Fusion bonding of composite materials

Abstract

To improve a strength of parts after being fused.SOLUTION: There is provided a composite material fusion method for fusing a first composite material 10 that is a composite material of thermoplastic resin and fibers and a second composite material 20 that is a composite material of thermoplastic resin and fibers. The fusion method comprises: a resin film arranging step of providing a thermoplastic resin film 1 between a first fusion surface 11 that is a surface of the first composite material 10 to be fused and that has been machine-processed, and a second fusion surface 21 that is a surface of the second composite material to be fused; a heating step of heating the first composite material 10 and the second composite material 20 in a state where the resin film 1 is provided between the first fusion surface 11 of the first composite material 10 and the second fusion surface 21 of the second composite material 20; and a pressurizing step of pressurizing the first composite material 10 and / or the second composite material 20 in a state where the resin film 1 is provided between the first fusion surface 11 of the first composite material 10 and the second fusion surface 21 of the second composite material 20.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a method for fusing composite materials. [Background technology]

[0002] Aircraft parts such as aircraft fuselages and main wings may use composite materials such as thermoplastic carbon fiber reinforced plastics (CFRTP). A technique for joining parts made of such thermoplastic composite materials by fusing them together is known (see, for example, Patent Document 1). When fusing composite materials together, the surfaces of the composite materials to be fused (fusion interfaces) are brought into contact with each other, and the composite materials are heated in this state until the temperature exceeds the melting point of the resin contained in the composite materials, thereby melting the fusion interfaces of the composite materials. With the fusion interfaces molten, the composite materials are pressurized so that pressure acts on the fusion interfaces, thereby fusing the composite materials together.

[0003] The document WO 02 / 04494 describes a method for welding together at least two parts, in particular two rigid parts, each of which comprises a thermoplastic material and has a surface to be welded. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 6990343 Summary of the Invention [Problem to be solved by the invention]

[0005] One method for fusing composite parts together is to machine the fusing surfaces of each composite into a tapered shape and then fuse the machined surfaces together (taper splice joining). However, this method cannot achieve tapering all the way to the edges of the fusing surfaces due to machining accuracy limitations. Therefore, when the fusing surfaces of two composite parts are brought into contact, a gap forms between the edges. If a gap forms, the portion of the composite material facing the gap may not be sufficiently pressurized. If sufficient pressure is not applied, the portion becomes an unpressurized portion. Unpressurized portions can cause internal defects (wrinkles or delamination) due to fiber undulations within the molten resin. Internal defects can reduce the strength of the fused part. This problem can also occur when a gap forms between composite parts, not just with tapered splice joining.

[0006] Furthermore, when fusing thermoplastic composites, the bond strength is ensured by the resin. The fibers on the non-machined surfaces of composites are covered with resin. Therefore, when fusing non-machined surfaces, sufficient resin is present, ensuring sufficient bond strength. On the other hand, the machined surfaces of composites have exposed fibers due to machining, resulting in a lack of resin. Therefore, when fusing machined surfaces, there is a risk of insufficient resin and insufficient bond strength. Therefore, fusing machined surfaces together can reduce the strength of the fused parts. This problem can also occur when one of the fused surfaces is a machined surface, not just with taper splices.

[0007] The present disclosure has been made in consideration of the above circumstances, and aims to provide a method for fusing composite materials that can improve the strength of parts after fusing. [Means for solving the problem]

