Fusion bonding method

Abstract

This fusion bonding method for fusion bonding a second member to a first member comprises an arrangement step and a scanning step. The arrangement step is for arranging a susceptor on the side of the second member opposite to the surface that faces a repair target area of the first member, the second member being arranged according to the repair target area, and a heat transfer member being interposed between the susceptor and the second member. The scanning step is for scanning a magnetic field generation device along the surface of the susceptor from the side of the susceptor opposite to the surface facing the heat transfer member after completion of the arrangement step. The susceptor is a member that generates heat by the magnetic field of the magnetic field generation device in the scanning step.

Description

Fusion method

[0001] This disclosure relates to a fusion method.

[0002] For example, Non-Patent Document 1 below describes adhering a composite material patch to a repair location via a film-shaped adhesive for aircraft repair.

[0003] Masayoshi Sihara et al., "Development of a High-Speed Repair Method for Aircraft Composite Material Structures", Mitsubishi Heavy Industries Technical Report, Vol. 53, No. 4 (2016), New Product / New Technology Special Issue

[0004] In the adhesion of the above composite material patch, etc., it is necessary to heat the adhesive. Therefore, the inventor considered heating the adhesive by induction heating. However, in that case, it was found that there is a possibility of temperature variation for each heated region.

[0005] This disclosure provides a fusion method for fusing a second member to a first member. The fusion method has an arrangement step and a scanning step. The arrangement step is a step of arranging a susceptor via a heat transfer member on the side opposite to the surface of the second member facing the repair target location, which is arranged according to the repair target location of the first member. The scanning step is a step of scanning a magnetic field generating device along the surface of the susceptor from the side opposite to the surface of the susceptor facing the heat transfer member after completion of the arrangement step. The susceptor is a member that generates heat by the magnetic field of the magnetic field generating device in the scanning step.

[0006] It is a diagram showing the configuration of an aircraft repair system according to the first embodiment. It is a flowchart showing the procedure of aircraft repair according to the same embodiment. It is a flowchart showing the detailed procedure of a part of the process shown in FIG. 2. It is a cross-sectional view showing a part of the process shown in FIG. 3. It is a cross-sectional view showing a part of the process shown in FIG. 3. It is a heat map showing a part of the process shown in FIG. 3. It is a diagram showing a part of the process shown in FIG. 3. It is a diagram showing a part of the process shown in FIG. 3. It is a plan view exemplifying the raster set in the process shown in FIG. 3. It is a heat map showing the effect of the same embodiment. It is a flowchart showing the procedure of the scanning pattern setting step according to the second embodiment.

[0007] <First Embodiment> The first embodiment will now be described with reference to the drawings. "Repair System" Figure 1 shows the configuration of the aircraft repair system according to this embodiment. The airframe 10 is the airframe of the aircraft to be repaired. The material of the airframe 10 is, for example, carbon fiber reinforced thermoplastic (CFRTP). The solenoid coil 12 is a magnetic field generator for fusing repair patches to the repair location on the airframe 10 by electromagnetic induction heating. The solenoid coil 12 is attached to the robot arm 14. The robot arm 14 is fixed to the trolley 16. The trolley 16 is equipped with a control device 20.

[0008] The control device 20 comprises a PU 22, a storage device 24, and a communication device 26. The PU 22 is a processing unit that executes software processing such as a CPU or GPU. The storage device 24 stores a program consisting of commands that define the processing to be executed by the PU 22. The objects controlled by the control device 20 are the robot arm 14 and the solenoid coil 12. By executing the above program, the PU 22 controls the displacement of the robot arm 14 and the energization of the solenoid coil 12.

[0009] The robot arm 30 is responsible for moving predetermined components, such as placing the repair patch on the repair location of the machine body 10. The control device 32 controls the robot arm 30. The higher-level control device 40 includes a PU 42, a storage device 44, and a communication device 46. The PU 42 is a processing unit that executes software processing such as a CPU or GPU. The storage device 44 stores a program consisting of commands that define the processing to be executed by the PU 42. The higher-level control device 40 controls the robot arms 14 and 30. The higher-level control device 40 transmits command signals related to the control of the robot arm 14 to the control device 20 via the communication device 46. The higher-level control device 40 also transmits command signals related to the control of the robot arm 30 to the control device 32 via the communication device 46. The higher-level control device 40 performs the command signal transmission process by having the PU 42 execute the program stored in the storage device 44.

[0010] "Regarding the Repair Process" Figure 2 shows the steps of the repair process. In the following, each step will be represented by a number preceded by an "S".

[0011] In the series of steps shown in Figure 2, first, a non-destructive inspection of the machine body 10 is performed (S10). Step S10 may include, for example, a step of inspecting the machine body 10 for internal damage using an ultrasonic flaw detection device. Next, scarf processing is performed to remove the damaged portion from the machine body 10 and process it into a predetermined shape (S12). Next, the size of the repair patch and the number of repair patches are determined according to the shape of the damaged area, which is the area to be repaired (S14). In other words, in this embodiment, the damaged area is repaired to the desired shape by stacking sheet-like repair patches on the area to be repaired. Note that the shapes of the multiple repair patches stacked may differ from each other. Step S14 includes a step of measuring the shape of the area to be repaired.

