CN105365232A - 用于聚合物复合材料修复的通过感应加热实现的机械联锁 - Google Patents

用于聚合物复合材料修复的通过感应加热实现的机械联锁 Download PDF

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CN105365232A
CN105365232A CN201510601690.0A CN201510601690A CN105365232A CN 105365232 A CN105365232 A CN 105365232A CN 201510601690 A CN201510601690 A CN 201510601690A CN 105365232 A CN105365232 A CN 105365232A
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polymer composites
interfacial structure
workpiece
regional area
polymeric composite
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CN201510601690.0A
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CN105365232B (zh
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X·黄
C-S·王
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GM Global Technology Operations LLC
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GM Global Technology Operations LLC
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C73/00—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
    • B29C73/04—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using preformed elements
    • B29C73/10—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using preformed elements using patches sealing on the surface of the article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/0272—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould using lost heating elements, i.e. heating means incorporated and remaining in the formed article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C37/0078—Measures or configurations for obtaining anchoring effects in the contact areas between layers
    • B29C37/0082—Mechanical anchoring
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/04—Dielectric heating, e.g. high-frequency welding, i.e. radio frequency welding of plastic materials having dielectric properties, e.g. PVC
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1477—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation making use of an absorber or impact modifier
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/36—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction
    • B29C65/3604—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the type of elements heated by induction which remain in the joint
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/36—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction
    • B29C65/3604—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the type of elements heated by induction which remain in the joint
    • B29C65/3644—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the type of elements heated by induction which remain in the joint being a ribbon, band or strip
    • B29C65/3648—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the type of elements heated by induction which remain in the joint being a ribbon, band or strip said strip being perforated
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/36—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction
    • B29C65/3672—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the composition of the elements heated by induction which remain in the joint
    • B29C65/3676—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the composition of the elements heated by induction which remain in the joint being metallic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/36—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction
    • B29C65/3672—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the composition of the elements heated by induction which remain in the joint
    • B29C65/3684—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the composition of the elements heated by induction which remain in the joint being non-metallic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/481—Non-reactive adhesives, e.g. physically hardening adhesives
    • B29C65/4815—Hot melt adhesives, e.g. thermoplastic adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
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    • B29C65/5014—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like characterised by the structure of said adhesive tape, threads or the like being fibre-reinforced