[0008] In order to solve the above problems, the composite material fusion method of the present disclosure employs the following means. A method for fusing a composite material according to one aspect of the present disclosure is for manufacturing an aircraft part, the composite material being made of a thermoplastic resin and a fiber, and the method comprises: A method for fusing a first composite material having a first fusion surface and a second composite material, the second composite material being a composite of a thermoplastic resin and fiber and having a second surface and a second fusion surface inclined relative to the second surface, the method comprising: a resin film providing step of providing a resin film between the first fusion surface, which is the surface of the first composite material to be fused, and the second fusion surface, which is the surface of the second composite material to be fused; a heating step of heating the first composite material and the second composite material in a state where the resin film is provided between the first fusion surface of the first composite material and the second fusion surface of the second composite material; and a step of providing a resin film between the first fusion surface of the first composite material and the second fusion surface of the second composite material. and a pressurizing step of pressurizing the first composite material and the second composite material in a state in which the first composite material and the second composite material are in a state in which the first composite material and the second composite material are in a melted state. In the resin film placing step, the resin film is placed so as to face a space formed between the first fused surface of the first composite material and an end plane formed at one end of the second fused surface of the second composite material. In the heating step, the first composite material and the second composite material are heated by a pair of heaters that are provided so as to sandwich the first composite material and the second composite material and have a first heater in contact with the first surface and a second heater in contact with the second surface, so that the resin film melts and flows into the space. In the pressurizing step, the first composite material and the second composite material are pressurized by the pair of heaters. . [Effects of the Invention]

[0009] According to the present disclosure, the strength of the parts after fusion can be improved. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 2 is a diagram showing a method for fusing composite materials according to an embodiment of the present disclosure, and is a longitudinal cross-sectional view of a first composite material and a second composite material with a resin film sandwiched therebetween. [Figure 2] FIG. 2 is an enlarged view of a main part (part II) of FIG. [Figure 3] 1 is a graph showing the effect of improving fusion strength of a composite fusion method according to an embodiment of the present disclosure. [Figure 4] 1 is a perspective view of a component having a spacer fused to a skin using a composite fusion method according to an embodiment of the present disclosure; FIG. [Figure 5] FIG. 5 is a view taken along arrows VV in FIG. 4. DETAILED DESCRIPTION OF THE INVENTION

[0011] Hereinafter, one embodiment of the method for fusing composite materials according to the present disclosure will be described with reference to the drawings. The fusion method according to this embodiment is used, for example, to fuse together members formed of composite materials that are the material for manufacturing aircraft parts that make up aircraft structures, such as stringers, spars, frames, and ribs. An example of the composite materials (first composite material 10 and second composite material 20) to be fused is carbon fiber reinforced plastic (CFRTP), which is a composite of thermoplastic resin and fibers. Specifically, the composite material may be a laminate formed by stacking multiple fiber reinforced sheets, the fibers of which are impregnated with resin.

[0012] In this embodiment, an example in which a first composite material 10 and a second composite material 20 are fused together will be described. First, the shapes of the first composite material 10 and the second composite material 20 and the arrangement of the resin film 1 will be described with reference to Figures 1 and 2. In Figures 1 and 2, the resin film 1 is illustrated thicker than it actually is to emphasize it. Also, in Figures 1 and 2, the space S is illustrated larger than it actually is to emphasize it.

[0013] 1, the first composite material 10 and the second composite material 20 have the same shape and are arranged so as to be point symmetrical. The first composite material 10 and the second composite material 20 are formed by cutting a flat laminate with a cutting device.

[0014] The first composite material 10 has a tapered first fused surface (machined surface) 11. The first composite material 10 has two flat surfaces connected by the first fused surface 11. In the following description, the surface on the upper side of the paper will be referred to as the upper surface 12, and the surface on the lower side of the paper will be referred to as the lower surface 13. The first fused surface 11 is formed so as to be inclined with respect to the upper surface 12 and the lower surface 13. The second composite material 20 has a tapered second fused surface 21. The second composite material 20 has two planar surfaces connected by the second fused surface 21. In the following description, the surface on the upper side of the drawing will be referred to as the upper surface 22, and the surface on the lower side of the drawing will be referred to as the lower surface 23. The second fused surface 21 is formed so as to be inclined with respect to the upper surface 22 and the lower surface 23.

