Improving the process of repair of the aircraft panels made of composite materials

pressure - 1.0... 2.0 MPa;

time - 10 minutes;

Temperature - 80°C (adhesives VC-41, VC - 51) or 100°C (adhesive VC-36).

At the same approximate binder content in the prepreg is 35-40% by weight.

For the manufacture of a cold-curing prepreg layer fabric, flax, you laid on the release film (polyethylene). On the tape or fabric is applied to a freshly prepared non-metallic adhesive to a spatula until the filler is impregnated with glue by a release substrate.

Patch of the individual layers of the prepreg manufactured at the site of repair, consists of two parts: internal and external patches patches. Internal patch is circular or oval and designed to align in-podlitso plating unit in the repair area. External patch as a right or an elongated octagon, complementing internal, designed for operation under load filler fibers plating unit. Overlap external patch to the inner is 30 to 350 mm depending on the magnitude of loading unit and repair zones, while providing a smooth outer layers gathering patches steps 5-15 mm. Cutting blanks patches (internal and external) are produced by Pattern of thick paper. On Pattern paper cut layers of prepreg patches. Protective layers of prepreg are removed immediately before laying prepreg. The number of layers is calculated by internal patch formula:



where n - the number of plies of prepreg;

5 oS-skin thickness;

6i - monolayer thickness of fabric or tape used to repair (Excluding the thickness of the adhesive when the adhesive prepreg is used).

Subsequent layer prepreg should be different from the previous one by an amount that takes into account the presence of the recess in the casing of the bevel. Assembling patches separately on a release film, heat resistance of the film should correspond to the temperature curing adhesive used or prepreg.

Assembly diagram and install patches from prepreg layers is shown in Figure 11. Times-measures the lower workpiece is not less than 2.5 mm greater than the smallest size of the holes in the casing repaired.

Uniformity overlapping plies of prepreg is calculated by the formula:

where b - the value of the overlap;

1 - chamfer length recess in the casing;

n - the number of layers forming the inner patch.

The direction of the warp threads of the filler is determined by drawing on the aggregation

Gath, and in the absence of data is kept symmetrical layout, for example, 0°, 90°, ± 45°, +45°, 90°, 0°, etc.

Direction 0° along the spar or along the length of the unit.



Fig. 15. Scheme build and install patches: 1 - the repaired unit; 2 - insert sotobloka; 3 - expandable adhesive; 4 - layers of inner patches (seal); 5 - reinforced adhesive film; 6 - outer layers of the patch; 7 - film adhesive

Before installing the patch to repair zone contains film adhesive compatible with the binder, which is impregnated prepreg (eg, glue VC-51 film and binder EDT 69H) used for the manufacture of the patch. After assembling and manufacturing process is carried out patches curing patches and gluing them to the honeycomb core at a temperature and a pressure.

Existing technology

General - equipment and tools for repairs

General

A. Refer to the following figures for lists of tools and equipment. Miscellaneous equipment table 2.1-2.5 general, hand tools table 2.6-2.9 general.

B. This section lists the equipment and hand tools used when making repairs and also lists sources of supply. The purpose of this list is to provide information pertaining to item description and use.

C. Some of the procedures in this manual identify tools or equipment. You can use alternative tools that are equivalent unless the procedure tells you the specified tool or equipment item is mandatory. If you use alternative tools or equipment, make sure they give the same results and are as safe to the parts and personnel as the tools or equipment specified in the procedure.



