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    • 专利摘要:
    Methods are provided for repairing a defect in a polymeric composite structure. The methods include providing a yoke on a defect in a polymeric composite structure; the arrangement of a textured sheet on the polymeric yoke, the application of pressure to the polymeric yoke and the textured sheet; and heating the polymeric yoke. The textured leaflet has a surface texture that is the negative of a surface texture of the polymeric composite structure.
    公开号:FR3050684A1
    申请号:FR1753836
    申请日:2017-05-02
    公开日:2017-11-03
    发明作者:Xiaosong Huang；Selina X Zhao；Elisabeth J Berger；William R Rodgers；Tomohiro Ryutani；Glen E Novak
    申请人:Teijin Ltd；GM Global Technology Operations LLC；
    IPC主号:
    专利说明:

    AESTHETIC REPAIR OF A THERMOPLASTIC COMPOSITE OF
    CARBON FIBERS
    FIELD
    [1] This disclosure relates to the repair of carbon fiber composites by use of repair inserts.
    BACKGROUND
    [2] This section provides background information regarding this description, which is not necessarily the prior art.
    [3] Vehicle bodies desirably manage loads applied during normal service conditions, as well as under extraordinary conditions, such as a collision or exposure to impact or excessive forces. Vehicle crates are increasingly being built using materials such as polymer-based composites that offer higher strength-to-weight ratios than the low-carbon steel used in traditional designs. Polymeric composites in particular are useful in automobiles, and their use is expected to continue to increase in the future in an effort to further reduce vehicle mass. However, polymer composites pose greater difficulties when a repair is required, compared to conventional metal materials. Therefore, the development of an effective method of repairing defects in damaged or scratched composite structures remains important.
    ABSTRACT
    [4] This section presents a general summary of the description, and does not constitute an exhaustive description of its entire scope or characteristics.
    [5] The current technology proposes a method for repairing a die in a polymeric composite structure. The method comprises disposing a yoke, which may be a polymer encroachment, over a defect in a polymeric eomposite structure. The method also includes disposing a textured sheet on the polymeric yoke. The textured sheet has a first surface texture that is a negative of a second surface texture of the polymeric composite structure. Pressure can then be applied to the polymer insert and the textured sheet. The process further includes heating the polymeric yoke. In this way, a challenge in the polymeric composite structure can be repaired.
    [6] Current technology also proposes another method for repairing a die in a polymer composite structure. The method optionally includes filling a defect in a polymeric composite structure having a surfactant texture with a filler material. A polymeric yoke is then disposed on the defect, the polymeric yoke having a first color that corresponds to a second color of the polymeric composite strueture. A textured sheet is disposed on the polymeric yoke, the textured sheet having a surface texture which is a negative of the surface texture of the polymeric eomposite strueture. A source of heat may be disposed on the textured sheet, while a source of pressure may be disposed on the source of heat. The method also includes applying pressure to the polymeric yoke and textured sheet, followed by heating the polymeric yoke with a heat source disposed on the textured sheet. Heating causes adhesion of the polymeric yoke to the polymeric composite structure. The application of pressure causes the textured sheet to transfer the first surface texture to the polymeric yoke, so that the polymeric yoke has a third surface texture that corresponds to the second surface texture of the structure. composite polymer.
    [7] In addition, current technology provides a method for repairing a defect in a corrugated polymeric composite structure. The method includes disposing a yoke on a defect in a corrugated polymeric composite structure that has a first corrugated surface. Next, a rigid plate that has a second corrugated surface corresponding to or complementary to the first corrugated surface is disposed on the corrugated polymeric composite structure in a region corresponding to where the yoke is disposed. The method further comprises heating the yoke with a heating blanket or induction heater.
    [8] Other areas of applicability will be evident from the description presented here. The description and specific examples in this summary are for illustrative purposes only and are not intended to limit the scope of this description.
    DRAWINGS
    [9] The drawings described herein are intended to illustrate only selected embodiments and not all possible embodiments, and are not intended to limit the scope of this specification.
    [10] Figure 1 is a schematic illustration of a method for repairing a die in a polymeric composite structure in accordance with certain aspects of the present disclosure; [11] Figure 2A is an illustration of a repair of an aesthetic defect according to certain aspects of the present description; [12] Figure 2B is an illustration of a structural defect repair in accordance with certain other aspects of this disclosure; [13] Fig. 3A is an illustration of a method for repairing a defect in a polymeric composite structure according to certain aspects of the present disclosure as in Fig. 1, wherein a heating blanket is used as a heating source; [14] Fig. 3B is an illustration of a method for repairing a defect in a polymeric composite structure according to certain aspects of the present description as in Fig. 1, where an induction heater is used as a source of heater ; [15] Fig. 4A is an illustration of a method for repairing a defect in a polymeric composite structure according to certain aspects of the present disclosure as in Fig. 1, wherein a vacuum bag is used as a pressure source; [16] Fig. 4B is an illustration of a method for repairing a defect in a polymeric composite structure according to certain aspects of the present disclosure as in Fig. 1, wherein a sandbag is used as a pressure source; [17] Figure 5A is an illustration of a vacuum bag raised from a corner or junction of a polymeric composite structure when a negative pressure is sucked by the vacuum bag; [18] Figure 5B is an illustration of a vacuum bag sucked into a corner or junction of a polymeric composite structure due to the inclusion of a fold in the vacuum bag prior to suction of a negative pressure by the vacuum bag according to certain aspects of the present description; [19] Figure 6 is an illustration of a method for repairing an aesthetic defect in a corrugated polymeric composite structure in accordance with certain aspects of the present disclosure; [20] Figure 7A is an illustration of a method according to some aspects of the present description as in Figure 6, where a heating blanket is used as a heating source; and [21] Fig. 7B is an illustration of a method according to certain other aspects of the present description as in Fig. 6, or an induction heater is used as a heating source.