[0015] The first fused surface 11 and the second fused surface 21 are formed by cutting the flat-plate-shaped laminate as described above. In this way, the first fused surface 11 of the first composite material 10 and the second fused surface 21 of the second composite material 20 are machined. In the following description, the machined surface will be referred to as the "machined surface." Machining refers to processing using a machine (e.g., cutting or milling). Specific examples include cutting or milling a workpiece (in this embodiment, a laminate) with a blade, a water jet, ultrasonic waves, etc. Furthermore, the machined surface is a surface that is machined to expose fibers compared to other surfaces. In this embodiment, the first fused surface 11 and the second fused surface 21 are machined surfaces.

[0016] Due to machining accuracy requirements, the first fused surface 11 is not tapered to one end (the lower end in this embodiment). An end plane 14 that is approximately perpendicular to the lower surface 13 is formed at one end of the first fused surface 11. The first fused surface 11 and the lower surface 13 are connected via the end plane 14. Due to machining accuracy requirements, second fusion surface 21 is not tapered up to one end (the upper end in this embodiment) as shown in Fig. 2. One end of second fusion surface 21 has an end plane 24 that is substantially perpendicular to upper surface 22. Second fusion surface 21 and upper surface 22 are connected via end plane 24.

[0017] As shown in FIG. 1, the first composite material 10 and the second composite material 20 are arranged so that the first fused surface 11 and the second fused surface 21 come into contact with each other when fused (more specifically, they come into contact via a resin film 1, which will be described later). At this time, as shown in FIGS. 1 and 2, a space S is formed between the first composite material 10 and the second composite material 20. More specifically, the space S is formed between the first fused surface 11 of the first composite material 10 and the end plane 24 of the second composite material 20. Also, the space S is formed between the second fused surface 21 of the second composite material 20 and the end plane 14 of the first composite material 10. The space S has a substantially triangular shape in vertical cross section. The space S is formed so as to be recessed from the upper surface 12 of the first composite material 10 and the upper surface 22 of the second composite material 20. Also, the space S is formed so as to be recessed from the lower surface 13 of the first composite material 10 and the lower surface 23 of the second composite material 20.

[0018] When the first composite material 10 and the second composite material 20 are fused together, the resin film 1 is provided between the first fused surface 11 and the second fused surface 21 . The resin film 1 is made of a thermoplastic resin. For example, the resin film 1 is made of PAEK (polyaryletherketone), PEEK (polyetheretherketone), etc. The resin film 1 is made of the same resin as the resin contained in the first composite material 10 and the second composite material 20. The thickness of the resin film 1 is 50 μm or more and 250 μm or less. There may be one or more resin films 1. When multiple resin films 1 are provided, the total thickness of the multiple resin films 1 is 50 μm or more and 250 μm or less. When the first composite material 10 and the second composite material 20 are fused together, the resin film 1 covers the entire first fused surface 11 and the second fused surface 21 in the depth direction of the paper in FIG. 1. In this embodiment, the resin film 1 is not disposed in the space S. The resin film 1 covers the areas of the first fused surface 11 and the second fused surface 21 that are adjacent to the areas facing the space S. The resin film 1 may also be disposed in the space S. In other words, it may cover the areas facing the space S. The resin film 1 faces the space S. In detail, the end surface of the resin film 1 faces the space S.

[0019] Next, the fusion method and the like according to this embodiment will be described. First, a flat laminate is cut with a cutting machine at an angle relative to the plate surface to produce the first composite material 10 and the second composite material 20. As a result, the first fused surface 11 and the second fused surface 21, which are the cut surfaces, become machined surfaces.

[0020] Next, as described above, the first composite material 10 and the second composite material 20 are arranged so that the first fused surface 11 and the second fused surface 21 are in contact with each other via the resin film 1. In other words, the resin film 1 is provided between the first fused surface 11 and the second fused surface 21 (resin film providing step). As a result, the resin film 1 is sandwiched between the first fused surface 11 and the second fused surface 21. At this time, two spaces S are formed between the first composite material 10 and the second composite material 20.

