JP2017206685A - 熱可撓性炭素繊維複合材料の外観修復 - Google Patents
熱可撓性炭素繊維複合材料の外観修復 Download PDFInfo
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- JP2017206685A JP2017206685A JP2017091003A JP2017091003A JP2017206685A JP 2017206685 A JP2017206685 A JP 2017206685A JP 2017091003 A JP2017091003 A JP 2017091003A JP 2017091003 A JP2017091003 A JP 2017091003A JP 2017206685 A JP2017206685 A JP 2017206685A
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- 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
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- 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
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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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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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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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- B29C70/443—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding and impregnating by vacuum or injection
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
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- Mechanical Engineering (AREA)
- Engineering & Computer Science (AREA)
- Health & Medical Sciences (AREA)
- Physics & Mathematics (AREA)
- Oral & Maxillofacial Surgery (AREA)
- Toxicology (AREA)
- Electromagnetism (AREA)
- Thermal Sciences (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Laminated Bodies (AREA)
- Treatments Of Macromolecular Shaped Articles (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Abstract
Description
[0003]車両ボディは、通常の使用状態の間にも、衝突または他の過剰な力もしくは衝撃に晒される間などの異常状態下でも、加えられる負荷に対処することが望ましい。車両ボディは、従来設計の低炭素鋼より強度重量比が大きいポリマーベースの複合材料などの材料を使用して構築されることが多くなっている。特にポリマー複合材料は自動車に有用であり、車両の重量をさらに軽減する取り組みの中で、それらの使用は将来的に増加し続けると予想される。しかし従来の金属材料に比べて、ポリマー複合材料は修復を要する場合に、より大きい困難を呈する。したがって、損傷または傷を受けた複合構造体の欠陥に対する効果的な修復方法の開発が、依然重要となろう。
[0005]本技術は、ポリマー複合構造体の欠陥を修復する方法を提供する。方法はポリマー複合構造体の欠陥上にパッチを配置することを含み、このパッチはポリマーパッチであり得る。方法はまた、ポリマーパッチの上にテクスチャードシートを配置することを含む。テクスチャードシートは、ポリマー複合構造体の第2の表面テクスチャのネガ像である第1の表面テクスチャを有する。そして圧力がポリマーパッチおよびテクスチャードシートに加えられる。方法はさらに、ポリマーパッチを加熱することを含む。この方法で、ポリマー複合構造体の欠陥を修復し得る。