[0012] Next, the scanning pattern of the solenoid coil 12 is determined (S16). The scanning pattern is determined by defining the appropriate movement path of the solenoid coil 12 for fusing the repair patch.

[0013] Figure 3 shows the details of the process in S16. The series of steps shown in Figure 3 are executed by the higher-level control device 40. In the following, when the higher-level control device 40 outputs a command signal to the control device 20 to instruct the movement of the robot arm 14, and the control device 20 operates the robot arm 14, this is referred to as the higher-level control device 40 operating the robot arm 14. Similarly, when the higher-level control device 40 outputs a command signal to the control device 32 to instruct the movement of the robot arm 30, and the control device 32 operates the robot arm 30, this is referred to as the higher-level control device 40 operating the robot arm 30. In the following, the description that the process in which the PU 22 of the control device 20 operates the robot arm 14 based on the command signal from the higher-level control device 40 is sometimes omitted.

[0014] In the series of processes shown in Figure 3, first, PU 42 operates the robot arm 30 to laminate the release film 50 shown in Figure 4 onto the repair area of ​​the machine body 10 (S20). The release film 50 is a component that prevents the repair patch from fusing to the machine body 10. The material of the release film 50 may be, for example, fluororesin. Next, PU 42 operates the robot arm 30 to place the thermocouple 52 shown in Figure 4 on top of the release film 50 (S22). The thermocouple 52 is placed at multiple different locations on the area to be repaired.

[0015] Next, PU42 operates the robot arm 30 to place one repair patch 54 as shown in Figure 4 (S24). The repair patch 54 has a two-layer structure, for example, a film adhesive 54b and a repair member 54a. The repair member 54a is a sheet-like composite material of reinforcing fibers such as glass fiber, carbon fiber, or aramid fiber and resin. Next, PU42 operates the robot arm 30 to laminate a perforated release film 56 as shown in Figure 4 (S26). The perforated release film 56 is, for example, the release film 50 with holes punched in it. Next, PU42 operates the robot arm 30 to laminate a degassing cloth 58 as shown in Figure 4 (S28). The degassing cloth 58 is, for example, a sheet-like woven or nonwoven fabric.

[0016] Next, the PU 42 stacks the heat transfer material 60 shown in Figure 4 by operating the robot arm 30 (S30). The heat transfer material 60 is a sheet-like metal member with high thermal conductivity. It is desirable that the material of the heat transfer material 60 has a higher thermal conductivity than the material of the susceptor 62. The material of the heat transfer material 60 may be copper or aluminum, for example. It is desirable that the heat transfer material 60 has sufficient thickness. Ideally, the thickness of the heat transfer material 60 should be greater than or equal to the radius of the solenoid coil 12. The thickness of the heat transfer material 60 may be less than the radius of the solenoid coil 12, but it is desirable to make it as thick as possible. The heat transfer material 60 is flexible. In order to satisfy both the requirement that the heat transfer material 60 have sufficient thickness and the requirement that the heat transfer material 60 be flexible, it is desirable that the heat transfer material 60 be a foil-like laminate.

[0017] Next, the PU 42 stacks the susceptors 62 shown in Figure 4 by operating the robot arm 30 (S32). The susceptors 62 are heat sources that generate heat through induction heating. The susceptors 62 may be made of a magnetic material. The susceptors 62 are flexible. To make the susceptors 62 flexible, they may be constructed from a metal mesh. One example of the material for the susceptors 62 is iron. The material for the susceptors 62 may be aluminum or copper. The thickness of the susceptors 62 may be thinner than the thickness of the heat transfer material 60. It is desirable that the material for the susceptors 62 is a material with higher heat generation efficiency compared to the material for the heat transfer material 60. If the heat generation efficiency is low when the susceptors 62 are constructed as a sheet-like member, the heat generation efficiency may be improved by constructing the susceptors 62 as a mesh structure.

[0018] Next, PU42 operates the robot arm 30 to laminate the heat insulating cloth 64 shown in Figure 5 (S34). Next, PU42 operates the robot arm 30 to laminate the bag film 66 shown in Figure 5 (S36). In step S36, the components laminated in steps S20 to S34 are covered by the machine body 10 and the bag film 66. Then, PU42 operates a vacuum pump (not shown) to reduce the pressure inside the space covered by the machine body 10 and the bag film (S38).

[0019] Then, the PU 42 operates the robot arm 14 to position the solenoid coil 12 opposite to a localized predetermined location among the areas to be repaired, and energizes the solenoid coil 12 (S40). Multiple predetermined locations are provided. The predetermined locations are set in the vicinity of the thermocouple 52.