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5057—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like positioned between the surfaces to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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    • B29C65/562—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits using extra joining elements, i.e. which are not integral with the parts to be joined
    • B29C65/564—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits using extra joining elements, i.e. which are not integral with the parts to be joined hidden in the joint, e.g. dowels or Z-pins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
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    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
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    • B29C66/5326—Joining single elements to the wall of tubular articles, hollow articles or bars said single elements being substantially flat
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
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    • B29C2035/0811—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using induction
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本发明公开了用于聚合物复合材料修复的通过感应加热实现的机械联锁。一种修复聚合物复合材料工件的方法。该方法包括识别聚合物复合材料工件具有缺陷的局部区域。多个三维界面结构与该局部区域的至少一部分相邻地对齐。该方法包括将聚合物复合材料补片施加至局部区域，从而使得界面结构置于聚合物复合材料工件和聚合物复合材料补片之间。可以引入交变电磁场来选择性地引发界面结构的局部加热。该局部加热软化聚合物复合材料工件和聚合物复合材料补片与界面结构相邻的区域，致使界面结构渗透进入相应的聚合物复合材料工件和聚合物复合材料补片中一距离。

Description

用于聚合物复合材料修复的通过感应加热实现的机械联锁
相关申请的交叉引用
本申请要求于2014年8月6日提交的美国临时申请No.62/033,721的优先权。上面所提及的该申请的整个公开内容通过参考结合到本文中。
技术领域
本公开内容涉及使用粘合促进结构、例如金属界面结构，来修复热塑性和聚合物复合材料零件的方法。
背景技术
在本文提供的背景技术描述用于大概地介绍本公开内容的背景的目的。当前列举的发明人的工作(就在该背景技术部分中所描述的程度而言)，以及本说明书的在申请时间时不会以其它方式限制为现有技术的各方面，既不会明示地也不会暗含地被承认是反对当前技术的现有技术。
机动车辆的主体必须管理在正常车辆使用期间和在例如碰撞的非常状况下所施加的负载。车辆主体越来越多地使用例如聚合物或聚合物基复合材料的材料构造，这些材料相比用在老的设计中的低强度、低碳钢提供更高的强度-重量比。特别地，聚合物复合材料已被广泛用在汽车中，并且它们的应用预期在未来持续增长，设法进一步降低车辆质量。因此，开发用于压紧受损复合材料结构的有效修复方法就将一直是重要的。