[0023]当業者に対して本開示を完全にするため、かつ本開示の範囲を十分に伝えるために、例示的の実施形態が提供される。本開示の実施形態の完全な理解を提供するために、特定の組成物、構成要素、デバイス、および方法の例などの多くの特定の詳細が記載される。特定の詳細を採用する必要はないこと、例示的な実施形態は多くの異なる形式で具現化され得ること、および本開示の範囲を制限すると解釈するべきではないことは、当業者には明白となろう。いくつかの例示的な実施形態において、よく知られた処理、よく知られたデバイス構造、およびよく知られた技術の詳細は説明されない。
[0031]ポリマー複合材料は、自動車、自動二輪車、ボート、牽引車、バス、移動住宅、キャンピングカー、戦車などの車両に広く使用されており、車両重量をさらに軽減する取り組みによってポリマー複合材料の利用は将来的に増加するであろう。補強された複合材料は、自動車または他の車両(たとえば自動二輪車、ボート)の構成要素に使用することに特に好適である。しかしまた、非限定的例として、宇宙空間の構成要素、産業設備および機械、農業設備、重機械を含む、他の様々な産業および用途にも使用し得る。たとえば、補強された複合材料は、なめらかな形状または複雑な三次元形状を有する自動車の構造的構成要素を形成するために使用され得る。非限定的例として、ガスタンク防護シールド、車両底部シールド、構造用パネル、ドアパネル、室内フロア、フロアパン(たとえばカーゴバンのフロアパン)、ルーフ、外面、グローブボックスとコンソールボックスとトランクとトランクフロアとトラックの荷台とを含む格納領域などが挙げられる。
10a 外観的欠陥
10b 構造的欠陥
12 ポリマー複合構造体
12a ポリマー複合構造体
12b ポリマー複合構造体
14 充填材
16 露出面
18 非露出面
20 プレート
22 パッチ、ポリマーパッチ
23 輪郭
24 テクスチャードシート
26 熱源
26a ヒートブランケット
26b 伝導性シート
28 下面
28a 下面
28b 下面
30 インデューサ
32 圧力源
32a 減圧バッグアセンブリ
32b サンドバッグ
34 ポート
36 角部または接合部
40 剛性板
110 欠陥
112 ポリマー複合構造体
116 露出面
118 非露出面
122 パッチ、ポリマーパッチ
123 輪郭
124 テクスチャードシート
126 熱源
126a ヒートブランケット
126b 伝導性シート
128 下面
128a 下面
128b 下面
130 インデューサ
132 圧力源
150 剛性板、熱伝導剛性板
152 底面
Claims (20)
- ポリマー複合構造体の欠陥を修復する方法であって、
ポリマー複合構造体の欠陥の上にポリマーパッチを配置するステップと、
前記ポリマーパッチの上にテクスチャードシートを配置するステップであって、前記テクスチャードシートは、前記ポリマー複合構造体の第2の表面テクスチャのネガ像である第1の表面テクスチャを有する、配置するステップと、
前記ポリマーパッチおよび前記テクスチャシートに圧力を加えるステップと、
前記ポリマーパッチを加熱するステップと、
を含む方法。 - 前記ポリマーパッチの第1の色は前記ポリマー複合構造体の第2の色と視覚的に同じである、請求項1に記載の方法。
- 前記ポリマーパッチは熱可撓性ポリマーを備え、前記ポリマーパッチは約1μm以上から約1mm以下までの厚さを有する、請求項1に記載の方法。
- 前記ポリマーパッチは前記ポリマー複合構造体と同じポリマーマトリックスを有するポリマー複合材料を備え、任意選択で、前記ポリマー複合構造体と同じ補強材料を備える、請求項1に記載の方法。
- 前記テクスチャードシートが可撓性のテクスチャードシートである、請求項1に記載の方法。
- 可撓性シリコーンシートの上に加熱要素を配置するステップをさらに含み、前記加熱要素は熱を加えて前記ポリマーパッチを加熱する、請求項5に記載の方法。
- 前記テクスチャードシートは、前記ポリマーパッチの露出面に接触したヒートブランケットの表面であり、前記ヒートブランケットは前記ポリマーパッチを加熱するための熱を提供する、請求項1に記載の方法。
- 前記圧力を前記ポリマーパッチおよび前記テクスチャードシートに加えるステップは、減圧バッグの縁部が前記ポリマー複合構造体に対して密封されるように前記ポリマーパッチおよびテクスチャードシートの上に減圧バッグを配置し、前記減圧バッグに連通するポートを介して減圧を引くステップを含む、請求項1に記載の方法。
- 前記圧力を前記ポリマーパッチおよび前記テクスチャードシートに加えるステップは、前記テクスチャードシート上に配置した熱源の上部にサンドバッグを配置するステップと、任意選択で機械的力を前記サンドバッグに加えるステップとを含む、請求項1に記載の方法。
- 前記テクスチャシートの上に加熱要素を配置するステップをさらに含み、前記加熱要素はヒートブランケットまたは誘導加熱器である、請求項1に記載の方法。