Table 2.1

Tool	Manufacturer's designation	Manufacturer	Remarks
Cleaner, vacuum (B)	Industrial-type model#apn4423 (tornado); use a 556AL barrel as a dust receiver	Breuer/tornado corp. 7401 w. Lawrence ave. Chicago, IL60656	Clean up sanding dust and debris
Containers, 1 liter beaker-type, polyethylene	#13915-679 sherwood or Equiv	V.W.R. Scientific 355 treck drive Seattle, wa98188	Mixing resins and potting compounds
Containers, safety, foot-lever-type	Metal, eagle 906-fl or equiv	V.W.R. Scientific 355 treck drive seattle, wa98188	Holding used clothes with toxic materials
Cork sheet	0.125-in	Commercial - any source
Caul plate	Fabricate locally using0.016 aluminum sheet		Use to distribute pressure over areas of a repair
Countersink, microstop, 100° adjust able drive	#6300-large, #6400-small,	Mc master-carr P.O. Box 740100 Atlanta, ga30374-0100 www.mcmaster.com	Countersinking holes for Rivets, screws, or bolts
Cutter, honeycomb, valve stem type, two-piece	30-030-1 holder (D) 30-030-2 cutter	Onsrud cutter mfg co. 800 liberty drive P.o.box 550	Aluminum honeycomb cutter
Cutter, honeycomb, valve stem type one-piece	31-010 0.50 dia(C) 31-015 0.75 dia(C) 31-020 1.0 dia(C) 31-025 1.5 dia(D) 31-030 2.0 dia(D)	Libertyville, il60048 or any other commercial source	Aluminum honeycomb cutter
Drill motor (B)	15c 1489 or equivalent	Aero industrial tool 482 east meadow ave. e. meadow, ny11554	Conventional drilling, sanding, or circular sawing
	Pneumatic, ј-in chuck model #3008-0 or equivalent	Chicago pneumatic 1800 overview dr. rockhill, sc29730
Drill motor, 90° Angle	Pneumatic, variable speed, model #1ol-1201вor equivalent	Aero industrial tool 482 east meadow ave. e. meadow, ny11554	Conventional drilling, sanding, or circular sawing
Gauge, air pressure	0 to 100 psi, model j4654 or equivalent	Marsh distributor P.O. box 361 antioch, il60002	To indicate air line pressure
Gauge, vacuum		Marsh distributor P.O. box 361 Antioch, IL 60002	To indicate vacuum line pressure
Gloves, cotton		Mc master-carrp.o.box 740100 Atlanta, GA30374-0100 www.mcmaster.com	Use for handling cleaned parts or adhesives
Gloves, insulating	Heat insulating	Any source	Use for handling hot parts
Heater assembly (B)	Hot air, bf-400-10, or equivalent	Engineered air systems 1270 n. price rd. St. Louis, mo63132	Hot air blower to duct air to area being cured

Table 2.2

Miscellaneous equipment

Tool	Manufacturer's designation	Manufacturer	Remarks
Air-blast gun	Vacu-blast JR., #41303 or equivalent	Vacu-blast Woodson house Ajax avenue slough Berkshire, SL1 4DS England -or-P.O. box 286, Herington, Kansas 67449	Clean metal surfaces
Aspirator, vacuum	Vacuum model TD-260 or Equivalent	Air-vac engineering P.O. box 215, 30 progress ave Seymour CT 06483, Airtronics 1940 124th ave ne bldg. A-107 Bellevue, WA 98005	Converts air pressure to vacuum
Bags, pressure	10-LB sand or shot bags	Commercial-any source	Use as a substitute pressure medium
Blanket, heating	5 watts/in2 minimum	Atacs products, inc. 14040 interurban aves Tukwila, WA98168 Heatcon composite systems600 andover park Eseattle, WA98188 -or-Unit 8, EdisonRD, ST. Ives, Huntingdon, Cambridge PE17 4LZ England GMI 9 rue buffault 75009 Paris, France -or-GMI/emptech, 5957 Glendale drive Chilliwack, b.c.,, Canada V2R 3A5 JR technology LTD. 81 north end, meldreth Royston, herts, England SG86NU Pyrometric service corp. 1312 s. 96TH ST Seattle, WA98108-5010 Tayco engineering, inc. 10874 hope st P.O. Box 6034 Cypress, CA90630 Wichitech industries, inc. Oakland center, 8990 RT. 108 Columbia, md 21045	To provide heat for curing adhesive



Table 2.3

Miscellaneous equipment

Tool	Manufacturer's designation	Manufacturer	Remarks
Heater, air (B)	1000 to 2000 watts, model HGS 50110j	Master appliance corp. 2420 18th st. Racine, wi53403	For heat-tacking adhesives, heat-drying honeycomb core or assemblies, warming compounds and/or resins
	Alternate	Ideal industries, inc.1006 park avenue sycamore, il60178
Lamp, heating	250 to 300 watts, explosionproof, tungsten or quartz tube	Mc master-carr P.O. Box 740100 Atlanta, ga30374-0100 www.mcmaster.com	Low-temperature curing of adhesives, potting compounds, or resins
Lamp, heating assembly	25 or 40/4 #375g30 or Equivalent	Deltrol controls corp. 2740 so. 20th st. Milwaukee, wi53215	Low-temperature curing of adhesives, potting compounds, or resins
Mat, fiberglass	2 OZ fiberglass or 7500	Ren plastics 5656 s. Cedar st. Lansing, mi 48909 Dexter corp. (hysol products) one dexter drive seabrook, nh03874	Can be used for laminated tooling, fiberglass bleeder cloth, insulation material, or a substitute for osnaburg bleeder cloth
	Tooling mat
Motor assembly, Pneumatic	Arbor saw/motor	Aero industrial tool 482 east meadow ave. E. Meadow, ny11554	To cut away damaged material
Multitester	Low current, low ohm, kelvin-bridge-type	Commercial - any source	Taking electronic measurements
Peening tool, power (B)	1/4-in. Stem (drill rod), Slot end for flapper strip Mil-b-1170, type ii, class e, style 1		Use for shot peening requirements
Power supply, dc	Regal line model R2518 unfiltered bench model r series dc or equiv.		Use as power source for phosphoric acid anodizing
Recorder, temperature, 24-point, automatic chart-type	Model #15306836-24	Honeywell	Measuring temperature at the adhesive cure line by thermo couples; 1 through 24 points available
Recorder, temperature, 1-point, individual printout, roller chart	Model #122 115-volt, 60-cycle	Gulton graphic Instrument 1900 s. Country tr. E. Greenwich, RI 02818	Measuring one thermocouple on a line chart
Regulator, air pressure	0 to 125 psi, model 11-002-025 or equivalent	С.A. Norgren co. 5400 s. Deleware ST. Littleton, co 80120	Measure and regulate air pressure
Regulator, vacuum	0- to 30-inch hg, or Equivalent	Mc master-carr P.O. box 740100 atlanta, ga 30374-0100 www.mcmaster.com	Measuring vacuum at the assembly