[0021] Next, a pair of heaters 2 are arranged to sandwich the first composite material 10 and the second composite material 20. Specifically, one of the heaters 2 is provided so as to contact the upper surface 12 of the first composite material 10 and the upper surface 22 of the second composite material 20. The other heater 2 is provided so as to contact the lower surface 13 of the first composite material 10 and the lower surface 23 of the second composite material 20. At this time, the pair of heaters 2 are arranged so that the first fusion surface 11 and the second fusion surface 21 are located between the pair of heaters 2.

[0022] Next, the heater 2 is heated to heat the first composite material 10 and the second composite material 20 in a state in which the resin film 1 is provided between the first fused surface 11 of the first composite material 10 and the second fused surface 21 of the second composite material 20 (heating step). More specifically, the first composite material 10 and the second composite material 20 are heated to a temperature equal to or higher than the melting point of the resin contained in the first composite material 10 and the second composite material 20. This melts the resin contained in the first composite material 10 and the second composite material 20. At this time, the resin film 1 is also heated through the first composite material 10 and the second composite material 20 and melts.

[0023] Next, a pair of heaters 2 apply pressure to sandwich the first composite material 10 and the second composite material 20, with the resin film 1 provided between the first fused surface 11 of the first composite material 10 and the second fused surface 21 of the second composite material 20 (pressurizing process). In the heating and pressurizing steps, the molten resin film 1 flows into the space S as shown by arrow A in Fig. 2. This fills the space S with the molten resin film 1. Therefore, in the pressurizing step, pressure also acts on the area facing the space S via the filled resin.

[0024] While the pressure is applied, the heater 2 is lowered in temperature to cool the first composite material 10 and the second composite material 20. As a result, the first composite material 10 and the second composite material 20 are solidified, and the first fused surface 11 of the first composite material 10 and the second fused surface 21 of the second composite material 20 are fused together. In this manner, in this embodiment, the first composite material 10 and the second composite material 20 are joined by taper splice.

[0025] According to this embodiment, the following advantageous effects are achieved. When fusing thermoplastic composites, the bond strength is ensured by the resin bonding. On the non-machined surface of the composite, the fibers are covered with resin. Therefore, when fusing the non-machined surface, there is sufficient resin to ensure the bond strength. On the other hand, on the machined surface of the composite, the fibers are exposed due to the machining process, and there is a lack of resin. Therefore, when fusing the machined surface, there is a possibility that there will not be enough resin to achieve sufficient bond strength. In this embodiment, a thermoplastic resin film 1 is provided on the machined surface (first fused surface 11) of the first composite material 10 in the resin film providing step. This causes the resin film 1 to melt due to heat transmitted through the first composite material 10 in the heating step. This allows resin to be replenished on the machined surface of the first composite material 10. This makes it possible to improve the fusion strength compared to when the resin film 1 is not provided. This in turn improves the strength of the part after fusion. In this embodiment, the second fused surface 21 of the second composite material 20 is also a machined surface. This means that the resin film 1 is placed between the machined surface of the first composite material 10 and the machined surface of the second composite material 20. Therefore, the molten resin film 1 can replenish resin on both the machined surface of the first composite material 10 and the machined surface of the second composite material 20. Therefore, even when welding machined surfaces together, which tend to reduce welding strength, the welding strength can be improved. This can improve the strength of the parts after welding.

[0026] If a space is formed between the first composite material 10 and the second composite material 20, there is a possibility that the portions of the first composite material 10 and the second composite material 20 that face the space S may not be sufficiently pressurized in the pressurizing step. If sufficient pressure is not applied in the pressurizing step, there is a possibility that undulations of the fibers may occur in the molten resin of the first composite material 10 and the second composite material 20. In this embodiment, the resin film 1 is placed so as to face the space S formed between the first composite material 10 and the second composite material 20. This allows the molten resin film 1 to flow into the space S during the heating process. This fills the space S with resin. Therefore, during the pressurizing process, the surface facing the space S can be suitably pressurized via the filled resin. This makes it possible to suppress defects in the composite material (such as fiber undulations) caused by insufficient pressurization. This makes it possible to improve the strength of the part after fusion.

