GB2504206A - Repair of carbon fibre composite - Google Patents

Repair of carbon fibre composite Download PDF

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Publication number
GB2504206A
GB2504206A GB1310094.6A GB201310094A GB2504206A GB 2504206 A GB2504206 A GB 2504206A GB 201310094 A GB201310094 A GB 201310094A GB 2504206 A GB2504206 A GB 2504206A
Authority
GB
United Kingdom
Prior art keywords
hole
carbon fibre
composite
repaired
repair
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB1310094.6A
Other versions
GB2504206A8 (en
GB201310094D0 (en
GB2504206B (en
Inventor
Robert Stuart Broadbent
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
RSB DESIGN Ltd
Original Assignee
RSB DESIGN Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by RSB DESIGN Ltd filed Critical RSB DESIGN Ltd
Publication of GB201310094D0 publication Critical patent/GB201310094D0/en
Publication of GB2504206A publication Critical patent/GB2504206A/en
Publication of GB2504206A8 publication Critical patent/GB2504206A8/en
Application granted granted Critical
Publication of GB2504206B publication Critical patent/GB2504206B/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • 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
    • B29C73/02—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 liquid or paste-like material
    • 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
    • B29C73/06—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 plugs sealing in the hole
    • 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
    • B29C73/06—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 plugs sealing in the hole
    • B29C73/08—Apparatus therefor, e.g. for inserting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/14—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a face layer formed of separate pieces of material which are juxtaposed side-by-side
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • 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
    • B29C73/24—Apparatus or accessories not otherwise provided for
    • B29C73/26—Apparatus or accessories not otherwise provided for for mechanical pretreatment
    • B29C2073/268—Apparatus or accessories not otherwise provided for for mechanical pretreatment for drilling holes in the area to be repaired
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/20—Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
    • B32B2307/212—Electromagnetic interference shielding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2311/00—Metals, their alloys or their compounds
    • B32B2311/24—Aluminium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/18—Aircraft

Abstract

Carbon fibre composites C having damaged surface structure, pre-drilled holes or plug-fill holes drilled in an incorrect position can repaired by inserting another carbon fibre composite P into the hole within the composite being repaired. Torque is applied to the inserted composite P, causing it to swell and self lock into the hole. Any protruding part of the insert may then removed (shaved flush), if necessary. The disclosed insert P is a screwed rod or stud that engages with a treaded hole. The repaired carbon fibre composite may be used in a multilayer product, also including an aluminium mating part M and an intermediate sacrificial scrim Q. The method may also be used to provide lightening strike protection.