    [22] Corresponding numerals indicate corresponding parts in all the several views of the drawings.
    DETAILED DESCRIPTION
    [23] Exemplary embodiments are presented so that this description is accurate, and they will fully communicate the scope to those skilled in the art. Many specific details are presented in the form of examples of specific compositions, components, devices and methods, to provide an accurate understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details may not be employed, that exemplary embodiments may be implemented in many different forms, and that they should in no way be considered as limiting the scope of the description. In some exemplary embodiments, well known methods, well-known device structures, and well-known technologies are not described in detail.
    [24] The terminology used herein is intended to describe examples of particular embodiments only, and is not intended to be limiting. The terms "includes", "comprising", "encompassing" and "having" are included and therefore specify the presence of the specified features, elements, compositions, steps, integers, operations and / or components, but do not exclude the presence or the addition of one or more other, features, integers, steps, operations, elements, components and / or groups thereof. Although the open term "comprising" should be understood as a non-restrictive term used to describe and claim various embodiments presented herein, in some aspects this term may alternatively be understood rather as a more limiting and restrictive term, such as that "consisting of" or "consisting essentially of". Thus, for any given embodiment reciting compositions, materials, components, elements, features, integers, operations and / or process steps, the present disclosure also specifically encompasses embodiments consisting of, or consisting essentially of these compositions, materials, components, elements, features, integers, operations and / or processing steps recited. In the case of "consisting of", the alternative embodiment excludes any additional compositions, materials, components, elements, features, integers, operations and / or processing steps, while in the case of "consisting essentially of", of any additional compositions, materials, components, features, features, operations and / or processing steps that may materially affect the fundamental and novel features are excluded from such an embodiment, but from any compositions, materials, components, elements , features, integers, operations and / or processing steps that do not materially affect the fundamental and novel features may be included in the embodiment.
    [25] Any process steps, processes, and operations, described herein, are not to be understood as necessarily requiring their performance in the particular order discussed or illustrated unless specifically identified in the form of a performance order. It should also be understood that additional or alternative steps may be employed unless otherwise specified.
    [26] When it is indicated that a component, element or layer is "on", "engaged with", "connected to" or "coupled to" another element or layer, it may be directly on, engaged, connected or coupled to the other component, element or layer, or intervening elements or layers may be present. In contrast, when it is indicated that an element is "directly on", "directly engaged with", "directly connected to" or "directly coupled to" another element or layer, there can be no elements or intervening layers present. Other words used to describe a relation between elements should be interpreted in a similar way (eg "between" against "directly between", "adjacent" against "directly adjacent", etc.). As used herein, the term "and / or" encompasses any and all combinations of one or more of the associated listed items.
    [27] Spatial or temporal relation terms, such as "before", "after", "inside", "outside", "below", "below", "below", "above", "above", and analogous, can be used herein for easy description purposes to describe the relationship of an element or feature with one or more other elements or features, as illustrated in the figures. The terms spatial or temporal relationship may be intended to encompass different orientations of the device or system in use or operation, in addition to the orientation shown in the figures.
    [28] Throughout this specification, the numerical values represent approximate range measurements or limits to include minor eearts with respect to the given values as well as embodiments having about the value mentioned, as well as those having exactly the value mentioned. All numerical parameter values (eg, quantities or conditions) in this specification, including the appended claims, are to be understood as being modified in all cases by the term "about", whether the term "about" appears or not. actually before the numerical value. 'Approximate' means that the numerical value indicated allows a slight inaccuracy (with some approach to the accuracy of the value, approximately or reasonably close to the value, almost.) If the inaccuracy provided by "about" is not In another aspect of the art with this ordinary meaning, the term "about", as used herein, indicates at least variations that may be due to ordinary methods of measuring and using these parameters.
    [29] In addition, the range description encompasses the description of all values and other ranges divided within the entire range, including the bounds and sub-ranges indicated for the ranges. As referred to herein, the ranges, unless otherwise indicated, encompass boundaries and encompass the description of all distinct values and other ranges divided within the entire range. Thus, for example, a range "from A to B" or "from about A to about B" includes A and B.
    [30] Exemplary embodiments will now be described more fully with reference to the accompanying drawings.
    [31] Polymer composites are widely used in vehicles such as automobiles, motorcycles, boats, tractors, buses, mobile homes, caravans and tanks, and their use will increase in the future with increased efforts. to further reduce the mass of vehicles. Reinforced composites are particularly suitable for use in components of an automobile or other vehicle (eg motorcycles, boats), but they can also be used in various other industries and applications, including aerospace components, industrial machinery and equipment, farm equipment, heavy machinery, as non-limiting examples. For example, reinforced composites can be used to form automobile structural components having complex or contoured three-dimensional shapes. Non-limiting examples include tank shielding shields, underbody shields, structural panels, door panels, interior floors, floor plates (eg of a van), roofs, exterior surfaces, storage areas, including glove boxes, consoles, chests, trunk floors, platforms, and the like.
    [32] Compared to existing metallic materials, polymer composites require different repair processes. Therefore, the development of effective repair processes for damaged polymeric composite structures is necessary. For aesthetic repairs, the materials used to fill the surface defects desirably have good adhesion with a parent polymer composite structure to provide repair durability, and have a color and texture corresponding to the color and texture. of the parent polymer composite. Conventional methods used for aesthetic repairs of polymeric composite stuccoes do not reliably give good UV resistance, abrasion resistance, and aesthetic characteristics. Therefore, new methods for repairing aesthetic defects in polymeric composite structures are desirable.