Table 2.4

Miscellaneous equipment

Tool	Manufacturer's designation	Manufacturer	Remarks
Safety face shield	Tru-safe #199-1 or safeline#6799 <10 by 18-1/4) or equiv	Commercial - any source	For face and eye protection
Safety face shield Holder	Rice head shield #707 Or equivalent		Holds replaceable face shield
Safety glasses	5944d smoke clear lenses or equivalent	H.l. Boutonco. Inc. Buzzard bay, ma 02532 Mc master-carr P.O. box 740100 Atlanta, GA30374-0100 www.mcmaster.com	For eye protection
Scale, balance	1.0 gram accuracy, multiple models	Mettler 1900 Polaris pkwy Columbus, oh 43240 or Ohaus corporation 29 Hanoverrd Florham park, nj07932	Weighing compounds and resin mixtures
Sealant gun	Air-operated or equivalent glue gun	Mc master-carr P.O. Box 740100 Atlanta, ga30374-0100 www.mcmaster.com	Dispensing of fillers and sealants
Shaver, micro-rivet-Head	Model 2t-405, adjustable, or equivalent	Advanced air tool co.,Inc.131 AllenBlvd. Farmingdale, ny11735-5616	Shave protruding rivet heads
Sine plate	0° to 45° inclination from horizontal position	Brown 8 Sharpe Precision park 200 French town rd. N. Kingstown, ri02852	Use with core-slicing equipment
Spray unit	Power unit, atomized W/glass 6 oz container	Precision valve corp. P.O. box 309 Yonkers, ny10702	Used to apply small amounts of liquid primer, adhesive, or resins
Surface bleeder, surface breather, and insulation	Bms9-3, type d	See 51-20-03, fig. 2
Temperature controller console, portable self-contained (A)(B)		Atacs products, inc. 14040 interurban ave. S. Tukwila, wa98168	Use with heat blankets, thermocouples, and vacuum unit for application and recording of heat and pressure
		Gmi9 rue buffault 75009 Paris, France -or-Gmi/emptech 5957 Glendale drive Chilliwack, b.c., Canada v2r 3a5

Table 2.5

Miscellaneous equipment

Tool	Manufacturer's designation	Manufacturer	Remarks
		Heatcon composite systems 600 Andover park e. Seattle, wa98188 Jr technology ltd. 81 north end, Meldreth Royston, herts, England Sg86nu Pyrometric service corp. 1312 s. 96th st. Seattle, wa98108-5010 Taycoengineering, inc.10874 hope st. P.O. Box 6034 Cypress, ca90630 Wichitech industries, Inc.Oakland center 8990 rt. 108 Columbia, md21045
Transformer, Portable (B)	Variablecontrol115-volt, 60-cycle		Use with heating blankets as A power supply
Vacuumunit (B)	Any unit compatible with Temperature control console		Includes vacuum pump and Transducer
Vacuumprobe, quickdisconnect	Vacu-valve, 401 round Base, 401a rectangular base	Airtech international, Inc. 5700 skylab road huntington beach, ca92647	Use for evacuation of air Inside bag film

technical composite panel aircraft



3. Special part

The invention relates to the repair, restoration or reconstruction of a composite article having a defect on the surface or throughout the thickness, which requires repair or eliminated. In the process of reconstruction or restoration of a composite article comprising a sponge layer, such as a cellular material having a defect, damaging the product, and wherein successively) placed on the bottom of the defect by at least one additional member or material, shape and dimensions of which correspond to the shape and size of the defect, b) inserted into the defect replaces the spongy part, g) is placed on the elements in the defect transferred sequentially stacked, a device such as a textile layer for draining gases released from the resin during step (d), and a sheath for the above-mentioned gas outlet forming the rest of the product chamber, sealed against the outer atmosphere surrounding the defect and the above additional elements and d) continuing to evacuate the sealed chamber is heated an additional element. An additional element or a material containing the above-mentioned continuous or chopped fibers, are mechanically robust, organized or unorganized, which is placed on the bottom of the defect, either separately or appropriately in relation to the fibers of the aforementioned element or the aforementioned material for the first resin placed on the receiving step d) of the polymeric matrix, wherein said fibers are distributed. Exchangeable cancellous portion is, for example, a honeycomb material, and b) placed on the outer portion of the second spongy resin with at least one element of fabric continuous or chopped fibers. Second resin is applied separately or as appropriate to the fibers of the above item. A radiation source which heats the additional element comprises an infrared radiation that is positioned with respect to the defect so as to irradiate the shell for discharging the gases released from the polymer matrix and with the proviso that the above-mentioned radiation source acting on the other side of the spongy part. The method allows to obtain a monolithic product that does not separate into components.