Description

RSBDESIGNLTD
DESCRIPTION OF PATENT
A method for repairing damage or ncorrectIy tositioned holes drified or damaged hoes in Carbon bre Composte Structure (See Patent Drawings I and 2) for iUustrated details and a descripUon in how this Repair Works and how to cany out this Repair Work (as a typic& example) GRAPHIC #2 KEY GB1212987.O SHEET 3 OF 5 EXAMPLE REPAIR SCENARIO #1 #1 -DIA. 3,2 MM DRILL STRIKE 6,0 MM DEEP (A) ADJACENT TO A PRODUCTION STANDARD DIA.10,0 MM" HOLE (B) IN CARBON FIBER CARBON FIBER COMPOSITE PANEL 30MM THICK (C) #2 -TAP HOLE (B) M10 (F) IDEALLY USING A REVERSABLE PRE-SET TYPE
SHROUDED TAPPING TOOL TO ENSURE HOLE IS TAPPED SQUARE AND
TRUE TO THE SURFACE AND PREVENT A VOLCANO EFFECT ON ENTRY.
#3 -INSERT PROPIETARY M10 CARBON FIBER PEEK HEXAGON DRIVE SCREW (G) INTO HOLE AT PRE-DETERMINED TORQUE WHICH WILL
COMPRESS THE HOLE AND ALLOW THE UNIQUE PROPERTIES OF THE
CARBON FIBER PEEK SCREW TO SWELL AND SELF-LOCK INTO THE
THREADED HOLE (F) NOTE: FOR COMPLETE INTEGRITY -OPTION TO WET ASSEMBLE THE CARBON FIBER PEEK SCREW (G) USING SUITABLE LOCTITE COMPOUND.
#4 -CAREFULY SHAVE FLUSH BOTH SIDES TO PART SURFACE (H) TAKING CARE NOT TO MARK SURFACE.
#5 -POSITION AND DRILL NEW HOLE (D) DIA. 12,0 MM ON NEW HOLE CENTER OFF-SET (J) TO CLEAN OUT DRILL STRIKE DAMAGE OR DRILL SMALLEST STANDARD DIAMETER POSSIBLE.
ACCEPTABLE TO LEAVE REMAINS OF CARBON FIBER PEEK SCREW
BONDED IN HOLE SHOWN (L) AND REMAINS OF DRILL STRIKE (A) NOTE: IT IS NOT NECESSARY TO REMOVE ALL DRILL STRIKE DAMAGE (A) AT THIS
STAGE UNLESS A PAN HEAD OR HEXAGON HEAD FASTENER IS TO BE
FITTED AND OFF-SET (J) WOULD NEED TO BE INCREASED.
IN THIS EXAMPLE THE HOLE (D) WILL HAVE A 100 DEG. COUNTERSINK
FASTENER FITTED WHICH WILL TAKE OUT ANY REMAINING DRILL STRIKE
AS SHOWN IN FIG. #6(E) #6 -100 DEGREE COUNTERSINK (K) AND COMPLETED REPAIRED HOLE IS
READY FOR INSERTING DRAWING STANDARD FASTENER SYSTEM TO
ALL OTHER STANDARD PRODUCTION DRAWING REQUIREMENTS, NOTES & CODINGS AS APPLICABLE.
REPAIR IS COMPLETE.
NOTE: ALL EVIDENCE OF DRILL STRIKE HAS BEEN COMPLETELY REMOVED.
GRAPHIC #2 KEY GB1212987.O SHEET 4 OF 5 EXAMPLE REPAIR SCENARIO #1 (continued) (E) SHOWS WHERE IT WOULD BE IN RELATION TO REWORKED HOLE (FOR INFORMATION ONLY) PORTION OF CARBON FIBER PEEK SCREW (L) WILL REMAIN INTACT IN THE
HOLE
NOTE: REPAIR IS ALSO SUITABLE FOR PLUGING REDUNDANT OR DAMAGED
PLAIN AND COUNTERSINK HOLES AND REPAIRING DAMAGE TO A
SURFACE.
ALSO ALLOWS LIGHTENING STRIKE PROTECTION TO BE ADDED ON
COMPLETION IF REQUIRED IF ADDITIONAL METALLIC PARTICLES HAVE NOT
BEEN ADDED TO THE PEEK! CARBON FIBER "MIX" FOR THE CARBON PEEK SC REWS.
EXAMPLE REPAIR SCENARIO #2 GRAPHIC #3 KEY
REFER SECTION X-X
IF REVERSE SIDE OF HOLE IS NOT ACCESSIBLE (M) (IE.PART IS IN AN ASSEMBLY) AND CANNOT BE SPLIT IT IS ACCEPTABLE TO REPAIR BY PLUG TAPPING CARBON FIBER PART ONLY (C) AND INSERTING A FLAT BOTTOM CARBON SCREW INTO TAPPED HOLE (P) IN REPAIR PART THUS NEGATING NEED TO FLUSH FAR SIDE OR STRIP DOWN.
ADD SACRIFICIAL PLATE! SHIM (Q) BETWEEN ASSEMBLY TO PROTECT MATING PART NOT REQUIRING REPAIR (M) GRAPHIC#1 KEY
HOW IT WORKS
GB1212987.O SHEET I OF S #1 -DISCREPANT HOLE IS TAPPED (J) M6/ M8/ M10/ M12/ UP TO >M5O IN MATERIAL THICKNESSES (K) FROM 4MM TO >80MM THICK DETAIL (A) IS AN AUTO REVERSE TAPPING TOOL WITH OPTIONAL HOLE SUPPORT AND VACUUM ATTACHMENT.
MANUAL TAPPING IS ALSO POSSIBLE.
#2-CARBON FIBER HEXAGON HEAD SCREW (D) IS DRY OR WET ASSEMBLED WITH RESIN OR APPROVED LOCTITE (OPTIONAL) WITH WASHER (E) ADDED TO PROTECT THE PART SURFACE -(TIGHTENED TO A PRE-TORQUE CONDITION) WHICH COMPRESSES AND BONDS INTO THE HOLE FIBERS AS REQUIRED.
DETAIL (BI) AND (B2) = DENOTES OPEN CLEARANCE.
DETAIL (C) = DENOTES HOLE STACK FIBERS ARE AUTOMATICALLY COMPRESSED WHERE REQUIRED.
#3 -THE CARBON FIBER SCREW, NOW IN TORQUE EXHIBITS SELF-
LOCKING INTO THE CUT THREADS AS THE INHERENT PROPERTIES OF
THE SCREW EXPAND (IN REVERSE) WHEN TORQUED SO ARE NOW
CLOSE TOLERANCE AND FULLY INTEGRAL WITH EACH AND EVERY
PITCH BY THE HELICOIL FIBERS INSIDE THE CARBON PEEK SCREW
WITH THE TAPPED HOLE AS ONE BONDED PART, COMPRESSED (G) AND LOCKED WITH NO VOIDS, CLEARANCES OR TRAPPED AIR GAPS (HI) AND (H2).
SHAVE CARBON FIBER SCREW FLUSH WITH PART SURFACE BOTH
SIDES (Fl) AND (F2) OR (Fl) ONLY IF A BLIND HOLE OR RESTRICTED HOLE ON THE UNDERSIDE REMOVING WASHER (E) DETAIL (HI) AND (H2) = CLOSED CLEARANCE.
THE REPAIRED SURFACE FINISH IS VIRTUALLY INVISIBLE AND
IMMEDIATELY READY FOR FULL USE.
GB201310094A 2012-07-20 2013-06-06 Repair of holes or damage in carbon fiber composite structure Expired - Fee Related GB2504206B (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB201212987A GB201212987D0 (en) 2012-07-20 2012-07-20 Repair of holes or damage in carbon fibre composite structure