由聚合物复合材料制成的例如面板和保险杠的汽车零件，优选设计成抵抗低速碰撞造成的损伤，小的石子或物体产生的冲击，以及斜靠人员的重量。然而，在更高的能量冲击下，在面板和保险杠中能够形成各种擦伤、凹痕、裂纹以及其它的缺陷或损伤。假定特定的零件形状、尺寸或组装技术，更换部件有时比修复它的成本更低。在绝大多数其它的情况中，修复受损部件将是所期望的。因此，仍存在用于聚合物复合材料的改进的修复技术的需求。
发明内容
这部分提供了本公开内容的总体概述，并不是其完整范围或其所有特征的全面公开。
在各种方面中，当前教导提供用于修复聚合物复合材料工件的方法。该方法可以包括识别聚合物复合材料工件的具有至少一个缺陷的局部区域。多个三维界面结构可以与该局部区域的一部分相邻地对齐。该方法可以包括将聚合物复合材料补片施加至该局部区域，从而使得该界面结构置于聚合物复合材料工件和聚合物复合材料补片之间。交变电磁场随后可被引入与界面结构相邻，以选择性地引发界面结构的局部加热。该局部加热软化聚合物复合材料工件和聚合物复合材料补片与界面结构相邻的区域，致使每个界面结构渗透进入相应的聚合物复合材料工件和聚合物复合材料补片中一距离。
在其它方面，当前教导提供修复两个聚合物复合材料部件之间的增强接合部的方法。该方法可以包括提供具有第一接合部端部的第一聚合物复合材料部件和具有第二接合部端部的第二聚合物复合材料部件。第一和第二接合部端部可以对齐，并且该方法可以包括在对齐的接合部端部之间布置多个三维金属界面结构。交变电磁场可被引入与界面结构相邻，以选择性地引发该界面结构的局部加热，在与该界面结构相邻的第一和第二聚合物部件中形成软化区域。该方法可以包括将每个界面结构的至少一部分嵌入到第一和第二聚合物复合材料部件的相应软化区域中以形成增强接合部。
还是在其它方面，当前教导提供提高车辆主体结构中聚合物复合材料接合部的强度的方法。该方法可以包括对齐形成车辆主体结构的第一和第二聚合物复合材料面板。具有多个三维金属界面结构的基底可被提供在第一和第二聚合物复合材料面板之间。该方法可以包括通过使用电磁感应技术选择性地加热界面结构，并形成第一和第二复合材料面板的与该界面结构相邻的软化区域。界面结构的至少一部分随后会被嵌入至第一和第二聚合物复合材料面板的相应软化区域中。
技术方案1.一种修复聚合物复合材料工件的方法，所述方法包括：
识别所述聚合物复合材料工件的具有缺陷的局部区域；
将多个三维界面结构与所述局部区域的至少一部分相邻地对齐；
将聚合物复合材料补片施加至所述局部区域，从而使得所述界面结构置于所述聚合物复合材料工件和所述聚合物复合材料补片之间；
引入交变电磁场以选择性地引发所述界面结构的局部加热；以及
软化所述聚合物复合材料工件和聚合物复合材料补片的与所述界面结构相邻的区域，致使所述界面结构渗透进入相应的聚合物复合材料工件和所述聚合物复合材料补片中一距离。
技术方案2.根据技术方案1所述的方法，其中，所述界面结构包括导电金属或者导电炭材料。
技术方案3.根据技术方案2所述的方法，其中，所述界面结构包括选自由Fe3O4、FeCo、碳纳米管及其混合物构成的组的磁性材料。
技术方案4.根据技术方案2所述的方法，其中，所述界面结构包括至少两个腿延伸部。
技术方案5.根据技术方案1所述的方法，其中，所述多个界面结构在基底上对齐并被预组装。
技术方案6.根据技术方案5所述的方法，其中，所述基底包括柔性聚合物膜。
技术方案7.根据技术方案5所述的方法，其中，所述基底包括金属连接板、金属网、预浸渍材料、树脂网、树脂膜和纤维纱材料中的至少一种。
技术方案8.根据技术方案1所述的方法，包括提供多孔金属板部件，其限定从所述打孔金属板部件的相对主表面向外延伸的多个界面结构，其中，对齐多个三维界面结构的步骤包括将打孔金属板部件与所述局部区域的至少一部分对齐。
技术方案9.根据技术方案1所述的方法，进一步包括将树脂施加至所述局部区域并在所述树脂中使所述界面结构对齐。
技术方案10.根据技术方案1所述的方法，进一步包括在引入电磁辐射步骤期间将压力施加在所述聚合物复合材料补片和所述聚合物复合材料工件之间。
技术方案11.一种在两个聚合物复合材料部件之间制备增强接合部的方法，所述方法包括：
提供具有第一接合部端部的第一聚合物复合材料部件和具有第二接合部端部的第二聚合物复合材料部件；
对齐所述第一和第二接合部端部，并在对齐的接合部端部之间布置多个三维金属界面结构；
引入与所述界面结构相邻的电磁场，以选择性地引发所述界面结构的局部加热，在与所述界面结构相邻的第一和第二聚合物部件中形成软化区域；以及
将每个界面结构的一部分嵌入所述第一和第二聚合物复合材料部件的相应软化区域中以形成增强接合部。
技术方案12.根据技术方案11所述的方法，其中，所述金属界面结构包括相互之间大致等距的多个腿延伸部。
技术方案13.根据技术方案12所述的方法，其中，所述金属界面结构具有四脚形状。
技术方案14.根据技术方案11所述的方法，其中，所述多个金属界面结构在基底上对齐并被预组装。
技术方案15.根据技术方案14所述的方法，其中，所述基底包括柔性聚合物膜、金属连接板、金属网、预浸渍材料、树脂网、树脂膜和纤维纱材料中的至少一种。