    [33] In various aspects, the present disclosure provides methods for repairing a defect in a polymeric composite structure with a polymeric yoke. A polymer composite comprises at least one polymer and at least one reinforcing material. In some aspects, the polymer may be a thermoplastic polymer. For example, the composite polymer structure may be a thermoplastic composite reinforced with carbon fibers. The defect may be aesthetic, such as a crack, a groove, or a stitch, or the defect may be structural, such as a large crack that covers two surfaces of a polymeric composite structure or a hole. A structural defect may be a site that facilitates the propagation of cracks or other defect mechanisms, while an aesthetic defect diminishes the aesthetics of the exposed region (s) of the polymeric composite structure. The polymeric composite structure may be any structure composed of a polymeric composite material on a vehicle, such as a panel. Therefore, the polymeric composite structure may be a smooth panel, a curved panel, or a corrugated panel, such as a panel used in a truck body or any of the applications previously discussed above. In some aspects, the polymeric yoke used to repair a defect in the polymeric composite structure is a thermoplastic yoke that comprises a thermoplastic polymer. In some other aspects, the polymeric insert may be a polymeric composite material. The polymer insert may have a composition identical to the composition of the polymeric composite structure, including the same reinforcing material in the same proportions (for example a similar fiber content), or have a different polymer composite composition and / or a fiber content different from that of the polymer composite structure. For example, the polymeric insert may have the same composition as the polymeric composite structure, but may include a fiber content that is less than or greater than the fiber content of the polymeric composite structure.
    [34] Referring to Figure 1, current technology provides an illustrative method for repairing a challenge in a polymer composite structure 12 composed of a polymer composite. The polymeric composite structure 12 may be a section of a vehicle, such as a body sheet or panel defining a floor of a truck body. The defect 10 may be an aesthetic defect or a structural defect. In some embodiments, such as those where the defect is a deep scratch, a notch. a hole or perforation, the method may comprise filling the defender with a filler material, as will be described later. In other embodiments, such as those where the defect 10 is a shallow ridge, filling of the defect 10 with a filler material is not necessary. As shown in FIG. 1, the polymeric composite structure 12 comprises a visibly exposed surface 16 and a visibly unexposed surface 18.
    [35] Figures 2A and 2B show cross-sections of a polymeric composite structure such as the polymeric composite structure 12 of Figure 1. In Figure 2A, an aesthetic defect 10a is shown in a polymeric composite structure 12a, while in Figure 2B a structural defender 10b is shown in a polymeric composite structure 12b. As shown in Figures 2A and 2B, in some embodiments, the present method includes filling the defect in the polymeric composite structure with a filler material 14. More particularly, Figure 2A shows a cosmetic defect 10a in the form of a scratch or notch in the polymer composite structure 12a. The method of Figure 2A may include filling the cosmetic defect 10a with a filler material 14. The filler material 14 may be any filler material that hardens to fill the defect 10a. Examples of suitable filler materials include thermoplastics, such as polyamides, acrylics, polycarbonates, thermoplastic polyesters, polysulfones, and their copolymers as non-limiting examples, as well as thermosets, such as polyimides. epoxies, vinyl esters, polyesters, acrylates and polyurethanes, by way of non-limiting example. As shown in FIG. 2A, the filling material 14 is leveled, for example by being scraped or smoothed, so that the filling material 14 is aligned with an exposed, i.e. visible, surface 16, of the composite polymer structure 12.
    [36] Figure 2B shows a polymeric composite structure 12b, which is similar to the composite polymer structure 12a of Figure 2A, but rather has a structural die 10b in the form of a hole extending from the surface. exposed to an unexposed, i.e., non-visible, surface 18. As shown in FIG. 2B, the method comprises attaching a plate 20 to the unexposed surface 18, such that the plate 20 covers the defect 10b. The plate 20 may be composed of any material capable of supporting the filling material 14. By way of non-limiting examples, the plate 20 may be composed of metal, an alloy, steel, glass, a polymer, or a polymer composite. The attachment of the plate 20 to the unexposed surface 18 of the polymeric composite structure 12 may be effected by any method known in the art, such as by means of an adhesive of a material, it is to say of screw, or of one of their combinations. As shown in Figure 2B, the method comprises filling the structural defect 10b with the filling material 14. Then, as shown in Figure 2B, the filling material 14 is scraped or smoothed so that the filling material is aligned. with an exposed, i.e. visible, surface 16 of the polymeric composite structure.
    [37] In Figures 2A and 2B, the method also includes solidifying, drying or polymerizing the filler material 14 so that the filler material hardens and fills the aesthetic defect 10a or the structural defect 10b. Depending on the composition of the filler material 14, the solidification, drying or polymerization of the filler material 14 may include heating the filler material 14, adding an activator to the filler material 14, the exposure filling material 14 to ultraviolet (UV) light, incubation for a period of time, or a combination thereof. After the filler material 14 has been applied, smoothed and polymerized, the polymeric composite structure is ready for further processing to repair the defect in accordance with certain aspects of the present disclosure.