The present invention concerns mainly the product recovery or reconstruction, particularly composite articles or composite parts or products or items made of composite material having a defect to be corrected or eliminated by affecting at least its surface, and even its entire thickness. More specifically, the invention relates to the restoration or reconstruction or repair of articles such as defined hereinabove, by placing the above-mentioned defect in or on the above-mentioned defect, on the one hand the continuous or chopped fibers, are mechanically robust, organized, for example in the form of technical or fabric layer or fugitive example, in bulk or in non-woven form, and, on the other hand, a thermoplastic or a thermoplastic resin or a structured or structured polymeric material (a resin or mixture of polymers), in particular a thermosetting or termosshivaemogo, wherein the integer defines the solid matrix, which are distributed or arranged above the fiber.

As an example, the fibers are glass fibers, carbon fibers or Kevlar fibers, the resin is an epoxy or polyester, or a phenolic, or dimaleimidnuyu resin. These fibers may be separately placed into the defect from the resin, in this case, the above fibers are arranged in the above defect, for example in the form of superimposed layers of fabric, then the fabric weight is injected in liquid form resin or with a resin in this case Ready-to-drink use a composite material, such as pre-impregnated material comprising the weave formed by the above-mentioned fibers and the resin matrix, for example, semi-structured or unstructured. In all cases, the structure obtained by a defect or a defect, a so-called monolith or monolithic unit because in the solid state is virtually impossible to split, for example by peeling, to the aforementioned components, namely the fiber or fibers, with one hand, and resin, on the other hand.

As used herein and in the claims, unless otherwise indicated, the term "composite»is meant the structure, the article or material formed by joining heterogeneous materials or several basic components, namely in particular, fibers and resins interconnected and having a set of properties, especially mechanical, which does not possess any of the components individually.

As used herein, "resin»refers to polymeric materials which, in essence, can be identified by the term "adhesive»or "glue»such as structural, it is a curable or thermoplastic polymeric materials. In accordance with current repair of the domestic aviation company, and more specifically, the method of implementation, shown in Figure 1 of this document describes a method for recovery or reconstruction work, eg composite article having a defect, affecting at least its surface. According to this method: A - a defect or flaw is placed at least one additional member or material, shape and dimensions of which correspond to the shape and size of the above-mentioned defect, wherein the element or material comprises a continuous or chopped fibers, are mechanically robust, organized or disorganized; for example, the defect was placed in a superposition of layers of a fabric, connecting mechanically strong organized fibers; b - in the defect or the defect placed polymeric material or resin to produce a polymer matrix in which the fibers are distributed; for example, this polymer material is fed to a defect in a liquid form under pressure, thereby impregnating the above-mentioned fibers and the polymer after curing, yielding a solid polymeric matrix material in which the fibers are distributed; in - on an additional element impregnated polymer matrix and sequentially one above the other, are placed means for draining the gases released from the polymeric matrix during the next step (g) and the degassing membrane, forming with the rest of the article during recovery or Repair chamber, sealed towards the outside atmosphere surrounding the defect and the additional element;

As an example, a device for degassing is a layer of textile material for gas drainage; r - still evacuating the sealed chamber, an additional element is heated by a radiation source whose radiation comprises infrared radiation, placing this source with respect to the aforementioned defect so as to irradiate the sheath to remove gases released from the polymeric matrix. The current method of repair process identified before it is described only for the treatment or repair of massive articles of the same material, except for any product. On the other hand, today, to repair a monolithic composite article, for example, in the aviation industry, work as follows, as shown in Figure 1, which represents a schematic view:

- preparing, in particular, by cutting one or more elements of two or material, shape and dimensions corresponding to the shape and size of the defect 1a subject to removal or filling; This material, or the elements connected with each other or superposed on each other, are themselves a composite material, in the sense that they are inseparably combined polymer matrix and continuous or chopped fibers, organized or unorganized, mechanically durable, such as carbon, Kevlar, glass, etc.;

- Transferred and placed element or elements 2, or the thus prepared material into a defect or a defect of the work piece 1a;

- An element 2 and the product 1 is placed in series on one and the other side surface of the defect and other ones:

- a perforated or non-perforated film 9, non-adhesive with respect to the additional item 2, further processed, e.g. crosslink kable;

- A textile layer 3 to drain through its peripheral edge 3a of the gases that are released from a polymer matrix during its processing, for example, its cross-linking;

- Film 8, sealed with respect to the polymer material;

- A flexible heating device 10 as a cover, typically including heating electric resistances are immersed in an electrically insulating material such as silicone;

- Layer 11, the heat insulation relative to the surrounding environment;

- A flexible sheath 4 and for discharging the gases formed posredstom respective devices 12 (e.g., gaskets) with the rest of the chamber 5 of the article 1, sealed with respect to ambient atmosphere; this shell surrounds not only the defect 1a, and the additional element 2 but also all the superposed elements described before. The shell 4 for discharging gas, a vacuum, e.g., via a pump 13 and a flexible heating device is connected to the power source 14. Using appropriate controls, in particular temperature sensors, a heat treatment, for example, a polymeric matrix is subjected termosshivaniyu when this latter is heat-curable or crosslinkable polymer. The heat treatment is strictly controlled according to, inter alia, on the nature of the polymer matrix and the desired mechanical characteristics.

The present invention relates to the restoration or reconstruction of composite articles such as "sandwich", i.e. products having in their composition a solid layer of sponge, for example a material such as "honeycomb»of various materials, such as cardboard, impregnated with phenolic resin, plastic, and metal or a structural foam. This spongy layer is structurally connected at least on one side, with a monolithic layer such as defined before, i.e. combining a monoblock polymer matrix and the mechanically strong fibers distributed in the matrix. Today there is no satisfactory solution to allow repair or reconstruct composite products such as "sandwich", particularly when you can only get to the surface of the above-mentioned products.

In fact, in order to reconstruct or recover such a product, for example, the upper surface of an aircraft wing having a sandwich-like composite structure, defect is first treated to give it a regular or controlled geometry. Then, the bottom of the treated defect was placed resin or adhesive, and then an additional element of the sponge material, the sponge-aligned layer level repaired product, the resin also connecting it to the rest of the sponge layer; and finally, the monolithic layer to the level of the repaired product is applied mechanically strong fibers and the polymeric matrix layer for recovery in the above-mentioned defect. The application of heat and pressure required in order to connect and bind the set of elements or materials which fill the defect, and the latter with the rest of the products recovered or reconstructed provide, performing one or more times with the following operating steps:

- At the level of product in the repaired defect and successively placed one on top of another layer of the textile material to drain through its peripheral edge gases released from the polymeric matrix during the next step, the flexible heating means in the form of a cover, which includes electrical heating resistance immersed in the electrically material, such as silicone, and a shell for discharging the aforementioned gases, forming with the remaining part of the product chamber sealed with respect to ambient atmosphere surrounding the defect and the elements and materials that are placed therein;

- Still evacuating the sealed chamber through the flexible heating device is heated further elements and materials that cause or initiate the crosslinking of the polymer matrix in the case of a thermosetting resin. In the case of composite products having inaccessible surface such as inner, heat-treating the resin on the bottom of the defect does not exist other solutions than:

- Strongly heated by the heating device of the flexible core defect to try to reach the inner surface of the heat; but such a strong heat, besides the fact that it is not very effective, capable of repairing damage to the outer surface of the product; or in case it is necessary to cool the flexible heating device or along the periphery of the product;

- Remove the product to gain access to its interior surface, the repaired or replaced by a product that in some cases it is impossible or in any case is economically disadvantageous. In the first case, when the temperature cycle do not provide required for crosslinking the resin in the depth of the defect, the latter does not occur or is deficient, so that the entire reconstruction of the product is a compromise. Known reconstruction or restoration method of a composite article comprising a sponge layer, such as a cellular material having a defect, damaging the product, and wherein successively) placed on the bottom of the defect by at least one additional member or material, shape and dimensions of which correspond to the shape and size of the defect, b) inserted into the defect replaces the spongy part, g) is placed on the elements in the defect transferred sequentially stacked, a device, such as a textile layer for draining gases released from the resin during step (d), and a sheath retraction for the above gases, forming with the remaining part of the product chamber, sealed against the outer atmosphere surrounding the defect and the above additional elements and d) continuing to evacuate the sealed chamber is heated an additional element.

However, this method also provides for efficient recovery of the composite article due to the fact that crosslinking does not occur due to the depth of the defect resin. Object of the present invention is to find solutions for the reconstruction or restoration of composite products such as sandwich. According to the present invention, beyond all expectation, found that the use of a radiation source emitting infrared radiation disposed in relation to the treated defect so as to irradiate the shell for discharging the gases released from the polymer matrix allows the heat on the other side of the sponge layer sandwich composite articles with respect to the aforementioned shell degassing, and this despite the thermal resistance, normally exerted all spongy layer.