[0020] Figure 5 shows an example in which the solenoid coil 12 is positioned so that one of the thermocouples 52 is included within the area perpendicularly projected onto the repair patch 54. In step S40, the magnetic field generated by the solenoid coil 12 acts on the susceptor. As a result, the susceptor 62 generates heat. The heat generated in the susceptor 62 is diffused into the heat transfer material 60.

[0021] Returning to Figure 3, PU 42 determines, based on the temperature detected by the thermocouple 52, whether the heating criteria required for fusing the repair patch 54 to the machine body 10 are met (S42). For example, PU 42 may determine that the criteria are not met if the area of ​​the region of the repair patch 54 that is above a predetermined temperature is less than a predetermined area. The predetermined temperature is set to be above the temperature required for the film adhesive 54b of the repair patch 54.

[0022] If PU42 determines that the criteria are not met (S42: NO), it changes at least one of two parameters: the distance between the susceptor 62 and the solenoid coil 12, and the power consumption of the solenoid coil 12 (S44). Then, PU42 returns to step S40. Steps S40 to S44 are repeated until the criteria are met.

[0023] On the other hand, if PU42 determines that the criteria have been met (S42: YES), PU22 of the control device 20 sets the raster (S46). The raster is set to a region in which the temperature of the repair patch 54 rises to a predetermined temperature or higher by induction heating using the solenoid coil 12.

[0024] Figure 6 illustrates the temperature distribution of the repair patch 54 due to induction heating by the solenoid coil 12. In Figure 6, a higher density of dots indicates a higher temperature. In Figure 6, the circular area enclosed by the dashed line represents the area where the temperature of the repair patch 54 has risen above a predetermined temperature. In this embodiment, since the raster is set to a rectangular shape, the raster may, for example, be set to a square inscribed in the circle drawn by the dashed line. Note that if the temperature distribution is not point-symmetric, the area where the temperature of the repair patch 54 has risen above a predetermined temperature may be elliptical instead of circular. In that case, the PU 22 may set the raster to a rectangle inscribed in an ellipse.

[0025] Returning to Figure 3, PU22 sets a scanning pattern for the solenoid coil 12 that can raise the temperature of the entire surface of the repair patch 54 to above a predetermined temperature (S48). PU22 sets the scanning pattern for the solenoid coil 12 by arranging a raster without any gaps across the entire surface of the repair patch 54 facing the area to be repaired.

[0026] Figure 7 illustrates the arrangement of rasters using solid lines. Figure 7 shows an example where three square-shaped rasters are arranged side by side. The area enclosed by the dashed line in Figure 7 is the area where the temperature of the repair patch rises above a predetermined temperature. Also, Figure 7 shows the outline of the solenoid coil 12 projected perpendicularly onto the repair patch 54 using a double-dash line.

[0027] PU22 sets the scanning pattern to displace the center of the shape formed by perpendicularly projecting the solenoid coil 12 onto the repair patch 54 along a line connecting the centers of the raster. In other words, PU22 sets the movement path of the center of the solenoid coil 12 to a path along the line connecting the centers of the raster.

[0028] Figure 8 illustrates a scanning pattern. The curve in Figure 8 is a line connecting the centers of the raster 70. The scanning pattern shown in Figure 8 specifies that the movement path of the center of the solenoid coil 12 is the curve described above.

[0029] Furthermore, step S40 may, for example, be a step in which solenoid coils 12 are placed opposite each other on raster 70a and raster 70b in Figure 8 to perform localized heating treatment. Also, at least one of the two dimensions and shapes of raster 70 may differ between raster 70a and raster 70b. For example, if the arrangement of the heat transfer material causes heat diffusion in the upward and lateral directions of raster 70b to be smaller than heat diffusion in the downward direction in Figure 8, then raster 70b may have a vertically elongated rectangular shape, as illustrated in Figure 9. Note that Figure 9 shows an example in which raster 70a and 70b differ not only in shape but also in dimensions.

[0030] Incidentally, when repair patches 54 of different shapes are stacked on the area to be repaired, the scanning pattern has a separate pattern for each repair patch 54 to be fused. Returning to Figure 3, the PU 22 heats the entire surface of the repair patch 54 by scanning the solenoid coil 12 according to the scanning pattern and energizing the solenoid coil 12 (S50). This process simulates the heating process of the repair patch 54 when actually fusing the repair patch 54 to the area to be repaired.

[0031] Based on the detected value of the thermocouple 52 as an input variable, PU22 determines in step S50 whether the temperature of the entire area of ​​the repair patch 54 has risen above a predetermined temperature (S52). For step S52, it is desirable that in step S22, several thermocouples 52 are placed in locations other than the thermocouple 52 used in step S40. Note that "the temperature of the entire area of ​​the repair patch 54 has risen above a predetermined temperature" does not mean that there is a time when the temperature of the entire area is above the predetermined temperature. "The temperature of the entire area of ​​the repair patch 54 has risen above a predetermined temperature" means that during step S50, the union of areas that have risen above the predetermined temperature includes the entire area of ​​the repair patch 54.