[0027] Furthermore, when the space S is not filled with resin, a step is formed at the connection between the first fused surface 11 of the first composite material 10 and the end flat surface 14. Also, a step is formed at the connection between the second fused surface 21 of the second composite material 20 and the end flat surface 24. The presence of such a step can cause a stress peak to occur at the step, which can lead to a decrease in fusion strength. In this embodiment, since the space S is filled with resin in the heating and pressurizing steps, there are no steps on the first fused surface 11 of the first composite material 10 and the second fused surface 21 of the second composite material 20. This makes it possible to suppress stress peaks at the steps, and therefore to prevent a decrease in strength. Furthermore, if the resin film 1 is not provided between the fusion surfaces, the fusion strength is low, and therefore a high pressure is required as the pressure in the pressurizing step to obtain the desired fusion strength, which may increase the equipment costs. On the other hand, in this embodiment, since the resin film 1 is provided between the fusion surfaces, sufficient fusion strength can be obtained even with a relatively low pressure, and therefore an increase in equipment costs can be suppressed.

[0028] Furthermore, in this embodiment, the resin contained in the first composite material 10 and the second composite material 20 is the same as the resin of the resin film 1. This allows the molten resin film 1 to be integrated with the first composite material 10 and the second composite material 20. This allows the first composite material 10 and the second composite material 20 to be fused together more effectively.

[0029] The above-mentioned effect of improving fusion strength will be explained in detail using Fig. 3. The vertical axis of Fig. 3 represents the breaking load, and the horizontal axis represents the pressure applied to the first composite material 10 and the second composite material 20 in the pressurizing step. The pressure on the horizontal axis represents the pressure as a ratio when the reference pressure is set to 1.0. 3 show cases where a resin film 1 is provided between the first composite material 10 and the second composite material 20. As explained above, A to C show cases where the resin film 1 is provided over substantially the entire surfaces of the first fused surface 11 and the second fused surface 21, and D shows a case where the resin film 1 is provided only at both ends of the first fused surface 11 and the second fused surface 21 (i.e., only in a predetermined area adjacent to the space S). Furthermore, E to I show cases where no resin film 1 is provided between the first composite material 10 and the second composite material 20.

[0030] 3, when the resin film 1 is provided between the first composite material 10 and the second composite material 20 (bar graphs A to D), the breaking load is larger at all pressures than when the resin film 1 is not provided (bar graphs E to I). This shows that providing the resin film 1 improves the fusion strength.

[0031] Furthermore, the breaking load does not change significantly when pressurized at a pressure of 1.0 (bar graph A) or when pressurized at a pressure of 0.3 (bar graph C). This shows that when resin film 1 is provided, the breaking load does not change significantly even if the applied pressure in the pressurizing process is reduced. Therefore, it can be seen that sufficient fusion strength can be obtained even if the applied pressure in the pressurizing process is reduced, and therefore there is no need to install high-pressure equipment, which can prevent increases in equipment costs. On the other hand, it can be seen that the breaking load tends to decrease as the pressure decreases when the resin film 1 is not provided. Therefore, in this case, in order to obtain the desired fusion strength, a high pressure is required as the pressure in the pressurizing step, which can be seen to increase the equipment costs.

[0032] Furthermore, when comparing the case where the resin film 1 is provided over substantially the entire surface of the first fused surface 11 and the second fused surface 21 and pressurized at a pressure of 1.0 (bar graph A), the case where the resin film 1 is provided only on both ends of the first fused surface 11 and the second fused surface 21 and pressurized at a pressure of 1.0 (bar graph D), and the case where the resin film 1 is not provided and pressurized at a pressure of 1.0 (bar graph E), the difference in fracture load between bar graph A and bar graph D is greater than the difference in fracture load between bar graph D and bar graph E. This shows that the effect of the resin film 1 replenishing the resin on the machined surface has a greater impact on improving the fusion strength than the effect of filling the space S with resin.