技术方案16.根据技术方案11所述的方法，进一步包括在布置所述多个三维金属界面结构之前，将树脂施加在对齐的接合部端部之间。
技术方案17.根据技术方案11所述的方法，其中，将每个界面结构的一部分嵌入所述第一和第二聚合物复合材料部件的相应软化区域中的步骤包括在对齐的接合部端部之间施加压缩力。
技术方案18.根据技术方案11所述的方法，包括提供至少一个打孔金属板部件，其限定从所述打孔金属板部件的相对主表面向外延伸的多个金属界面结构，其中，对齐多个三维界面结构的步骤包括在第一和第二接合部端部之间对齐多孔金属板部件。
技术方案19.根据技术方案11所述的方法，其中，所述界面结构包含凹入形状。
技术方案20.一种提高车辆主体结构中聚合物复合材料接合部的强度的方法，所述方法包括：
对齐形成所述车辆主体结构的第一和第二聚合物复合材料面板；
在第一和第二聚合物复合材料面板之间，提供包括多个三维导电界面结构的基底；
通过电磁感应选择性地加热导电界面结构，在与所述导电界面结构相邻的所述第一和第二聚合物复合材料面板中形成软化区域；以及
将每个导电界面结构的一部分嵌入所述第一和第二聚合物复合材料面板的相应软化区域中。
其它适用性领域和各种方法从本文所提供的描述将变得显而易见。在该发明内容中的描述和具体示例意图仅用于说明目的，并没有意图限制本公开内容的范围。
附图说明
当前教导从详细的描述和附图将被更加全面地理解，其中：
图1A图示具有表面缺陷的聚合物复合材料工件；
图1B图示具有延伸穿过工件的缺陷的聚合物复合材料工件；
图1C图示图1B的聚合物复合材料工件，所述缺陷使用本公开内容的打补丁技术而修复；
图2图示使用本公开内容的技术利用增强接合部机械联锁的两个聚合物复合材料部件；
图3图示示例性的感应加热器，其置于两个聚合物复合材料面板的接合部端部之间的界面结构相邻；
图4图示包括至少部分地嵌入聚合物复合材料部件内的多个界面结构的增强接合部的局部区域的放大部分；
图5图示示例性的多孔金属板连接器，其限定由其向外延伸的多个界面结构；
图6图示在基底上对齐和预组装的多个界面结构；以及
图7A-7I图示具有不同的示例性几何构型的多个界面结构。
应当注意的是，在这里阐述的附图意图举例说明当前技术的那些当中的材料、方法和装置的总体特征，用于描述特定方面的目的。这些图可能没有精确地反映任何给定方面的特征，并且，并不必意图限定或限制该技术范围内的特定实施方式。此外，特定的方面可以结合来自附图组合的特征。
具体实施方式
下文的描述在本质上仅为说明性的，并且决没有意图限制本公开内容、其应用或使用。如本文所使用的，短语“A、B和C中的至少一个”应当被解释为是指逻辑上的(A或B或C)，使用非排他性的逻辑“或”。应当理解的是，方法中的步骤可以以不同的顺序执行，而不改变本公开内容的原理。所公开的范围包括整个范围内的所有范围和子范围的公开。
本文使用的标题(例如“背景技术”和“发明内容”)和子标题仅意图用于本公开内容内主题的总体结构，并没有意图限制该技术或其任何方面的公开。具有所指出的技术特征的多个实施方式的叙述没有意图排除具有其它技术特征的其它实施方式，或者结合所指出的技术特征的不同组合的其它实施方式。
如本文所使用的，词语“包括”及其变形意图是非限制性的，从而使得在列举中所描述的项目并不会排除其它相似的项目，其在该技术的材料、组成、装置和方法中也可以是有用的。类似地，术语“能够”和“可以”及它们的变形意图是非限制性的，从而使得实施方式能够或可以包含特定的元素或特征的叙述并不会排除不包含这些元素或特征的当前技术的其它实施方式。
为了容易描述，在本文可以使用空间上相对的术语，例如“内部”、“外部”、“在……之下”、“在……下方”、“下部”、“在……上方”、“上部”、“在……上”以及它们的变形，以描述一个元素或特征与另一个元素(多个)或特征(多个)的关系。空间上相对的术语涵盖装置在使用或操作中的不同取向。如本文所使用的，当涂层、层或材料被“施加到另一个基底或物体上”、“施加面军另一个基底或物体之上”、“形成在另一个基底或物体上”、“沉积在另一个基底或物体上”等的时候，增加的涂层、层或材料可以被施加、形成、沉积在整个基底或物体上，或者在基底或物体的至少一部分上。
本公开内容的广泛教导能够以多种的形式来实施。因此，虽然这个公开内容包括特定示例，但是本公开的真正范围并不应当被如此限制，因为其他的改进在本领域技术人员对说明书及随后的权利要求进行研究的基础上将会是显而易见的。
用于汽车的聚合物复合材料零件(例如部件和工件)在正常使用期间或者作为与外来物体碰撞的结果会被损伤。该损伤在本质上为非结构性的(擦伤、凹痕、表面裂纹、界面裂纹、子界面裂纹、脱粘、分层等)或者结构性的(较深地或者完全贯穿所述部件的裂纹)。在各种方面中，期望的是在聚合物复合材料部件或其部分之间具有增强接合部，其可以有能力承受工件显著的弯曲或变形。取决于损伤或缺陷的类型，粘合剂、例如树脂有时能够被用于修复部件或工件的至少一部分，例如通过填充在所述损伤或缺陷中或者覆盖所述损伤或缺陷。粘合剂或粘结剂能够被用于填充缺陷，以将修复补片附接在复合材料基底上，或者当执行替换技术时，将新的面板粘合到结构上。在各种方面中，单独的粘合剂或粘结剂并不会提供足够的强度，特别是在更高的温度环境中。