[0032] If PU22 determines that the temperature in a portion of the repair patch 54 has not risen above a predetermined temperature, in other words, that the requirement for overall heating has not been met (S52: NO), it changes the scanning speed, which is the displacement speed of the solenoid coil 12 (S54). Then, PU22 repeats the process in S50 with the changed scanning speed.

[0033] On the other hand, if PU22 determines that the requirement for full-surface heating is met (S52: YES), it sets the scanning speed that was being used at that time to the actual scanning speed in the fusion process of the repair patch 54 (S56).

[0034] If step S56 is completed, then step S16 in Figure 2 is completed. If step S16 is completed, pretreatment for the fusion of the repair patch 54 is performed (S18). Step S18 may include a step of drying the area to be repaired on the aircraft body 10. Step S18 may include a step of sanding the surface of the area to be repaired on the aircraft body 10. Step S18 may include a step of cleaning the area to be repaired on the aircraft body 10.

[0035] When step S18 is completed, the PU 42 of the upper control unit 40 operates the robot arm 30 to apply one repair patch to the area of ​​the machine body 10 to be repaired (S24). Next, the PU 42 performs the same steps as in steps S26 to S38 in Figure 3. Then, the PU 42 scans the solenoid coil 12 and energizes the solenoid coil 12 according to the scanning pattern set in step S48 and the scanning speed determined in step S56 (S60). In this step, the PU 22 performs the same processing as in step S50.

[0036] Once step S60 is completed, the PU 42 of the upper control unit 40 determines whether the required number of repair patches 54 have been stacked (S62). If the PU 40 determines that the required number of patches has not yet been reached (S62: NO), it returns to step S24. In step S24, which follows a negative determination in step S62, at least a portion of the repair patches 54 will not directly contact the aircraft body 10, but will be positioned in contact with repair patches 54 that have already been fused.

[0037] On the other hand, if it is determined that the required number of PU42 layers have been stacked (S62: YES), a non-destructive inspection of the area to be repaired is performed (S64). The step in S64 may be, for example, a step of inspecting whether or not there are any voids inside the machine body 10 using an ultrasonic flaw detection device.

[0038] If no abnormalities are found in step S64, the area to be repaired is painted (S66). When step S66 is completed, the series of steps shown in Figure 2 is completed.

[0039] "Operations and Effects of this Embodiment" PU22 set the scanning pattern of the solenoid coil 12 by arranging the raster 70 without gaps over the entire area of the repair patch 54. As a result, the temperature of the repair patch 54 can be raised to a predetermined temperature or higher at least once over the entire area.

[0040] According to the embodiment described above, the following operations and effects can be obtained. (1) PU42 arranged the heat transfer material 60 between the susceptor 62 and the repair patch 54. As a result, it is possible to suppress unevenness in the temperature of the repair patch 54 compared to the case where the heat transfer material 60 is not arranged.

[0041] Fig. 10 shows the temperature distribution of the repair patch 54 by induction heating using the solenoid coil 12. The heat map on the left side of Fig. 10 shows the temperature distribution of the repair patch 54 when the heat transfer material 60 is not used. The heat map on the right side of Fig. 10 shows the temperature distribution of the repair patch 54 when the heat transfer material 60 is used.

[0042] As shown in Fig. 10, when the heat transfer material 60 is not used, the temperature of the central portion is low. This portion corresponds to the portion where the central portion of the solenoid coil 12 is vertically projected onto the repair patch 54.

[0043] (2) The material of the aircraft 10 is CFRTP. Since CFRTP has a high melting temperature, the heating time for fusion tends to be long. If the heating time becomes long, there is a risk that the temperature of the aircraft 10 will rise above the allowable temperature. Therefore, the merit of sequentially fusing a plurality of sheet-like repair patches 54 is particularly large.

[0044] (3) If flexibility is imparted to the heat transfer material 60 and the susceptor 62, even if the surface of the repair target location is curved, the heat transfer material and the susceptor 62 can be made to follow the surface shape of the repair target location.

[0045] <Second Embodiment>Hereinafter, the second embodiment will be described with reference to the drawings, focusing on the differences from the first embodiment.

[0046] In the above-described embodiment, the fusion heat treatment of the repair patch 54 was performed by continuously displacing the solenoid coil 12 with the robot arm 14. In contrast, in the present embodiment, each time an operation of arranging the solenoid coil 12 corresponding to a raster arranged so as to cover the entire surface of the repair patch 54 is performed, a process of energizing the solenoid coil 12 is executed. That is, in the present embodiment, the entire surface of the repair patch 54 is heated by repeating the process of arranging the solenoid coil 12 corresponding to the raster and the process of energizing the solenoid coil 12.