    [38] Referring back to Figure 1, the method comprises disposing a yoke 22 on the defect 10 in the polymeric composite structure 12. The positioning of the yoke 22 on the bolster 10 is illustrated by an outline yoke 23 on the polymeric composite structure 12. The arrangement of the yoke 22 is effected whether or not the defect 10 is filled by a filling material. When the defect is filled with a filler material, the yoke 22 is disposed on the defect 10 after the filler material has hardened. The yoke 22 is made of a polymeric material, such as a thermoplastic polymer or uncured thermosetting polymer. Accordingly, the yoke 22 may be a thermosetting polymer yoke, or a thermoplastic polymeric yoke. In some embodiments, the polymeric yoke is a polymeric composite yoke having a polymer and a reinforcing material dispersed therein. The yoke 22 is of sufficient thickness to cover a repaired surface and fill the gaps, yet is thin enough to be masked or camouflaged, i.e. combined, in the polymeric composite structure 12. Therefore, The yoke 22 optionally has a thickness of from about 1 μm or more to about 1 mm or less. In some aspects, the yoke 22 has a color and / or composition that substantially matches those of the polymeric composite structure 12 so that when the process is complete, the yoke 22 covers the defect 10 and is not visible. or only slightly visible. Alternatively, the yoke 22 may be transparent, so that the color of the polymeric composite structure 12 is visible through the yoke 22. Therefore, color matching can be performed by visual inspection. Fillers, such as carbon black or titanium dioxide, by way of non-limiting examples, may be incorporated into the yoke material so that the color of the yoke material is finely adjusted to match the color of the yarn material. In other aspects, the yoke 22 need not have a color and / or composition corresponding to those of the polymeric composite structure 12. In some embodiments, suitable yoke materials also comprise the same polymer matrix or resin as the polymer composite structure 12, but do not contain reinforcing fibers.
    [39] In other aspects, the polymeric composite structure 12 and the yoke 22 may be composed of any fiber reinforced composite material disclosed in US Patent Publication Nos. 2013/0122262, 2013/0272780, and 2015/0108793, and International PCT Publications No. WO 2012/117593, WO 2012/105716, WO 2012/102315, WO 2012/105080, WO 2012/105387, WO 2012/105389, WO 2012/105717, WO 2012 / 108446 and WO 2012/140793. In various aspects, the yoke 22 may be composed of either the same fiber-reinforced composite material as that of the polymeric composite structure 12, or of a fiber-reinforced composite material different from that of the polymeric composite structure 12, which is compatible with the polymeric composite structure 12. In addition, the yoke 22 may be composed of the same fiber-reinforced composite material as that of the polymeric composite structure 12, but with a higher or lower fiber content.
    [40] Thus, the yoke 22 may be composed of yoke materials comprising a polymeric matrix or resin reinforced with reinforcing fibers. Suitable non-limiting examples of fibers for yoke 22 or polymeric composite structure 12 include carbon fibers, glass fibers (such as glass or quartz fibers), aramid fibers (such as fibers KEARLAR® para-aramid synthetic fibers and ARON® para-aramid synthetic fibers), boron fibers, ceramic fibers, polyester fibers, ultra-high molecular weight polyethylene fibers (UHMWPE), fibers hemp, basalt fibers, and their combinations. The fibers may be in the form of fiber mats having interconnected or in contact fibers, or they may be individual fibers randomly distributed within the resin matrix. Suitable fibers may comprise relatively short fibers (having lengths of about 0.1 mm and <about 10 mm), relatively long fibers (having lengths of about 10 mm and <about 100 mm), or continuous fibers ( having lengths> about 100 mm), and may include any of their combinations. Long fibers can provide a good balance of moldability / productivity / mechanical characteristics. The fibers can also be chopped.
    [41] The fibers in the yoke or the polymeric composite material may be randomly configured, for example in a substantially bi-directional pattern or in a pattern oriented in a specific direction. In some embodiments, a fiber mat can be used with strongly oriented planar or unidirectionally oriented fibers or combinations thereof. The fiber mat can have randomly oriented fibers for a good balance of moldability / productivity / mechanical characteristics. In some embodiments, a random fiber mat may be used. The random mat may contain reinforcing fibers having an average fiber length of from about 3 mm or more to about 100 mm or less and a thermoplastic resin. Such a random fiber mat is further described in WO 2012/105080 discussed above. In addition, a unidirectional orientation carbon fiber layer may be incorporated to enhance the local stiffness and strength for a load carrying structure. In various embodiments, the yarn material has a fiber concentration lower than or equal to the fiber concentration in the polymeric composite structure.
    [42] As discussed above, the yarn material is composed of a reinforcing material dispersed in a polymer resin or matrix, which may be the same as or different from the polymeric composite structure material. By way of non-limiting example, the polymer resin may comprise; a polyamide resin (such as PA6, PAA, PA12, PA46, PA66, PA610, or caprolactam), a vinyl ester, a phenolic resin, a bis-maleimide, a polyamide-imide resin, a polyimide resin, a vinyl chloride resin, vinylidene chloride resin, vinyl acetate resin, polyvinyl alcohol resin, polystyrene resin, acrylonitrile-styrene resin, acrylonitrile-butadiene resin styrene, an acrylic resin, a methacrylic resin, a polyethylene resin, a polypropylene resin, a polyether-imide resin, a polyphenylene sulfide resin, a polybenzimidazole resin, a polyacetal resin, a resin polycarbonate, a polyethylene terephthalate resin, a polyethylene naphthalate resin, a polybutylene terephthalate resin, a polyacrylate resin, a polyaiyl ether sulfone resin, a polyphenyl resin ethylene ether, a polyphenylene sulfide resin, a polysulfone resin, a polyether sulfone resin, a polyether ether ketone resin, a polylactide resin, a polycarbonate resin, or any copolymer or combination of these resins. Therefore, non-limiting examples of yarn materials, i.e., thermoplastic yarn materials, include polyesters (including polyethylene terephthalate (PET)), polyurethane, polyolefins, poly (acrylic acid) (PAA), poly (methyl acrylate) (PMA), poly (methyl methacrylate) (PMMA), acrylonitrile-butadiene-styrene (ABS), polyamides (including polycaprolactam (nylon)), poly (lactic acid) (PLA), polybenzimidazole, polycarbonates, polyether sulphone (PES), polyether ether ketone (PEEK), polyetherimide (PEI), polyethylene ( PE, including Ultra High Molecular Weight Polyethylene (UHMWPE), Medium Density Polyethylene (MDPE), Low Density Polyethylene (LDPE), and Crosslinked Polyethylene (PEX)), Polyphenylene Oxide (PPO) , poly (phenylene sulphide) (PPS), polypropylene (PP), polystyrene (PS), poly (wine chlomre) yle) (PVC), polytetrafluoroethylene (PTFE), their copolymers, and combinations thereof.