[0033] The present disclosure is not limited to the above-described embodiments, and various modifications can be made without departing from the spirit of the present disclosure. For example, in the above embodiment, both the first fusion surface 11 of the first composite material 10 and the second fusion surface 21 of the second composite material 20 are machined surfaces, but the present disclosure is not limited to this. For example, the fusion method according to the present disclosure may be applied when welding a machined surface and a surface that has not been machined (hereinafter referred to as a "non-machined surface"). As an example of fusing a machined surface and a non-machined surface, for example, as shown in FIGS. 4 and 5, a spacer 32 may be fused to a skin 31 made of a composite material. As shown in FIG. 4, a spacer 32 is fixed to the surface of a skin 31 used in an aircraft. The skin 31 is manufactured by, for example, laminating prepregs impregnated with resin. That is, the skin 31 is not machined. Therefore, the surface of the skin 31 is a non-machined surface. On the other hand, as shown in FIG. 5, the thickness of the skin 31 is not constant. Therefore, the spacer 32 is tapered on the fusion surface (the lower surface in FIG. 5) to correspond to the thickness of the skin 31. Therefore, the fusion surface of the spacer 32 is a machined surface. Therefore, when fusing the spacer 32 to the surface of the skin 31, the machined surface and the non-machined surface are fused together. Even in such a case, by providing a resin film 1 between the machined surface and the non-machined surface during fusion, resin can be replenished on the surface of the machined surface, thereby achieving the effect of improving the fusion strength described above.

[0034] Furthermore, in the above embodiment, an example of fusing tapered fusion surfaces together has been described, but the present disclosure is not limited to this. When a space is formed between composite materials during fusing, defects in the composite material (such as fiber undulation) caused by insufficient pressure can be suppressed by applying the fusing method according to the present disclosure. For example, examples of when a space is formed between composite materials during fusing include when a recess is formed on the fusing surface or when fusing composite materials with an L-shaped cross section. When fusing composite materials with an L-shaped cross section, a space is formed between the outer portion of the curved portion and the other composite material.

[0035] In the above embodiment, the method of fusing the first composite material 10 and the second composite material 20 by applying heat and pressure has been described, but the present disclosure is not limited to this. For example, the fusing method according to the present disclosure may be applied to resistance fusing.

[0036] The method for fusing composite materials described in the above-described embodiment can be understood, for example, as follows. A method for fusing composite materials according to a first aspect of the present disclosure is a method for fusing a first composite material (10) that is a composite material of a thermoplastic resin and fibers, and a second composite material (20) that is a composite material of a thermoplastic resin and fibers, and includes a resin film installation step of providing a thermoplastic resin film (1) between a machined surface (11) of the first composite material to be fused, which is a machined surface, and a fusion surface (21) of the second composite material to be fused; a heating step of heating the first composite material and the second composite material in a state where the resin film is provided between the machined surface of the first composite material and the fusion surface of the second composite material; and a pressurizing step of pressurizing the first composite material and / or the second composite material in a state where the resin film is provided between the machined surface of the first composite material and the fusion surface of the second composite material.

[0037] When fusing thermoplastic composites, the bond strength is ensured by the resin bonding. On the non-machined surface of the composite, the fibers are covered with resin. Therefore, when fusing the non-machined surface, there is sufficient resin to ensure the bond strength. On the other hand, on the machined surface of the composite, the fibers are exposed due to the machining process, and there is a lack of resin. Therefore, when fusing the machined surface, there is a possibility that there will not be enough resin to achieve sufficient bond strength. In the above configuration, a thermoplastic resin film is applied to the machined surface of the first composite material in the resin film application process. As a result, the resin film melts due to heat transmitted through the first composite material in the heating process. This allows resin to be replenished to the machined surface of the first composite material. Therefore, the fusion strength can be improved compared to when a resin film is not applied. As a result, the strength of the part after fusion can be improved.

[0038] A method for fusing composite materials according to a second aspect of the present disclosure is the method of the first aspect, wherein the fusing surface of the second composite material is a machined surface that has been machined.