The problem is solved due to the fact that in the process of restoration or reconstruction of a composite article comprising a sponge layer, such as a cellular material having a defect, damaging the product, and wherein successively) placed on the bottom of the defect by at least one additional member or material, shape and whose dimensions correspond to the shape and size of the defect, b) inserted into the defect replaces the spongy part, g) is placed on the elements in the defect transferred sequentially stacked, a device such as a textile layer for draining gases released from the resin during step (d), and a sheath retraction for the aforementioned gases, forming with the remaining part of the product chamber, sealed against the outer atmosphere surrounding the defect and the above additional elements and d) continuing to evacuate the sealed chamber is heated an additional element or an additional element of the aforementioned material containing continuous or cut the fibers are mechanically strong, organized or unorganized, which are placed on the bottom of the defect, either separately or appropriately in relation to the fibers of the aforementioned elements or the aforementioned material, the first resin is placed, for the step (d) a polymeric matrix, wherein said fibers are distributed replacing spongy portion is, for example, a honeycomb material, and b) placed on the outer portion of the second spongy resin with at least one element of fabric continuous or chopped fibers, wherein the second resin is applied separately or appropriately in relation to the fibers of the aforementioned element, wherein a radiation source which heats the additional element comprises an infrared radiation that is positioned with respect to the defect so as to irradiate the shell for discharging the gases released from the polymer matrix and with the proviso that the above-mentioned radiation source acting on the other side of the spongy.

It is possible to exercise the method in one step. In addition, possible is the use of the first resin, the processing temperature which is substantially less than the processing temperature of the second resin. Proposed method can be implemented in two stages, namely a first step during which a resin is placed the bottom of the defect, replacing the aforementioned sponge inserted portion, for example, from the cellular material and initiate the operations (d) and (e), and a second step whereby the upper outer surface of the cancellous portion and the resin is applied again to commence operations (d) and (e).

The proposed method can be used an element of fabric is a composite, for example a prepreg, as it comprises the second resin forming a polymeric matrix in which the continuous or distributed chopped fibers. Moreover, each resin may be a polymeric material termos shivaemy or thermoplastic polymeric material. Infrared radiation may comprise radiation range included between 1 and 10 microns, while the radiation source may comprise at least one catalytic burner. Sheath degassing can be obtained on the basis of at least one material relatively transparent with respect to infrared radiation.

Another possible embodiment is a method of placing the first resin at the bottom of the defect and at least one other element of fabric continuous or chopped fibers. It is also possible to use other element of fabric which is a composite, for example a prepreg, as it comprises the first resin forming the resin matrix in which are distributed continuous or chopped fibers.

Furthermore, it is possible to use a composite product, which is a product of «sandwich» comprising a cancellous portion, and between two monolithic layers, the sponge layer was spongy and replacing parts can be made of a spongy material, for example, structural foam, such as an epoxy resin. It is also advisable to use tools for drainage gas, which is a grid, such as metal.

The present invention is described with reference to the accompanying drawings, in which:

- Figure 1 is a sectional view of the assembly that was prepared using the method of repair or renovation of the prior art;

- Fig. 2 is still a cross-sectional assembly which is produced using the method of repair or renovation of the invention, that which will then be applied according to the invention, composite articles such as "sandwich";

- Fig. 3 is a composite product such as "sandwich", reduced in accordance with the present invention;

- Figures 4 and 5 represent experimental setup allows exposure to prove the effectiveness of the infrared radiation, on the one hand through the shell to remove gases and, on the other hand, on the other side of the sponge layer which may belong to the composite article; According to these figures, reference numerals common to the reference numerals 1 to 3 denote the same elements or components or elements and components, although different, having the same function.

According to Figure 2, the repaired, reconstructed or recoverable product itself is made of a composite material is marked by reference numeral 1. It is, for example, a wall belonging wing aircraft. As a result of accidental impact, for example, is a composite product has a defect 1a, in this case, the hole that must be filled so as to restore the original product. First cut a hole or redraws to impart a predetermined correct form. For this purpose, one or more cut elements 2, which themselves are made of composite material is applied on one another and placed into the defect 1a so as to fill it, and this time to obtain a product repaired from a continuous surface both external and internal. Each element 2 is made of a composite material such as a polymer matrix comprises at least one polymeric material, e.g. a crosslinkable, wherein the distributed mechanically strong continuous or chopped fibers, e.g. carbon fibers; it is, for example, elements from the technical and / or preimpregnated fabric. These tissues and / or prepregs may be arranged alternately one above another. Suitable carbon fiber cloth under different names are available, for example from BROCHIER (France) called G801 and the respective prepregs are available, for example from HEXCEL (France) called REDUX 312L. These elements are placed in the hole 1a as shown in Figure 2, with a polymerizable resin, such as a polymer matrix based on at least one of the aforementioned cross-linkable polymeric material. Such resins are available from various companies, for example, STRUCTIL (France), in particular under the name EA9396. 2 additional items consistently and placed one above the other:

- A perforated or non-perforated film 9, non-adhesive with respect to the additional item 2, once crosslinked;

- A textile layer 3 for drainage gas via its peripheral edge 3a, namely, the gases released from the polymer matrix during the crosslinking step;

- Film 8, sealed relative to the liquid polymeric material, i.e. in relation to two elements of the matrix material;

- And finally, the casing 4 to discharge the gases produced through the gasket 12, with the rest of the chamber 5 of the article 1, sealed with respect to ambient atmosphere; this chamber surrounds defect 1a and 2 additional element.

According to the present invention, an additional element 2 is heated by placing an infrared source 6, for example, a catalytic burner 7 emits infrared radiation in the wavelength range from 1 to 10 microns, in relation to the defect 1a so as to irradiate the sheath 4 for discharging gases which at the same time, compressed as a result of pumping chamber 5, as described before. In contrast to the image in Figure 1, no longer using flexible heating device 10 and the heat insulating layer 11.

The catalytic burner is arranged per se known manner. It is a burner which allows the catalyst to burn mode of combustion air mixture, which is an oxidizing agent and fuel gas, passing through an inert refractory substrate, a perforated or permeable containing combustion catalyst. Namely, since the outer surface 15a of the substrate 15, the infrared radiation is emitted in the direction of the shell 4 for discharging gases.

Preferably, the shell 4 for discharging gases produced, starting from at least one material is relatively transparent with respect to infrared radiation emitted by the source 5, for example of polyamide or polyimide. The shell 4 for discharging gas may be arranged directly in contact with the textile layer 3 to a drainage. Control means 16, e.g. temperature sensors are located inside and / or outside of the shell 4 for discharging gas thus to control the heat treatment process, such as additional cross-linking polymer matrix product 2.

Many other radiation sources may be used provided that the emitted radiation meets the requirements described before. So, you can use an electric generator infrared radiation according to European Patent Application 0,147,340.

According to the present invention can eliminate the defect, e.g., in a wing of an aircraft, having a composite structure incorporates the type of "sandwich" comprising a cellular material, or any other filling spongy material, as follows:

- At the bottom of the defect cause a polymerizable resin, for example, already mentioned resin EA9396, and insert a replacement part honeycomb material;

- Act as described in relation to Figure 2 to implement the processing, for example polymerization or crosslinking of the resin, so that a replacement cell material is fixed in the structure, i.e. by placing one over another film 9, the layer 3 and the cladding 4, creating vacuum and directing on the repaired product infrared source;

- After cooling, the upper outer portion of cell material is re-applied to the same resin or prepreg and act as described in relation to FIG. 2, to fully integrate cell material in a composite structure;

- To align the outer surface finishing step is performed. This example can also be carried out only one step of repair, selecting two different resins, wherein the first requiring significant processing temperature of less than or polymerisation is applied to the bottom of the defect and then placed replacement honeycomb material, and the second having a higher processing temperature or polymerization is applied to a cell or tissue material prepregs so that the temperature produced by the source of infrared radiation, the polymerization was sufficient to build in a single step, wherein the thermal energy is exerted inside the defect is less significant than that on the outer surface of this latter. The process described before, was discovered and found to be valid with respect to its effectiveness, the experimental protocol described below with respect to Figures 4 and 5.

The experimental setup shown in Figure 4, is monitored and controlled by the control unit and portable operation, called ANITA, brand AN 8501, which in France is available at the company GMI, 204, Boulevard Saint Germain 75007 - PARIS. Starting from the substrate 1 or the flat product, upwards, superimposed:

- Or perforated film 9, for example, fabric coated material Teflon;

- Two elements 41 and 42 of the pre-impregnated fabric that is sold by HEXCEL called HEXCEL 1581 ES 36 D 50% (corresponding to the brand of fiberglass in 1581 by the same company, drenched in epoxy resin matrix brand ES 36 D of the same company, and the mass of resin corresponds to 50% of the total weight of the preimpregnated fabric);

- Measuring thermocouple 35 located between the two elements 41 and 42;

- A rectangular honeycomb structure element located inside the metal frame 36 of a material known as NOMEX, which is manufactured and sold by U.S. DUPONT DE NEMOURS, and respective honeycomb paper impregnated with the aromatic polyamide resin having aromatic rings connected in the meta position; honeycomb structure has a thickness of 55 mm and a hexagonal cell size 6h5h3 mm;

- Two layers of textile material 32 and 33, for example a nonwoven polymeric material, between which is inserted a thermocouple 34;

- Flexible heating device 10 containing electrical resistance, drenched in an insulating material such as silicon;