[0047] FIG. 11 shows a detailed procedure of the step S16 according to the present embodiment. In the steps shown in FIG. 11, steps corresponding to the steps shown in FIG. 3 are given the same step numbers for convenience.

[0048] In the series of steps shown in FIG. 11, when a negative determination is made in the step S52 (S52: NO), the PU 22 sequentially changes the sequential heating time (S54a). The sequential heating time is the time for applying the magnetic field of the solenoid coil 12 to the susceptor 62 while arranging the solenoid coil 12 corresponding to one raster. When the step S54a is completed, the step S50 is executed according to the changed sequential heating time. On the other hand, when an affirmative determination is made in the step S52, the PU 22 determines the sequential heating time used at that time as the actual sequential heating time in the fusion step of the repair patch 54 (S56a).

[0049] As described above, according to the present embodiment, since the heat treatment is performed while sequentially displacing the solenoid coil 12, the repair patch 54 can be fused without using a robot arm 14 or the like capable of displacing the solenoid coil 12 with high precision.

[0050] <Correspondence> The correspondence between the items in the above embodiment and the items described in the "Solution" column below is as follows. Below, the correspondence is shown for each solution number described in the "Solution" column. [1, 15] The first member corresponds to the machine body 10. The second member corresponds to the repair patch 54. The placement process corresponds to the processes S30 and S32 in Figure 2. The scanning process corresponds to the process S60. [2] The scanning pattern setting process corresponds to the process S16. [3, 7] The temperature sensor corresponds to the thermocouple 52. The temporary placement process corresponds to the processes S30 and S32. The rehearsal heating process corresponds to the process S40. The specific process corresponds to the process S40. The "movement path setting process" corresponds to the process S48. [4] The raster setting process corresponds to the process S46. The raster placement process and the movement path setting process correspond to the process S48. [5] The heating time setting step corresponds to step S54a. [6] The movement speed setting step corresponds to step S54. [8] The "step to change the distance" corresponds to step S44. [9] The "step to change the power consumption" corresponds to step S44.

[10] The items described in Solution 10 correspond to Figure 9.

[11] The items described in Solution 11 correspond to step S60 being executed after steps S36 and S38.

[12] The items described in Solution 12 correspond to repeating the processes of S24 to S38 and S60 until an affirmative judgment is made in step S62.

[13] This corresponds to the material of the machine body 10 being CFRTP.

[14] This corresponds to the repair patch 54 consisting of film adhesive 54b and repair member 54a.

[0051] <Other Embodiments> This embodiment can be implemented with the following modifications. This embodiment and the following modifications can be combined with each other to the extent that they do not contradict each other technically.

[0052] "Regarding the rehearsal heating process" In the above embodiment, in step S16, step S40 was performed followed by step S50, but this is not limited to this. For example, steps S40 and S50 may be combined. In that case, initially the shape and dimensions of the raster should be set to default values, and rehearsal heating should be performed on the entire surface of the repair patch 54. Then, depending on the temperature detected by the thermocouple 52 at that time, the shape and dimensions of the raster may be changed, or the process in S44 may be performed.

[0053] "Regarding the tuning targets for the rehearsal heating process" - The tuning targets for the rehearsal heating process are not limited to the dimensions of the raster, the shape of the raster, the distance between the susceptor and the magnetic field generator, the movement speed of the magnetic field generator, the heating time, and the power consumption of the magnetic field generator. The tuning targets for the rehearsal heating process may also be the thickness of the heat transfer material.

[0054] "Regarding the Raster Setting Process" - It is not essential that different raster shapes can be set depending on the area. For example, the raster shape may be set to only one similar shape with different dimensions. Also, it is not essential that the dimensions of the raster can be changed depending on the area. When scanning the entire surface of the repair patch 54, all rasters may have the same shape and dimensions.

[0055] Regarding the scanning pattern setting process: The process to which the user transitions if a negative result is obtained in step S52 is not limited to steps S54 and S54a. The transitioned process may be, for example, step S44.

[0056] - The scanning pattern setting step does not necessarily include a step of adjusting both the distance between the solenoid coil 12 and the susceptor 62 and the power consumption of the solenoid coil 12 according to the temperature detected by the thermocouple 52. The scanning pattern setting step may, for example, include a step of adjusting only one of the two elements described above.

[0057] "Regarding the determination of the repair patch size and required number of Ply" In the above embodiment, step S14 was performed prior to the scanning pattern setting step, but this is not limited to this. For example, the scanning pattern setting step may include a step of appropriately fusing multiple repair patches, and the repair patch size and required number of Ply may be determined according to the connection between the surface of the final repair patch and the surface of the machine body 10. It should be noted that including the determination of the repair patch size and required number of Ply in the scanning pattern setting step is particularly effective in the case described in the section "Regarding the scanning step for fusion" below. That is, it is particularly effective when the fusion step is a step of fusing a second member and a first member, which are pre-formed as a single stacked mass.