Publications (4)

Publication Number Publication Date
GB201310094D0 GB201310094D0 (en) 2013-07-17
GB2504206A true GB2504206A (en) 2014-01-22
GB2504206A8 GB2504206A8 (en) 2014-02-05
GB2504206B GB2504206B (en) 2014-07-09

Family

ID=46881757

Family Applications (2)

Application Number Title Priority Date Filing Date
GB201212987A Ceased GB201212987D0 (en) 2012-07-20 2012-07-20 Repair of holes or damage in carbon fibre composite structure
GB201310094A Expired - Fee Related GB2504206B (en) 2012-07-20 2013-06-06 Repair of holes or damage in carbon fiber composite structure

Family Applications Before (1)

Application Number Title Priority Date Filing Date
GB201212987A Ceased GB201212987D0 (en) 2012-07-20 2012-07-20 Repair of holes or damage in carbon fibre composite structure

Country Status (1)

Country Link
GB (2) GB201212987D0 (en)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10695985B2 (en) 2015-09-10 2020-06-30 Short Brothers Plc Method for designing and fitting, via interference, an insert into an opening in a non-metallic material
US11559959B2 (en) * 2019-03-20 2023-01-24 Airbus Operations Gmbh Machining method, application tool, and machining arrangement for modifying or repairing a surface spot of a workpiece surface of a fiber composite workpiece
EP4194186A1 (en) * 2021-11-08 2023-06-14 General Electric Company Composite components and methods of redefining openings in composite components

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2028230A (en) * 1978-08-08 1980-03-05 Commissariat Energie Atomique Method of manufacture of material reinforced with a threedimensional textile structure
US5310434A (en) * 1989-03-30 1994-05-10 Societe Europeenne De Propulsion Process for joining elements in the manufacture of thermostructural composite material parts

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2028230A (en) * 1978-08-08 1980-03-05 Commissariat Energie Atomique Method of manufacture of material reinforced with a threedimensional textile structure
US5310434A (en) * 1989-03-30 1994-05-10 Societe Europeenne De Propulsion Process for joining elements in the manufacture of thermostructural composite material parts

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10695985B2 (en) 2015-09-10 2020-06-30 Short Brothers Plc Method for designing and fitting, via interference, an insert into an opening in a non-metallic material
US11559959B2 (en) * 2019-03-20 2023-01-24 Airbus Operations Gmbh Machining method, application tool, and machining arrangement for modifying or repairing a surface spot of a workpiece surface of a fiber composite workpiece
EP4194186A1 (en) * 2021-11-08 2023-06-14 General Electric Company Composite components and methods of redefining openings in composite components

Also Published As

Publication number Publication date
GB201212987D0 (en) 2012-09-05
GB2504206A8 (en) 2014-02-05
GB201310094D0 (en) 2013-07-17
GB2504206B (en) 2014-07-09

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Legal Events

Date Code Title Description
PCNP Patent ceased through non-payment of renewal fee

Effective date: 20200606