- 前記ポリマーパッチを加熱するステップは、前記ポリマー複合構造体の融点よりも約30℃高い温度を超えない温度で前記ポリマーパッチを加熱するステップを含む、請求項1に記載の方法。
- 前記ポリマーパッチおよび前記ポリマー複合構造体は、ポリエステル、ポリウレタン、ポリオレフィン、ポリ(アクリル酸)、ポリ(メチルアクリレート)、ポリ(メチルメタクリレート)、アクリロニトリルブタジエンスチレン、ポリアミド、ポリ乳酸、ポリベンゾイミダゾール、ポリカーボネート、ポリエーテルスルホン、ポリエーテルエーテルケトン、ポリエーテルイミド、ポリエチレン、ポリフェニレンオキシド、ポリフェニレンスルフィド、ポリプロピレン、ポリスチレン、ポリ塩化ビニル、ポリテトラフルオロエチレン、これらのコポリマーからなる群から個々に選択される熱可撓性ポリマーを含み、前記ポリマー複合構造体は、炭素繊維、ガラス繊維、バサルト繊維、アラミド繊維、ボロン繊維、セラミック繊維、ポリエステル繊維、高分子量ポリエチレン繊維、麻すさ、およびそれらの組合せからなる群から選択される補強材料をさらに含む、請求項1に記載の方法。
- ポリマー複合構造体の欠陥を修復する方法であって、
表面テクスチャを有するポリマー複合構造体の欠陥を充填材で充填するステップと、
熱可撓性ポリマーを備えるポリマーパッチを前記欠陥の上に配置するステップであって、前記ポリマーパッチは前記ポリマー複合構造体の第2の色に整合した第1の色を有する、配置するステップと、
前記ポリマーパッチの上にテクスチャードシートを配置するステップであって、前記テクスチャードシートは前記ポリマー複合構造体の第2の表面テクスチャのネガ像である第1の表面テクスチャを有する、配置するステップと、
前記ポリマーパッチおよび前記テクスチャシートに圧力を加えるステップと、
前記テクスチャードシートの上に配置した熱源を用いて前記ポリマーパッチを加熱するステップと、を含み、
前記圧力を加えることおよび加熱することによって、前記ポリマーパッチは前記ポリマー複合構造体に接着し、前記圧力を加えることによって前記テクスチャードシートはその第1の表面テクスチャを前記ポリマーパッチに転写し、それによって前記ポリマーパッチは、前記ポリマー複合構造体の前記第2の表面テクスチャに整合する第3の表面テクスチャを有する、方法。 - 前記欠陥を充填するステップは、熱可撓性充填材または熱硬化性充填材を用いて前記欠陥を充填するステップと、前記充填材を前記ポリマー複合構造体の表面と同一平面になるように平坦にするステップと、を含む、請求項13に記載の方法。
- 前記ポリマーパッチは前記ポリマー複合構造体と同じポリマーマトリックスを有する熱可撓性ポリマー複合材料を備え、任意選択で、前記ポリマー複合構造体と同じ補強材料を備える、請求項13に記載の方法。
- 前記ポリマーパッチおよび前記テクスチャードシートに前記圧力を加えるステップは、約0.005MPa以上から約1MPa以下までの圧力を加えるステップを含む、請求項13に記載の方法。
- 前記ポリマーパッチを加熱するステップは、前記ポリマー複合構造体の融点よりも約50℃高い温度を超えない温度で加熱するステップを含む、請求項13に記載の方法。
- 前記熱源はヒートブランケットであり、前記テクスチャードシートはヒートブランケットの表面である、請求項13に記載の方法。
- 波状のポリマー複合構造体の欠陥を修復する方法であって、
ポリマー複合構造体の第1の表面における欠陥の上にパッチを配置するステップと、
前記パッチを有する前記第1の表面の領域上に、前記第1の表面に対して相補的な第2の表面を有する剛性板を配置するステップと、
ヒートブランケットまたは誘導加熱器を用いて前記パッチを加熱するステップと、
を含む、方法。 - 前記剛性板の前記第2の表面が、前記加熱中に前記パッチに転写されるテクスチャを備える、または前記方法が柔軟性テクスチャードシートを前記パッチと前記剛性板との間に配置するステップをさらに含み、前記テクスチャードシートは加熱時に前記パッチに転写される表面テクスチャを有する、請求項19に記載の方法。
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JP6682472B2 (ja) | 2020-04-15 |
DE102017109362A1 (de) | 2017-11-02 |
FR3050684B1 (fr) | 2020-10-16 |
FR3050684A1 (ja) | 2017-11-03 |
US10589477B2 (en) | 2020-03-17 |
US20170313002A1 (en) | 2017-11-02 |
CN107336449A (zh) | 2017-11-10 |
DE102017109362B4 (de) | 2023-08-10 |
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