当前公开内容总地涉及利用可被称为机械粘合促进结构或粘结推动结构的帮助，修复聚合物复合材料工件、主体面板和其它零件的方法。如本文所使用的，粘合促进结构或粘结推动结构可以包括能够在两个聚合物复合材料部件之间增强接合或粘结的三维界面结构。在一个示例中，界面结构与聚合物复合材料部件物理联锁。如将在下文描述的，在各种方面中，当前技术的方法提供被放置在两个聚合物复合材料面板之间的金属或其它导电界面结构的感应加热。更特别地，当前技术涉及使用感应加热，以便提供电磁场，例如交变电磁场，其致使界面结构的局部加热。该局部加热软化和/或熔融聚合物复合材料与界面结构相邻的部分，同时最小化或者无需加热聚合物复合材料的其它区域。一旦软化或熔融，每个界面结构的一部分就会透进聚合物复合材料面板并变成永久地嵌入在相邻的聚合物复合材料面板之间，形成增强机械接合部。
如在现有技术中已知的，当使用例如感应加热的技术引入或施加交变电磁场时，就会观察到金属或其它导电材料/颗粒作为由于电子或分子运动和磁化而发生的损耗的结果而加热。导电材料由于感应涡流而产生热量。导电材料的响应能够均匀地加热特定目标聚合物复合材料区域，同时最小化相邻区域的加热或者不存在对其的辅助加热。这能够显著地简化和/或最小化已经普遍用于各种聚合物复合材料修复的加热单元的需求和设计。
图1A和1B每一个图示具有缺陷的聚合物复合材料工件10，其可以使用本公开内容的技术来修复。图1A图示具有表面缺陷14a的工件10，例如擦伤、凹痕或表面缺陷。图1B图示延伸经过工件10的孔、结构性裂纹或结构性缺陷14b。各种方法可以包括检测和识别聚合物复合材料工件10具有一个或多个缺陷的局部区域12(在图1C中示出)。在大多数情况中，缺陷14a、14b能够用裸眼或者非破坏性评价技术来发现，例如振动红外热成像技术(vibrothermography)、脉冲热成像技术、相控阵超声技术等。
缺陷14a、14b例如可以具有从约0.1mm至约4mm或更大的深度，其取决于工件10的厚度和最终使用。如在图1A中所示的，缺陷14a可以包括表面凹痕或裂纹，其并不会实质延伸穿过整个的工件10。图1B和1C的特定的聚合物复合材料工件10可以包括在本文称为局部区域12的部分，其在缺陷14b附近并与工件10的前向和后向主表面的每一个相邻。如在图1C中所示的，缺陷14b可被部分地或完全地填充由附图标记15指代的合适的粘合剂、粘结剂或树脂。
本公开内容的方法提供使多个三维机械联锁或界面结构30与局部区域12的至少一部分相邻地对齐。一种示例性的对齐在图4中能够看到，其将在下文被讨论。在各种方面中，界面结构30可以具有这样的尺寸和形状，考虑到它们将被用于帮助连接和增强两个复合材料零件的事实，其最长尺寸的范围约100μm至约5mm。
界面结构30可以是导电的，并且可以包括导电金属或导电炭材料。在各种方面中，界面结构30可以包括不锈钢。界面结构30可以是铁磁体或者包括铁磁材料。设想的是，任何种类的铁磁材料都可被使用，包括但不限于：金属，例如铁、镍或钴；合金和化合物，例如基于钕、铁、钐和钴的那些，以及磁钢；和氧化物，包括氧化铁和铁氧体。在可能需要最小化任何剩磁的地方，可以应用软磁材料，例如基本上不掺杂的铁、铁氧化物(赤铁矿和磁铁矿)，以及软磁铁氧体，例如锰锌铁氧体(MnaZn(1-a)Fe2O4)或镍锌铁氧体(NiaZn(1-a)Fe2O4)。软磁材料的颗粒还可相互组合使用或者与其它材料组合使用。在各种方面中，界面结构30可以包括表现出磁性行为的纳米颗粒。在当前优选方面中，磁性颗粒或纳米颗粒可以包括Fe3O4、FeCo、碳纳米管及其混合物。如本文所使用的，术语纳米颗粒可以包括平均颗粒尺寸为约250nm或更小的颗粒，和平均颗粒尺寸大于约250nm至小于约1μm的颗粒，其在本领域中有时被称为“亚微米级”颗粒。磁性颗粒可以是单分散的，在这里所有颗粒具有极小变化的相同尺寸，或者是多分散的，在这里颗粒具有一定范围的尺寸并被平均化。
在多个三维界面结构30被策略性地施加和/或排列之后，聚合物复合材料补片16就能够被放置在聚合物复合材料工件10的至少一部分之上。在这点上，界面结构30将被置于聚合物复合材料补片16和聚合物复合材料工件10之间。在某些方面，取决于缺陷的类型，可能期望的是将聚合物复合材料补片16放置在聚合物复合材料工件10的两个相对的主表面上，如在图1C中所示的。