    [43] As will be appreciated by those skilled in the art, a fiber reinforced composite material may further contain other conventional ingredients, including other reinforcing materials, fillers or additives, such as organic / inorganic fillers, flame retardants, anti-UV agents (UV stabilizers), antioxidants, dyes or pigments, such as powdered carbon black, release agents, fabric softeners, agents plasticizers, surfactants, and the like. As regards the dyes or pigments, they can be used so that the color corresponds to that of the polymer composite structure 12.
    [44] Referring again to Figure 1, the method also includes the provision of a structured sheet 24 on the yoke 22. In some aspects, a surface texture includes a visible pattern, for example a hatch, a grained pattern, or other surface micropatterns. The textured sheet 24 therefore has a surface texture or grain that is the inverse or the negative or the mirror image of a surface texture of the polymeric composite structure 12, so that the surface texture of the composite structure Polymer 12 may be embedded within the yoke 22. Also, the textured sheet 24 may be made of any flexible material known in the art that can withstand high pressures and temperatures. In some embodiments, the textured sheet 24 is composed of silicone, i.e., the textured sheet 24 is a textured silicone sheet. In other embodiments, the textured sheet 24 is a textured sheet of polyimide or heat resistant rubber, or a textured sheet of a soft foldable metal. As described in more detail below, the surface texture of the textured sheet 24 will be transferred to the yoke 22, so that the yoke 22 has a grain or surface texture corresponding to the grain or surface texture of the polymeric composite structure 12. Therefore, once the process is complete, the yoke 22 will have the same texture as the polymeric composite structure 12, so that the yoke 22 visually combines with the exposed surface 16 of the structure In embodiments where the polymeric composite structure 12 does not have a surface texture, i.e. is smooth, the textured sheet is not necessary. Similarly, when other components employed in the process have a surface texture that corresponds to the surface texture of the polymeric composite structure 12, as further discussed herein, the textured sheet is not necessary.
    [45] The method further comprises disposing or applying a heat source, i.e., a heating element, 26, to the textured sheet 24 when present or to the yoke 22 when the textured sheet is not present. For example, the heat source 26 has a lower surface 28 that comes into contact with the textured leaflet 24 or the yoke 22. In some embodiments, the lower surface 28 of the heat source 26 includes a texture or grain which is the negative of the texture or grain in the polymeric composite structure 12. In these embodiments, a texture is transferred from the lower surface 28 of the heat source 26 to the yoke 22, and the textured sheet 24 is not necessary. The heat source 26 may be any heat source known in the art, such as a heating blanket or an induction heater.
    [46] Figure 3A shows a method similar to that described in the context of Figure 1 where the heat source 26 is a heating blanket 26a. The heating blanket 26a has a lower surface 28a which comes into contact with the textured sheet 24 when the bottom surface 28a does not have a texture or grain which is a negative of the texture or grain of the polymeric composite structure 12, ie Alternatively, it comes into contact with the yoke 22 when the bottom surface 28a has a texture or a grain that is the negative of the texture or grain of the polymeric composite structure 12. Said in another way, when the bottom surface 28a of the heating blanket 26a comprises a texture or grain, the textured sheet 24 is a surface of a heating blanket 26a which contacts an exposed surface 16 of the yoke 22.
    [47] Figure 3B shows a similar process to that described in the context of Figure 1 where the heat source 26 is an inductive heat generated by a conductive sheet 26b which is associated with an inductive device 30. The conductive sheet 26b has a bottom surface 28b that comes into contact with the textured sheet 24 when the bottom surface 28b does not have a texture or grain that is the negative of the structure or grain of the polymeric composite structure 12 or, alternatively, comes into contact of the yoke 22 when the lower surface 28b does not have a texture or grain that is the negative of the texture or grain of the polymeric composite structure 12. Therefore, in some aspects, the lower surface 28b of the Induction heating 26 may have a geometry corresponding to the geometry of the polymeric composite structure 12. The inductive device 30 is disposed on the unexposed surface 18 of the magnetic structure. polymeric mposite 12, such that the yoke 22 and the textured sheet 24 (when present) are positioned between the inductive heater 26b and the inductive system 30. Alternatively, the inductive system 30 may be disposed at above the conductive sheet 26b or the pressure source 32. The inductive system 30 cooperates with the conductive sheet 26b to generate heat.
    [48] Referring again to Figure 1, the method further comprises applying pressure to the yoke 22, the textured leaflet 24 (when the textured leaflet is needed), and the heat source 26. L Pressure application to the yoke 22 and the textured sheet 24 includes the application of a pressure source 32 to the heat source 26. The pressure source 32 may be any pressure source known in the art such as vacuum bagging, a mechanical force (such as a sandbag) or a magnetic force (for example with an electromagnet). Pressure application to the yoke 22 includes applying the standard atmospheric pressure, ranging from about 0.001 MPa or more to about 1 MPa or less, or about 0.005 MPa or more to about 0.1 MPa or least, at heat source 26, textured sheet 24 (when present), yoke 22, and polymeric composite structure 12.
