Repair patch, method for molding repair patch, method for repairing composite material, and molding jig

Patent metadata

Field	Value
Publication number	US-11338529-B2
Application number	US-201816756035-A
Country	US
Kind code	B2
Filing date	Aug 20, 2018
Priority date	Oct 17, 2017
Publication date	May 24, 2022
Grant date	May 24, 2022

Abstract

A repair patch includes a composite material to repair a a repair target of a composite material. The repair patch includes bonding surfaces which face a bonded surface of a counterbored hole formed in the part to be repaired, and are bonded to the counterbored hole; and an opposite surface opposite to the bonding surfaces in a thickness direction. The opposite surface has a curved plane with a first surface side curvature radius protruding toward the opposite surface in a cross section cut along a plane intersecting an axial direction in the opposite surface. The bonded surface has a curved plane with a second surface side curvature radius protruding toward the bonding surfaces facing the bonded surface in a cross section cut along a plane intersecting an axial direction in the bonded surface. The first surface side curvature radius is smaller than the second surface side curvature radius.

First claim

The invention claimed is:

1. An assembly comprising a part of a second composite material to be repaired and a repair patch made of a first composite material to be bonded to the part to be repaired, wherein the part to be repaired is a peripheral surface with a cylindrical shape extending along an axial direction, and the part to be repaired has a second bottom surface with a second distance between the peripheral surface and the second bottom surface measured in a second depth direction of the second composite material, the repair patch comprising:
a bonding surface configured to face a bonded surface of the part to be repaired, and to be bonded to the part to be repaired; and
a surface opposite to the bonding surface in a first thickness direction of the repair patch,
wherein the bonding surface has a first bottom surface with a first distance between the first bottom surface and a peripheral edge of the repair patch measured in the first thickness direction, and the first bottom surface to oppose the second bottom surface,
the opposite surface has a curved plane with a predetermined first surface side curvature radius in an intersecting plane which is a cross section along a plane intersecting a predetermined direction in the opposite surface, and
wherein the first distance is smaller than the second distance.

2. The assembly according to claim 1 ,
wherein the peripheral surface of the part to be repaired is an outer peripheral surface with the cylindrical shape,
wherein the outer peripheral surface has a curved plane with a second surface side curvature radius protruding from a side of the outer peripheral surface toward an outer side of the cylindrical shape in the intersecting plane,
wherein the opposite surface has the curved plane with the first surface side curvature radius protruding from a side of the bonding surface toward the opposite surface, and
wherein the first surface side curvature radius is smaller than the second surface side curvature radius.

3. The assembly according to claim 2 ,
wherein a thickness of the repair patch in the first thickness direction decreases from a central portion toward an outer side in the predetermined direction, and
wherein the first surface side curvature radius of the opposite surface decreases from the central portion toward the outer side in the predetermined direction.

4. The assembly according to claim 1 ,
wherein the peripheral surface of the part to be repaired is an inner peripheral surface with the cylindrical shape,
wherein the inner peripheral surface has a curved plane with a second surface side curvature radius which is recessed from an inner side of the cylindrical shape toward the inner peripheral surface in the intersecting plane,
wherein the opposite surface has the curved plane with the first surface side curvature radius which is recessed from a side of the opposite surface toward the bonding surface, and
wherein the first surface side curvature radius is larger than the second surface side curvature radius.

5. The assembly according to claim 4 ,
wherein a thickness of the repair patch in the first thickness direction decreases from a central portion toward an outer side in the predetermined direction, and
wherein the first surface side curvature radius of the opposite surface increases from the central portion toward the outer side in the predetermined direction.

6. The assembly according to claim 1 ,
wherein the first composite material is obtained by infiltrating reinforcing fibers with a thermosetting resin, and
wherein the thermosetting resin is precured.

7. The assembly according to claim 1 , further comprising a peel ply that is peelably bonded to the bonding surface.

8. The assembly according to claim 1 ,
wherein an indicator with which the axial direction is visually recognizable is attached to the opposite surface.

9. A method of repairing a part of a second composite material, wherein the part to be repaired is a peripheral surface with a cylindrical shape extending along an axial direction, and the part to be repaired having a second bottom surface with a second distance between the peripheral surface and the second surface measured in a second depth direction of the second composite material, the method comprising:
a lay-up step of laminating a plurality of fiber reinforced preforms together on a mold surface by using a molding jig having the mold surface;
a molding step of heating and molding the plurality of laminated fiber reinforced preforms to form a repair patch made of a first composite material; and a bonding step of bonding the repair patch to the part to be repaired, wherein a surface of the repair patch opposite to a bonding surface, which is bonded to the part to be repaired in a first thickness direction of the repair patch, has a curved plane with a first surface side curvature radius in an intersecting plane which is a cross section along a plane intersecting a predetermined direction in the opposite surface,
wherein the bonding surface has a first bottom surface with a first distance between the first bottom surface and a peripheral edge of the repair patch measured in the first thickness direction, and the first bottom surface to oppose the second bottom surface, and
wherein the first distance is smaller than the second distance.

10. The method of repairing according to claim 9 ,
wherein the peripheral surface of the part to be repaired is an inner peripheral surface with the cylindrical shape,
wherein the opposite surface of the repair patch has a curved plane with a first surface side curvature radius which is recessed from a side of the opposite surface toward the bonding surface in the intersecting plane,
wherein the inner peripheral surface has a curved plane with a second surface side curvature radius which is recessed from an inner side of the cylindrical shape toward the inner peripheral surface in the intersecting plane, and
wherein the repair patch is molded by using the molding jig such that the first surface side curvature radius is larger than the second surface side curvature radius.

11. The method of repairing according to claim 9 ,
wherein the peripheral surface of the part to be repaired is an outer peripheral surface with the cylindrical shape,
wherein the opposite surface of the repair patch has a curved plane with a first surface side curvature radius which protrudes from a side of the bonding surface toward the opposite surface in the intersecting plane,
wherein the outer peripheral surface has a curved plane with a second surface side curvature radius which protrudes from a side of the bonding surface toward the opposite surface in the intersecting plane, and
wherein the repair patch is molded by using the molding jig such that the first surface side curvature radius is smaller than the second surface side curvature radius.

12. A method of repairing a part of a second composite material, wherein the part to be repaired is a peripheral surface with a cylindrical shape extending along an axial direction, and the part to be repaired has a second bottom surface with a second distance between the peripheral surface and the second surface measured in a second depth direction of the composite material, the method comprising:
a providing step of providing a repair patch made of a first composite material to repair the part to be repaired, wherein a surface of the repair patch opposite to a bonding surface to be bonded to the part to be repaired in a first thickness direction of the repair patch, has a curved plane with a first surface side curvature radius in an intersecting plane which is a cross section along a plane interse

Assignees

• Mitsubishi Heavy Ind Ltd

Inventors

• Shimono Kodai
• Hasegawa Koichi
• Hirai Takuma
• Yoshino Shunsuke
• Nishimuro Jo

Classifications

• B29C73/10 Primary

  using patches sealing on the surface of the article (B29C73/14 takes precedence) · CPC title

• B32B37/1009

  using vacuum and fluid pressure · CPC title

• B29C66/82661

  by means of vacuum · CPC title

• B29C66/00145

  Vacuum, e.g. partial vacuum · CPC title

• B32B37/1207

  Heat-activated adhesive (B32B37/04 takes precedence) · CPC title