本公开内容的方法提供邻近包括界面结构30的局部区域12引入电磁场，例如交变电磁场，以选择性地引发界面结构30的局部加热。加热被施加意图软化和/或熔融邻近界面结构30的聚合物复合材料补片16和聚合物复合材料工件10的区域，包括在补片16和工件10之间的任意可选的树脂15。如在图4的放大部分中最佳地示出的，在引入交变电磁场的步骤期间，在部件之间加热和任选的施加外部压力能够和/或致使界面结构30渗透进入相应聚合物复合材料补片16和聚合物复合材料工件10内一距离，形成机械联锁的且增强的接合部。在各个方面，外部压力可以是从约0.01kPa至约10MPa。
通过示例的方式，当导电或铁磁材料被暴露至以千赫至兆赫频率范围运行的交变电磁场的时候，这些材料的感应加热能够发生。如在本领域中已知的，射频(RF)为在从约3kHz至约300MHz的范围内的振荡速率，其对应于无线电波和携带无线电信号的交变电流的频率。通过示例的方式，当使用特定的铁磁颗粒的时候，可以引入具有从约50kHz至约450kHz、从约250kHz至约300kHz、或者约280kHz的频率的射频电磁场。在其它示例中，当将特定的纳米管颗粒嵌入界面结构30中时，例如随后可被磁化的碳纳米管，就可引入具有频率从约1MHz至约20MHz、从约5MHz至约15MHz、或者约13MHz的射频电磁场。磁性颗粒感应热量所必需的特定的射频或射频范围可能依赖于材料的成分、颗粒尺寸、深度等而变化。例如参见He，Z.，Satarkar，N.，Xie，T.，Cheng，Y.-T.和Hilt，J.Z.(2011)，RemoteControlledMultishapepolymerNanocompositeswithSelectiveRadiofrequencyActuations.Adv.Mater.，23：3192-3196，其相关部分通过引用被结合到本文中。在各种方面，电磁场可被施加至局部区域和/或树脂的时间段从约1分钟至约45分钟，从约5分钟至约35分钟，或者从约5分钟至约25分钟的时候。应当理解的是，该时间可依赖于选择使用的树脂成分和特定的磁性颗粒而变化。在某些方面中，电磁场可被施加的时间段足以达到一定温度。例如，电磁场可被施加，直至局部加热将局部区域的温度提高至从约60℃至约250℃，从约120℃至约240℃，或者从约150℃至约200℃的范围。
在某些方面中，该方法可以包括将一种或多种树脂材料施加至局部区域12，并任选地对齐树脂中的界面结构30。应当理解的是，树脂成分和界面结构材料种类选择应当考虑工件成分。例如，在聚合物复合材料工件包括热塑性材料的情况下，有利的是选择的树脂成分和界面结构材料将被加热至恰当的温度，使得该聚合物复合材料工件围绕缺陷的区域达到适于软化或熔融的温度，以便界面结构恰当地透进工件中。在各种方面中，树脂材料能够是与工件10或修复面板16的复合材料基体相同的材料或者具有与其相同的成分。
在使用树脂的某些方面中，可能还想要制备一种树脂(多种)，优选地热塑性树脂，具有诸如功能性填料或其它额外的制剂或添加剂的任选材料。如在本文提及的，“功能性填料”为可操作以改善合成物的一种或多种性能的材料。这样的性能包括涉及合成物的配方、功能或实用的一种或多种化学或物理性能，诸如物理特性、性能特性、特定的最终使用设备的适用性、应用、或环境、便于制备该合成物以及在其制作后便于使用或处理该合成物。例如，可以包括在树脂配方中本领域技术人员已知的稳定剂、润湿剂、流变调节剂、有机和无机填料、分散剂、粘合剂、助粘剂、固化促进剂、增粘剂、蜡、脱氧剂、其混合物等，并被设想在当前技术的范围内。虽然某些添加剂在现有技术中可能已知是存在的，但是与当前技术中一起使用的量应当被控制以避免在工件上产生副作用。
图2图示使用本公开内容的技术与增强接合部机械联锁的两个聚合物复合材料部件。通过示例的方式，如果在工件、面板或其一部分上的损伤是不可修复的，那么损伤的面板或部分就可能需要被替换。新替换的面板将需要与其余的主体结构具有良好的粘结，其能够使用三维界面结构30来实现。如图所示，第一聚合物复合材料部件18提供有第一接合部端部20，并且第二聚合物部件22提供有第二接合部端部24。第一和第二接合部端部20、24在将被转换为增强接合部的区域26对齐并重叠。参考图3和4，多个界面结构30可以在第一和第二接合部端部20、24之间对齐，并且感应加热单元28可被提供以邻近界面结构30引入电磁场，诸如交变电磁场。类似于关于图1C讨论的修复技术，电磁场选择性地引发界面结构30的局部加热，在第一和第二聚合物部件18、22的接合部端部20、24中产生软化的或熔融的区域。通过在对齐的接合部端部20、24之间任选地施加外部压力或压缩力，每个界面结构30的一部分随后就会被嵌入第一和第二聚合物部件18、22的相应软化区域中以形成增强接合部26。