    [49] Figure 4A shows a method similar to that described in the context of Figure 1, where the pressure source 32 is a vacuum bag assembly 32a. The vacuum bag assembly 32a completely covers the components beneath it, i.e., the heat source 26, the textured sheet 24 (where present), the yoke 22, and the region of the polymeric composite structure 12 having the defect 10, so that the vacuum bag assembly 32a is in continuous contact with the exposed surface 16 of the polymeric composite structure 12. The vacuum bag assembly 32a can be attached to the exposed surface 16 of the polymeric composite structure with, by way of non-limiting example, an adhesive mastic. The vacuum bag assembly 32a includes an orifice 34 which receives a conduit associated with a source of negative pressure. Therefore, port 34 is in communication with a vacuum bag of vacuum bag assembly 32a. When the negative pressure source is turned on, a vacuum is created under the vacuum bag assembly 32a, which forces or presses together the heat source 26, the textured sheet 24, the yoke 22, and the composite structure In other words, the edges of the vacuum bag assembly 32a are sealed against the polymeric composite structure 12 and a vacuum, i.e. a negative pressure, is aspirated through vacuum bag assembly 32a. In addition, in some embodiments, the heat source 26 is positioned directly below the vacuum bag assembly 32a. Therefore, to prevent the heat source 26 from melting the vacuum bag, a flexible heat-resistant or substantially heat-resistant mask may be positioned between the heat source 26 and the vacuum bag assembly 32a. By "substantially heat resistant" is meant that the flexible mask does not transmit a quantity of heat through the mask sufficient to melt or otherwise negatively affect the vacuum bag assembly 32a. The mask may be composed of any flexible heat-resistant material, such as silicone.
    [50] Figure 5A is an alternative variant that illustrates a potential problem that may arise when using the vacuum bag assembly 32a. Figure 5A shows a cross-sectional view of the polymer composite substrate 12 and the vacuum bag assembly 32a. When the polymeric composite structure 12 is not flat, i.e., has a curved or corrugated surface, and the vacuum bag assembly 32a is laid flat against the exposed surface 16 of the polymeric composite structure 12 , the vacuum bag assembly 32a potentially lifts off the exposed surface 16 at the corners or junctions 36 when the negative pressure source is activated, as shown by the arrow. This lifting of the vacuum bag assembly 32a can cause poor contact with the polymeric composite structure 12, and negatively affects how the heat source 26, the textured sheet 24, the yoke 22 and the polymer composite structure 12 are forced together by the negative pressure. Therefore, as shown in FIG. 5B, folds 38 may be included in the vacuum bag assembly 32a when disposed on the exposed surface 16 of the polymeric composite structure 12. The folds 38 may be generated by for example, by disposing a set in the vacuum bag assembly 32a adjacent to the corners or seams 36. When a negative pressure is applied, the vacuum bag is pushed onto the exposed surface 16 of the polymeric composite structure 12, including at the corners or junctions 36 (as shown by the solid arrow) more effectively than when the folds 38 are not used.
    [51] Figure 4B shows a similar process to that described in the context of Figure 1, where the pressure source is a sandbag 32b. The sandbag 32b is disposed on the heat source 26, and together forces the heat source 26, the textured leaflet 24 (when present), the yoke 22, and the composite polymer structure 12. To increase the provided by the sandbag 32b, a rigid plate 40 may be mechanically pressed against the sandbag 32b in a direction towards the polymeric composite structure 12. In some embodiments, a downward mechanical force is pressed against the rigid plate 40.
    [52] Although the pressure causes conformation of the polymeric yoke 22 to the polymeric composite surface 12, the method includes the application of heat to the polymeric yoke 22. The heat is supplied or supplied by the heat source 26 The heat slightly melts the yoke 22 and possibly a portion of the exposed surface 16 of the polymeric composite structure 12 under the yoke 22, so that after heating the yoke adheres to the polymeric composite structure, thereby covering 10. When both the yoke 22 and the portion of the exposed surface 16 of the polymeric composite structure 12 under the yoke are melted, the melts combine together to form a strong bond between the yoke 22 and the structure. For example, when the yoke 22 and the composite polymer structure 12 are composed of the same material, both the yoke 22 and a part of the structure The composite polymer 12 will melt and combine together. In addition, because of the pressing forces of the texture sheet 24 (or the heat source 26 comprising a textured surface) against the yoke 22, the texture is transferred to the yoke 22 when the yoke 22 softens during the heater.
    [53] When the polymeric composite structure 12 is heated, the polymer composite softens, allowing the embedded fibers within the polymeric composite structure 12 to migrate to the exposed surface as a result of intrinsic compressive forces maintained by the composite. polymer that developed during the original processing of the polymer composite. This phenomenon is called "springback". The elastic return leads to a visibly non-uniform region surrounding the yoke 22. For example, because of the springback, the fibers in the composite polymer structure 12 are more visible than in areas where springback does not occur, c that is, the polymeric composite structure 12 is less heated or not heated at all. Therefore, to prevent or reduce spring back, the application of heat to the polymeric yoke 22 includes heating the yoke 22 to a temperature that is high enough to melt the polymeric yoke 22, but low enough to prevent or minimize elastic return or heat deformation of the polymeric composite structure 12. In various embodiments, the temperature does not exceed a temperature that is about 50 ° C higher than the melting point of the polymeric composite structure. As a result, the temperature is highly variable and strongly dependent on the yoke material. For example, heating the yoke 22 may include heating the yoke 22 at a temperature of about 190 ° C or higher to about 230 ° C or less. The heating is carried out for about 0.1 minutes or more at about 120 minutes or less or until a sufficient portion of the yoke 22 has melted so that the yoke 22 adheres to the polymeric composite structure 12 when the heating is stopped and the yoke cools and hardens.