[0058] "Regarding the scanning process for fusion bonding" - It is not essential that the fusion bonding process between the first member and the second member include a step in which the solenoid coil 12 is scanned each time a plurality of repair patches are placed on the repair target area. The fusion bonding process may, for example, be a process of fusing the first member with the second member, which is a single mass formed in advance through lamination. This modification of the fusion bonding process is particularly preferable when the first member is a thermosetting resin.

[0059] Regarding the fusion process: It is not mandatory for the fusion process to include all of steps S18, S26, S28, and S32-S38.

[0060] Regarding the susceptor and heat transfer member: - It is not essential that the materials of the susceptor 62 and the heat transfer member 60 are different from each other. - It is not essential that the process of sequentially laminating the heat transfer member 60 and the susceptor 62 be carried out prior to heating. For example, the process of laminating a component in which the susceptor 62 and the heat transfer member 60 are bonded together and integrated may be carried out in one step prior to heating.

[0061] - It is not essential that the heat transfer material 60 and the susceptor 62 are flexible. In particular, if the surface of the area to be repaired is flat and not curved, the heat transfer material 60 and the susceptor 62 may be rigid plate-shaped members or the like.

[0062] Regarding the first component: It is not essential that the aircraft body 10 be made of CFRTP. For example, it may be made of a thermosetting resin.

[0063] - The first component does not necessarily have to be an aircraft fuselage. The first component may be, for example, a ship hull. Alternatively, the first component may be, for example, a car body. "Regarding the temperature sensor" - The temperature sensor does not necessarily have to be a thermocouple 52. The temperature sensor may be, for example, a thermistor.

[0064] "Regarding Magnetic Field Generators" - It is not essential that the coil in a magnetic field generator is a solenoid coil. The coil in a magnetic field generator may be, for example, a planar coil or a toroidal coil.

[0065] - It is not essential that the magnetic field generator includes a solenoid coil. The magnetic field generator may be configured to include, for example, a magnetron. "Other" - The step in S18 may be performed prior to the step in S20 in the step in S16.

[0066] <Note> Solution 1. A fusion bonding method for fusing a second member to a first member, comprising a placement step and a scanning step, wherein the placement step is a step of placing a susceptor via a heat transfer member on the side of the second member that is positioned according to the repair target location of the first member and is opposite to the side facing the repair target location, and the scanning step is a step of scanning a magnetic field generator along the surface of the susceptor from the side of the susceptor that is opposite to the side facing the heat transfer member, after the completion of the placement step, and the susceptor is a member that generates heat due to the magnetic field of the magnetic field generator in the scanning step.

[0067] In the above method, the magnetic field of the magnetic field generator acts on the susceptor, causing it to heat up. The heat generated by the susceptor is then transferred to the second member via a heat transfer member. Therefore, compared to the case where the susceptor is placed in contact with the second member, it is possible to suppress temperature variations in different regions of the second member.

[0068] Solution 2. The fusion bonding method according to claim 1, wherein the method comprises a scanning pattern setting step which precedes the arrangement step, and the scanning pattern setting step is a step of setting the movement path of the magnetic field generator so that regions where the temperature of the second member becomes above a predetermined temperature due to scanning by the magnetic field generator overlap.

[0069] In the above method, the temperature of the second member can be raised to a predetermined temperature or higher over its entire range. Solution 3. The scanning pattern setting step comprises a temporary placement step of placing the heat transfer member and the susceptor on the side of the second member opposite to the side facing the release sheet, with the first member and the second member facing each other with a release sheet and a temperature sensor in between; a rehearsal heating step of applying the magnetic field of the magnetic field generator to the susceptor from the side of the susceptor opposite to the side facing the heat transfer member; and a identification step of identifying a region in which the temperature of the second member becomes above the predetermined temperature when the magnetic field generator is placed, based on the temperature detected by the temperature sensor as an input variable, and setting the movement path of the magnetic field generator based on the result of identifying the region in which the temperature becomes above the predetermined temperature, wherein the release sheet is a sheet for preventing the first member and the second member from being bonded together, and the fusion bonding method according to 2 above comprises a step of removing the release sheet and the temperature sensor from the repair target area prior to the placement step.

[0070] In the above configuration, prior to the placement and scanning processes, the temperature rise of the second member can be determined based on measured values ​​without actually fusing the first and second members together using a release sheet. Then, by executing the scanning process according to the movement path set based on the measured values, the temperature of the entire surface of the second member can be appropriately raised.

[0071] Solution 4. The fusion bonding method according to claim 3, wherein the scanning pattern setting step comprises: a raster setting step of setting a raster which is a rectangular region in which the temperature of the heat transfer member is above a predetermined temperature, based on the result of identifying the region in which the temperature is above a predetermined temperature; a raster arrangement step of arranging a plurality of rasters so as to cover the entire surface of the second member facing the first member; and a movement path setting step of setting the movement path of the magnetic field generator so as to pass through each of the plurality of rasters in which the region obtained by projecting the magnetic field generator onto the surface of the second member facing the first member passes through each of the plurality of rasters.

