of heating the repair patch a number of times equal to the determined number of layers.

7. The method for repairing a repaired portion according to claim 1 , further comprising the steps of placing a release material between the repair patch and the heat transfer material, and placing a first degassing member between the release material and the heat transfer material.

8. The method for repairing a repaired part according to claim 1 , further comprising the step of placing a second degassing member that functions as a thermal insulator on the susceptor.

9. A method for repairing a part to be repaired, comprising the steps of: repairing the part to be repaired using a repair patch containing a metal, The metal functions as a susceptor; placing a bond patch on the repaired portion, the bond patch comprising a resin; placing the repair patch over the bond patch; hermetically sealing the bonding patch and the repair patch with a bag film; a step of drawing a vacuum inside the bag film and heating the joint patch by inductively heating the metal of the repair patch using a magnetic field.

10. The method for repairing a repaired part according to claim 9, further comprising the step of placing a release material on the repair patch.

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