    [54] Fig. 6 is an illustration of another method for repairing a defect 110 in a corrugated polymeric composite structure 112. More particularly, Fig. 6 is an illustration of a variation of the method illustrated in Fig. 1. The defect 110 and the corrugated polymeric composite structure 112 may be any of the described types of defenses or polymeric composite structures, except that the polymeric composite structure 112 is corrugated, i.e., includes repeating sequences of high portions and low (hills / flats and valleys / grooves). It will be understood, however, that the present process can be applied to polymeric composite structures having irregular surface geometries other than corrugations or to polymeric composite structures with smooth or flat surface geometries. The corrugated polymeric composite structure 112 includes a first, i.e. corrugated, surface 116, and an unexposed surface 118.
    [55] The method illustrated in FIG. 6 comprises the arrangement of a yoke 122 on the defect 110 in the corrugated polymeric composite structure 112 and the provision of a textured sheet 124 on the yoke 112. The yoke arrangement 112 and textured sheet 124 is performed as described above with respect to FIG. 1. The positioning of the yoke 122 on the defect 110 is illustrated by a yoke contour 123 on the polymeric composite structure 112. 3B, the method shown in FIG. 6 comprises the disposition of a rigid plate 150 on the textured sheet 124 (when present) and the yoke 122 so that a lower surface 152 of the rigid plate 150 is in contact with the textured sheet 124 or the yoke 122. As discussed above, the corrugated polymeric composite structure 112 has a first corrugated surface. Therefore, the lower surface 152 of the rigid plate 150 has a corresponding or coordinated corrugation, i.e. a second corrugated surface that allows the rigid plate 150 to be disposed in conformity on the first corrugated surface of the Corrugated polymeric composite structure 112. Accordingly, the method comprises disposing rigid plate 150 which has a second corrugated surface 152 which is complementary to first corrugated surface 116 on a region of first corrugated surface 116 having the yoke. 122. Similarly, when the polymeric composite structure 112 has an exposed surface 116 with irregular geometry, the rigid plate 150 has a surface that is complementary to the irregular geometry of the exposed surface 116. Said in another way, the rigid plate 150 has a surface that is complementary to the exposed surface 116 of the polymeric composite structure 112, where the exposed surface can have smooth or flat geometry, wavy geometry, or irregular geometry.
    [56] The rigid plate 150 is made of a thermally conductive material, such as a metal, alloy, steel, or a highly thermally conductive composite, such as a strongly charged carbon composite (ie from about 50% (by weight) or more to about 90% (by weight) or less). In some embodiments, the lower surface 152 of the rigid plate 150 includes a texture or grain that is the negative of the texture or grain in the corrugated polymeric composite structure 112. In these embodiments, the texture or grain included in the lower surface 152 of the rigid plate 150 becomes transferred to the yoke during the implementation of the method, which renders the inclusion of the textured sheet 124 unnecessary.
    [57] The method further comprises disposing or applying a heat source 126 to the rigid plate 150. For example, the heat source 126 has a bottom surface 128 which engages the rigid plate 150. The heat source 126 may be any heat source known in the art, such as a heating blanket or an induction heater, as described above.
    [58] Figure 7A shows a process analogous to that of Figure 6, where the heat source 126 is a heat blank 126a. The heating blanket 126a has a lower surface 128a which contacts the rigid plate 150. Since the rigid plate 150 is thermally conductive, the heat provided by the heating blanket 126a is transferred through the rigid plate 150 and into the yoke 122.
    [59] Fig. 7B shows a method analogous to that of Fig. 6, wherein the heat source 126 is an inductive heat generated by a conductive sheet 126b which is associated with an inductive device 130. The conductive sheet 126b has a lower surface 128b which comes into contact with the rigid plate 150. The inductive system 130 is disposed on the unexposed surface 118 of the corrugated polymeric composite structure 112, so that the yoke 122, the textured sheet 124 (when present) and the rigid plate 150 is positioned between the induction heater 126b and the inductive system 130. Alternatively, the inductive system 130 may be disposed above the conductive sheet 126b or the pressure source 132. The inductive system 130 cooperates with the conductive sheet 126b to generate heat, which is transferred through the rigid thermally conductive plate 150 and to the yoke 122.
    [60] In some embodiments, the rigid plate 150 is conductive, so that the inductive system 130 cooperates with the rigid plate 150 to generate heat that is transferred to the yoke 122. Therefore, the method illustrated in FIG. Figure 6 optionally includes the application of pressure to the yoke 122, to the textured sheet 24 (when the textured sheet is necessary), to the rigid plate 150, and to the heat source 26 when the rigid plate 150 does not. is not heavy enough to give sufficient pressure to the yoke 122, when additional pressure is desired. The application of pressure comprises the application of a pressure source 132 to the heat source 126. The pressure source 132 may be any pressure source known in the art, such as vacuum bagging, a mechanical force, or a magnetic force. The pressure source may be applied as discussed above with reference to Figures 4A and 4B.
    [61] The method illustrated in FIG. 6 also includes the application of heat to the polymer insert 122. The heat is supplied or supplied by the heat source 126. The heating of the yoke 122 causes the adhesion of the yoke to the corrugated polymeric composite structure 112, as described above with respect to FIG.