[0072] In the above method, setting the raster makes it easier to set an appropriate movement path for raising the temperature of the entire surface of the second member to a predetermined temperature or higher. Solution 5. The fusion method according to 4 above, wherein the scanning step is a step of sequentially arranging the magnetic field generator such that the area projected onto the surface of the second member facing the first member corresponds to each of the plurality of rasters, and the scanning pattern setting step includes a heating time setting step of setting the time for arranging the magnetic field generator to correspond to one of the rasters based on the detected value of the temperature sensor.

[0073] The above method includes a heating time setting step, which allows setting an appropriate value for the duration for which the magnetic field generator is positioned in one location to raise the temperature of the second member to a predetermined temperature or higher. Solution 6. The fusion bonding method according to 4 or 5 above, wherein the scanning step is a step of continuously moving the magnetic field generator, and the scanning pattern setting step includes a movement speed setting step in which the movement speed of the magnetic field generator is set based on the value detected by the temperature sensor when the magnetic field generator is displaced along the movement path set by the movement path setting step.

[0074] In the above method, by providing a movement speed setting step, an appropriate movement speed can be set to raise the temperature of the second member to a predetermined temperature or higher. Solution 7. The fusion method according to any one of 3 to 6 above, wherein the rehearsal heating step includes a step of selectively arranging the magnetic field generator to correspond to a part of and multiple localized areas of the area to be repaired.

[0075] In the above method, by selecting a representative point of the second component during the rehearsal heating process and heating only that representative point, the time required for the rehearsal heating process can be shortened compared to the case where the magnetic field generator is scanned over the entire area.

[0076] Solution 8. The fusion method according to any one of 3 to 7 above, wherein the scanning pattern setting step includes a step of changing the distance between the susceptor and the magnetic field generator based on the result of identifying a region that is above a predetermined temperature, and the rehearsal heating step is performed according to the changed distance.

[0077] The magnetic flux density acting on the susceptor changes depending on the distance between the susceptor and the magnetic field generator, which in turn changes how the temperature of the second component rises. Therefore, in the above method, by changing the distance based on the detection results of the temperature sensor and further performing the rehearsal heating process, it is possible to find an appropriate distance for heating the second component to the desired temperature.

[0078] Solution 9. The fusion method according to any one of 3 to 8 above, wherein the scanning pattern setting step includes a step of changing the power consumption of the magnetic field generator based on the result of identifying a region that is above a predetermined temperature, and the rehearsal heating step is performed according to the changed power consumption.

[0079] The magnetic flux density acting on the susceptor changes depending on the power consumption of the magnetic field generator, which in turn changes how the temperature of the second component rises. Therefore, in the above method, by changing the power consumption based on the detection results of the temperature sensor and further executing the rehearsal heating process, it is possible to find the appropriate power consumption for heating the second component to the desired temperature.

[0080] Solution 10. The fusion method according to any one of 4 to 9 above, wherein the raster placement step includes the step of arranging rasters in which at least one of two characteristics, shape and dimensions, differs from each other depending on the area.

[0081] If the degree of heat diffusion differs from area to area of ​​the repair target, the areas where the temperature rises above a predetermined temperature may differ from local area to local area of ​​the second component. Therefore, in the above method, by setting at least one of the above two to multiple values, it is possible to raise the temperature of the second component above the predetermined temperature over its entire surface while reducing the areas where the net time spent above the predetermined temperature during the scanning process becomes excessively long.

[0082] Solution 11. The fusion bonding method according to any one of claims 1 to 10, wherein the arrangement step includes a step of covering the second member, the heat transfer member, and the susceptor with a bag film and reducing the pressure of the area to be repaired, and the scanning step is performed with the susceptor covered by the bag film.

[0083] In the above method, the first and second members can be fused together while the gas is removed from between them, thereby improving the adhesion between the first and second members.

[0084] Solution 12. The fusion method according to any one of claims 1 to 11, wherein the second member is a sheet-like member, and the sheet-like second member is laminated onto the area to be repaired by repeating the arrangement step and the scanning step multiple times.

[0085] The heating time required to fuse a sheet-like second member to the first member is shorter compared to the case where a member with the same thickness as the laminated second member is fused to the first member in one go. Therefore, it is possible to suppress excessive temperature increases in unintended areas due to heating for fusion.

[0086] Solution 13. The fusion method according to any one of 1 to 12 above, wherein the first member is a thermoplastic resin. When the first member is a thermoplastic resin, if the heating time for fusion with the second member is excessively long, the temperature of the first member is likely to rise beyond the acceptable range. Therefore, when dependent on Solution 12, the usefulness of Solution 12 is particularly great.

[0087] Solution 14. The fusion bonding method according to any one of 1 to 13 above, wherein the two members include a repair member embedded in the repair location and a sheet-like adhesive sandwiched between the repair member and the first member.