如在图4中所示的，界面结构30可以包括或形成芯部区域32，其具有自其延伸的多个腿延伸部34。腿延伸部34相互之间通常可以被等距间隔，某些腿延伸部34嵌入第一聚合物复合材料部件18内，并且其它腿延伸部34嵌入第二聚合物复合材料部件22内。在一个非限制性的示例中，界面结构30可以是具有基本上呈四脚形状的导电金属。在其它方面中，界面结构30可以具有轮廓，该轮廓的横截面区域限定凹入形状；或者可以具有至少一个延伸部，该延伸部具有凹入形状，用于锁入聚合物复合材料部件中的目的。如在本文所使用的，术语凹入形状通常是指非凸面的闭合形状多边形，例如具有至少一个大于180度的内角。
参见图5，除了使用多个单独的界面结构之外或者作为使用多个单独的界面结构的替代，当前技术还提供了整体式元件的使用，诸如多孔金属板部件40，其限定自其向外延伸的多个界面结构42。在各种方面中，界面结构42可以与所述板是一体的并由所述板冲压或雕刻出，在从两个主表面的相反方向上延伸(仅示出一个主表面)。
仍在其它方面中，图6图示在基底44上对齐并被预组装的多个界面结构46。通过示例的方式，基底44可以是柔性聚合物膜、金属连接板、金属网、树脂网、树脂膜、或纤维纱材料的形式，界面部件46附接至其。在某些方面中，基底44能够包括典型地被称为热塑性膜或复合材料增强件的东西，任选地包括可以使用树脂或类似化合物预浸渍的碳或其它增强纤维。通过示例的方式，基底44可以是膜形式的热塑性树脂。当经受感应加热时，树脂基底44就能够表现为热熔粘合剂，进一步增强复合材料之间的接合部。基底44的厚度依赖于界面结构30的尺寸和所期望的柔性而变化。
图7A-7I图示具有不同几何构型的多个界面结构。通常地，每个界面结构均具有主体部分48以及两个或更多个相对的端部部分50、52，其可以被提供具有对形成增强接合部连接有用的多个不同的形状或曲率。界面结构优选为整体式的部件，但是其可以由分开的零件接合在一起来形成。
应当理解的是，当前技术既不依赖于也不限制于任何特定类型的材料或制作方法，并且这些材料和方法可以根据需要、基于想要的结果而变化。
实施方式的上述描述被提供用于说明和描述的目的。没有意图是穷尽的，或者限制本公开内容。特定实施方式的单独的元件或特征通常并不限于该特定实施方式，而是在适用的情况下，是可互换的并且能够用在所选择的实施方式中，即使是没有未具体地示出或描述的实施方式。该实施方式还可以以多种方式变化。这样的变形并不会被认为背离本公开内容，并且所有的这样的改进均意图被包括在本公开内容的范围内。

Claims (10)

1.一种修复聚合物复合材料工件的方法，所述方法包括：
识别所述聚合物复合材料工件的具有缺陷的局部区域；
将多个三维界面结构与所述局部区域的至少一部分相邻地对齐；
将聚合物复合材料补片施加至所述局部区域，从而使得所述界面结构置于所述聚合物复合材料工件和所述聚合物复合材料补片之间；
引入交变电磁场以选择性地引发所述界面结构的局部加热；以及
软化所述聚合物复合材料工件和聚合物复合材料补片的与所述界面结构相邻的区域，致使所述界面结构渗透进入相应的聚合物复合材料工件和所述聚合物复合材料补片中一距离。
2.根据权利要求1所述的方法，其中，所述界面结构包括导电金属或者导电炭材料。
3.根据权利要求2所述的方法，其中，所述界面结构包括选自由Fe3O4、FeCo、碳纳米管及其混合物构成的组的磁性材料。
4.根据权利要求2所述的方法，其中，所述界面结构包括至少两个腿延伸部。
5.根据权利要求1所述的方法，其中，所述多个界面结构在基底上对齐并被预组装。
6.根据权利要求5所述的方法，其中，所述基底包括柔性聚合物膜。
7.根据权利要求5所述的方法，其中，所述基底包括金属连接板、金属网、预浸渍材料、树脂网、树脂膜和纤维纱材料中的至少一种。
8.根据权利要求1所述的方法，包括提供多孔金属板部件，其限定从所述多孔金属板部件的相对主表面向外延伸的多个界面结构，其中，对齐多个三维界面结构的步骤包括将多孔金属板部件与所述局部区域的至少一部分对齐。
9.根据权利要求1所述的方法，进一步包括将树脂施加至所述局部区域并在所述树脂中使所述界面结构对齐。
10.根据权利要求1所述的方法，进一步包括在引入电磁辐射步骤期间将压力施加在所述聚合物复合材料补片和所述聚合物复合材料工件之间。
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CN113165289A (zh) * 2018-12-13 2021-07-23 赛峰飞机发动机公司 有机基质复合材料零件的修复
CN109910318A (zh) * 2019-03-20 2019-06-21 上海交通大学 一种使用界面原位复合相增强金属/高分子连接强度的方法
CN109910318B (zh) * 2019-03-20 2021-06-29 上海交通大学 一种使用界面原位复合相增强金属/高分子连接强度的方法
CN113997574A (zh) * 2021-11-01 2022-02-01 南京工程学院 一种纤维增强热塑性树脂复合薄板超声波焊接方法

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