[0039] In the above configuration, the fusion surface of the second composite material is also a machined surface. This allows the resin film to be placed between the machined surface of the first composite material and the machined surface of the second composite material. Therefore, the molten resin film can replenish resin on both the machined surface of the first composite material and the machined surface of the second composite material. Therefore, even when welding machined surfaces, which tend to have a reduced fusion strength, together, the fusion strength can be improved. This allows the strength of the part to be improved after welding.

[0040] A method for fusing composite materials according to a third aspect of the present disclosure is a method for fusing a first composite material (10) that is a composite material of a thermoplastic resin and fibers, and a second composite material (20) that is a composite material of a thermoplastic resin and fibers, and includes a first fusion surface (11) that is the surface to be fused of the first composite material, and a second fusion surface ( 21 a resin film providing step of providing a resin film (1) between the first fused surface of the first composite material and the second fused surface of the second composite material; a heating step of heating the first composite material and the second composite material in a state where the resin film is provided between the first fused surface of the first composite material and the second fused surface of the second composite material; and a pressurizing step of pressurizing the first composite material and / or the second composite material in a state where the resin film is provided between the first fused surface of the first composite material and the second fused surface of the second composite material. BuildingIn the placing step, the resin film is placed so as to face the space formed between the first composite material and the second composite material.

[0041] If a space is formed between the first composite material and the second composite material, there is a possibility that the portions of the first composite material and the second composite material facing the space may not be sufficiently pressurized during the pressurization process.If sufficient pressure is not applied during the pressurization process, there is a possibility that fiber undulations may occur within the molten resin of the first composite material and the second composite material. In the above configuration, the resin film is placed so as to face the space formed between the first composite material and the second composite material. This allows the molten resin film to flow into the space during the heating process, thereby filling the space with resin. Therefore, during the pressurizing process, the surface facing the space can be suitably pressurized via the filled resin. This makes it possible to suppress defects in the composite material (such as fiber undulations) caused by insufficient pressurization. This makes it possible to improve the strength of the part after fusion.

[0042] A composite material fusion bonding method according to a fourth aspect of the present disclosure is any one of the first to third aspects, wherein the resin contained in the first composite material and the resin contained in the resin film are the same resin.

[0043] In the above-described configuration, the molten resin film and the first composite material are integrated together, which makes it possible to more effectively fuse the first composite material and the second composite material together. [Explanation of symbols]

[0044] 1: Resin film 2: Heater 10: First composite material 11: 1st fusion surface 12:Top surface 13: Bottom surface 14: End plane 20: Second composite material 21:Second fusion surface 22:Top surface 23: Bottom surface 24: End plane 31: Skin 32: Spacer S: Space

Claims

1. A method for fusing composite materials for manufacturing an aircraft part, comprising fusing a first composite material made of a thermoplastic resin and fibers, the first composite material having a first surface and a first fusion surface inclined relative to the first surface, and a second composite material made of a thermoplastic resin and fibers, the second composite material having a second surface and a second fusion surface inclined relative to the second surface, the method comprising: a resin film setting step of setting a resin film between the first fusion surface, which is a surface to be fused of the first composite material, and the second fusion surface, which is a surface to be fused of the second composite material; a heating step of heating the first composite material and the second composite material in a state where the resin film is provided between the first fused surface of the first composite material and the second fused surface of the second composite material; a pressurizing step of pressurizing the first composite material and the second composite material in a state where the resin film is provided between the first fused surface of the first composite material and the second fused surface of the second composite material, In the resin film installation step, the resin film is installed so as to face a space formed between the first fused surface of the first composite material and an end plane formed at one end of the second fused surface of the second composite material, In the heating step, the first composite material and the second composite material are heated by a pair of heaters that are disposed so as to sandwich the first composite material and the second composite material, the pair of heaters including a first heater in contact with the first surface and a second heater in contact with the second surface, and the resin film melts and flows into the space, In the pressurizing step, the first composite material and the second composite material are pressed by the pair of heaters.

2. The method for fusing composite materials according to claim 1 , wherein the resin contained in the first composite material and the resin contained in the resin film are the same resin.

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