    [62] The foregoing description of the embodiments has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the description. Features or individual elements of a particular embodiment are not generally limited to this particular embodiment but. where applicable, they are interchangeable and may be used in a selected embodiment, even if not specifically indicated or described. The same thing can also vary in many ways. These variants are not to be considered as deviating from the description, and all such modifications are intended to be encompassed within the scope of the description.
    权利要求:
    Claims (10)
    [1" id="c-fr-0001]
    ΚΕνΕΝΟΙΟΑΉΟΝ8
    A method of repairing a defect in a polymeric composite structure, the method comprising: disposing a polymeric yoke (22) on a defect (10) in a polymeric composite stent (12); disposing a textured sheet (24) on the polymeric yoke (22), the textured sheet (24) having a first surface texture which is the negative of a second surface texture of the polymeric composite structure; applying pressure to the polymeric yoke (22) and the textured sheet (24); and heating the polymeric yoke (22).
    [2" id="c-fr-0002]
    The method of claim 1, wherein each of the polymeric yoke and the polymeric composite structure comprises a thermoplastic polymer individually selected from the group consisting of: polyester, polyurethane, polyolefin, polyacrylic acid, poly (methyl acrylate), poly (methyl methacrylate), acrylonitrile-butadiene-styrene, polyamide, poly (lactic acid), polybenzimidazole, polycarbonate, polyether sulphone, polyether etherketone, polyether imide, polyethylene, polyphenylene oxide, polyphenylene sulfide, polypropylene, polystyrene, polyvinyl chloride, polytetrafluoroethylene, their copolymers, and the polymeric composite structure further comprises a reinforcing material selected from the group consisting of; carbon fibers, glass fibers, basalt fibers, aramid fibers, boron fibers, ceramic fibers, polyester fibers, ultra-high molecular weight polyethylene fibers, hemp fibers and their combinations, and the polymeric insert has a thickness of from about 1 μm or more to about 1 mm or less.
    [3" id="c-fr-0003]
    The method of claim 1, wherein a first color of the polymeric yoke is visibly the same as a second color of the polymeric composite strueture and the polymeric yoke comprises a polymeric composite having the same polymeric matrix as that of the polymeric composite structure and possibly the same reinforcing material as that of the polymeric composite structure.
    [4" id="c-fr-0004]
    The method of claim 1, wherein the textured sheet is a flexible textured silicone sheet, and the method further comprises disposing a heating element (26) on the flexible textured silicone sheet, wherein the element heater applies heat to heat the polymeric yoke and the heater (26) is a heating blanket or an induction heater.
    [5" id="c-fr-0005]
    The method of claim 1, wherein the textured sheet is a surface of a heating blanket that contacts an exposed surface (16) of the polymeric yoke, and wherein the blanket provides heat for the heating of the polymer insert.
    [6" id="c-fr-0006]
    The method of claim 1, wherein applying pressure to the polymeric insert and the textured sheet comprises disposing a vacuum bag (32a) on the polymeric yoke and the textured sheet, whereby the edges of the vacuum bag (32a) are sealed against the polymeric composite structure; and aspirating a vacuum through an orifice (34) in communication with the vacuum bag or applying pressure to the polymeric yoke and the textured sheet includes disposing a bag of sand (32b) above a heat source (26) disposed on the textured sheet and optionally applying a mechanical force to the sandbag (32b).
    [7" id="c-fr-0007]
    The method of claim 1, wherein heating the polymeric film comprises heating the polymeric film at a temperature not exceeding a temperature that is about 50 ° C higher than the melting point of the polymeric composite structure.
    [8" id="c-fr-0008]
    The method of claim 1, further comprising: prior to arranging the polymeric insert, filling a defect (10a) in the polymeric composite structure with a filler material (14), the composite polymeric structure comprising a thermoplastic polymer and having a surface texture; and arranging the polymeric insert comprising a thermoplastic polymer on the defect, the polymeric insert having a first color that corresponds to a second color of the polymeric composite structure, followed by disposing the textured slip on the polymeric yoke, and applying pressure and heating causing the polymeric yoke to adhere to the polymeric composite structure and causing the surface texture to be transferred from the textured sheet to the polymeric yoke, so that the polymeric yoke has a third texture surface corresponding to the second surface texture of the polymeric composite structure.
    [9" id="c-fr-0009]
    A method according to claim 8, wherein filling the defect comprises filling the defect with a thermoplastic or thermosetting filler material (14), and leveling the filler material (14) to be aligned with a surface (16). of the polymeric composite structure, the pressure application to the polymeric yoke and the textured sheet comprises applying a pressure of about 0.001 MPa or more to about 1 MPa or less, and heating the polymeric yoke. comprises heating at a temperature not exceeding a temperature of about 50 ° C higher than the melting point of the polymeric composite structure.
    [10" id="c-fr-0010]
    The method of claim 1, wherein the polymeric composite structure is corrugated, the method further comprising: after disposing the polymeric yoke, providing a rigid plate (40) having a second surface that is complementary to the first surface on a region of the first surface having the yoke; and the heater of the yoke with a heating blanket or induction heater, the second surface of the rigid plate comprising a texture that is transferred to the yoke during heating. or the method further comprising disposing a flexible textured sheet between the yoke and the rigid sheet, the textured sheet having a surface texture that is transferred to the yoke upon heating.
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    同族专利:
    公开号 | 公开日
    US10589477B2|2020-03-17|
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    法律状态:
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    优先权:
    申请号 | 申请日 | 专利标题
    US15/144,625|US10589477B2|2016-05-02|2016-05-02|Cosmetic repair of a thermoplastic carbon fiber composite|
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