[0088] In the above method, by providing a sheet-like adhesive, the first member and the repair member can be firmly bonded together. Solution 15. The fusion bonding method according to any one of 1 to 14 above, wherein the first member is the fuselage of an aircraft.

[0089] In aircraft repair, there is often a high demand for adhesion with the second component. Therefore, the value of implementing the above-mentioned rehearsal heating process, etc., prior to actually fusing the second component to the first component is particularly significant.

Claims

1. A fusion bonding method for fusing a second member to a first member, comprising a placement step and a scanning step, wherein the placement step is a step of placing a susceptor via a heat transfer member on the side of the second member that is positioned according to the repair target location of the first member, on the side opposite to the repair target location, and the scanning step is a step of scanning a magnetic field generator along the surface of the susceptor from the side of the susceptor that is opposite to the heat transfer member, after the completion of the placement step, and the susceptor is a member that generates heat by the magnetic field of the magnetic field generator in the scanning step.

2. The fusion bonding method according to claim 1, comprising a scanning pattern setting step which is a step preceding the arrangement step, wherein the scanning pattern setting step is a step of setting the movement path of the magnetic field generator such that regions in which the temperature of the second member becomes above a predetermined temperature due to scanning by the magnetic field generator overlap.

3. The scanning pattern setting step comprises: a temporary placement step of placing the heat transfer member and the susceptor on the side of the second member opposite to the side facing the release sheet, with the first member and the second member facing each other with a release sheet and a temperature sensor in between; a rehearsal heating step of applying the magnetic field of the magnetic field generator to the susceptor from the side of the susceptor opposite to the side facing the heat transfer member; and a identification step of identifying a region in which the temperature of the second member becomes above a predetermined temperature when the magnetic field generator is placed, based on the temperature detected by the temperature sensor as an input variable, and setting the movement path of the magnetic field generator based on the result of identifying the region above the predetermined temperature, wherein the release sheet is a sheet for preventing the first member and the second member from being bonded together, and the fusion bonding method according to claim 2, further comprising a step of removing the release sheet and the temperature sensor from the repair target area prior to the placement step.

4. The fusion bonding method according to claim 3, wherein the scanning pattern setting step comprises: a raster setting step of setting a raster which is a rectangular region in which the temperature of the heat transfer member is above a predetermined temperature, based on the result of identifying the region in which the temperature is above a predetermined temperature; a raster arrangement step of arranging a plurality of rasters so as to cover the entire surface of the second member facing the first member; and a movement path setting step of setting a movement path of the magnetic field generator so as to pass through each of the plurality of rasters in which the region obtained by projecting the magnetic field generator onto the surface of the second member facing the first member passes.

5. The fusion bonding method according to claim 4, wherein the scanning step is a step of sequentially arranging the magnetic field generator such that the area projected onto the surface of the second member facing the first member corresponds to each of the plurality of rasters, and the scanning pattern setting step includes a heating time setting step of setting the time for arranging the magnetic field generator to correspond to one of the rasters based on the detected value of the temperature sensor.

6. The fusion bonding method according to claim 4, wherein the scanning step is a step of continuously moving the magnetic field generator, and the scanning pattern setting step includes a movement speed setting step of setting the movement speed of the magnetic field generator based on the value detected by the temperature sensor when the magnetic field generator is displaced along the movement path set by the movement path setting step.

7. The fusion bonding method according to claim 3, wherein the rehearsal heating step includes a step of selectively positioning the magnetic field generator in a part of a plurality of localized areas among the areas to be repaired.

8. The fusion bonding method according to claim 3, wherein the scanning pattern setting step includes a step of changing the distance between the susceptor and the magnetic field generator based on the result of identifying a region that is above a predetermined temperature, and the rehearsal heating step is performed according to the changed distance.

9. The fusion bonding method according to claim 3, wherein the scanning pattern setting step includes a step of changing the power consumption of the magnetic field generator based on the result of identifying a region that is above a predetermined temperature, and the rehearsal heating step is performed according to the changed power consumption.

10. The fusion method according to claim 4, wherein the raster placement step includes the step of arranging rasters in which at least one of two characteristics, shape and dimensions, differs from each other, depending on the area.

11. The fusion bonding method according to claim 1, wherein the arrangement step includes a step of covering the second member, the heat transfer member, and the susceptor with a bag film and depressurizing the area to be repaired, and the scanning step is performed with the susceptor covered by the bag film.

12. The fusion bonding method according to claim 1, wherein the second member is a sheet-like member, and the sheet-like second member is laminated onto the repair target area by repeating the arrangement step and the scanning step multiple times.

13. The fusion method according to claim 1, wherein the first member comprises a thermoplastic resin.

14. The fusion method according to claim 1, wherein the second member includes a repair member embedded in the area to be repaired and a sheet-like adhesive sandwiched between the repair member and the first member.

15. The fusion bonding method according to claim 1, wherein the first member is the fuselage of an aircraft.

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