- A layer 31 of flexible for degassing of the heating device 10, the same layer 32 is arranged to degas by this device;

- And that end, a flexible membrane 4 for discharging gas generator through sealed connections 12 between this cladding and the substrate or article 1, a sealed chamber 5 containing the totality of the elements or components described before. Unlike FIG. 4, in accordance with Figure 5 experimental assembly shown in the latter no longer contains a flexible heating device 10 and the drainage layers 31 and 32 gases, as well as regulating the thermocouple 34. Drainage fixture consists of a metal mesh 44, located above the top surface of the element 24 from the cellular material. This metal mesh is supported by a frame 37 formed by two elements or edges of the nonwoven material, gripping the metal mesh 44 around the perimeter. Flexible heating device 10 is replaced by the infrared radiation source 6 located outside the flexible shell and radiating towards the latter. Element 24 from the cellular material has a thickness of 55 mm and a hexagonal cell shape (5h3h6 mm). Besides differences outlined before that, all other device parameters and operation remain the same. With the assembly of FIG. 4, in accordance with the requirements of provider preimpregnated fabric, flexible heating device 10 is programmed temperature cycle comprising:

- The temperature rise rate of 2.5°C / minute for about 40 minutes;

- A plateau at 120°C for 90 minutes;

- Lowering the temperature, ranging from 130 minutes.

When using thermocouples 35 ascertain that during the cycle before that particular temperature at pre-impregnated fabric is not more than 30°C, while the thermocouples 34 indicate that the top member 24 is about 110°C temperature. In these conditions it is impossible to get a good pre-polymerization of the polymer matrix impregnated fabric 41, as referred to 120C (corresponding to the plateau temperature) gave just slightly softened prepreg and still very flexible. In particular, it is possible to easily peel from the pre-impregnated member 41 of the fabric member 24 of the honeycomb material. Therefore, do not exhibit any signs of polymerization, taking into account the determined before this maximum temperature 30C. With the assembly 5, infrared radiation source is placed approximately 400 mm above the membrane degassing 4. This is a catalytic thermoreactor RX, such as sold by SUNKISS, infrared radiation which has the following characteristics:

- The power emitted by a unit surface area: 20 to 50 kW/m2;

- The infrared radiation lies in the range from 1 micron to 10 microns. Already, causing the radiation source to function, ascertain effective heating elements at 41 and 42, i.e. the thermocouples 35, that allows to adjust the temperature at these same prepreg elements that cannot be implemented with an assembly according to Figure 4. Thus, it is possible to control the temperature at the elements 41 and 42, by acting on the radiation source to obtain the temperature change almost exactly similar cycles required to crosslink the polymer matrix to yield, inter alia, the temperature plateau at 120^o C and, if necessary, even above. Upon completion of testing state that the polymer matrix is pre-impregnated members 41 and 42 apparently uniformly polymerized and dry to the touch. The resulting solid sheets and combined with the solid component 24 from the cellular material. Thus, taking into account the comparison of two tests carried out, allows the infrared source via the cellular polymerized prepreg material, which is impossible with a flexible heating device. The same test that identified before it can be carried out with similar results, with cellular material from other types, such as aluminum, brand Derenid, selling French firm EDERENA CONCEPT. Thanks to the invention according to Figure 3, and it becomes possible to reconstruct or restore Sandwich composite article comprising a sponge layer 22, such as honeycomb molded between two layers 21 and 20. Order to accomplish this, the defect 1a is first treated to make a monolithic layer of a hole 20 with bevelled edges in the spongy layer of the cylindrical bore 22, and a monolithic layer 21 again opening with bevelled edges. Several elements 23 cut out of pre-impregnated fabrics were placed one on another in a chamfered hole in a monolithic layer 20. Then element 24 of honeycomb material are placed into a cylindrical hole in the cancellous layer 22, for example, with a curable resin. Finally, several elements 2 are cut from the pre-impregnated fabric was placed one on another in a chamfered hole in a monolithic layer 21. With all these elements completely fill the defect 1a, reaching the same level as at the outer surface of the article 1, and with respect to its inner surface. Then, at the top of a monolithic layer 21, limiting defect 1a, in one or two stages of manufacture proceeds as described before in relation to this figure 2.

Claim1. Reconstruction or recovery method for a composite article (1), comprising a sponge layer (22), for example, a cellular material having a defect (1a), damaging the product, and wherein successively) placed on the bottom of the defect (1a), at least One additional member or material, shape and dimensions of which correspond to the shape and size of the defect (1a), b) inserted in the defect (1a) which replaces the spongy portion (24), g) are placed on the items carried in the defect (1a), sequentially over each another device, such as a textile layer (3) for draining the gases released from the resin during step (d) and the sheath (4) for removal of the aforementioned gases, forming with the remaining part of the product chamber (5), sealed with respect to the the outer atmosphere surrounding the defect (1a) and the aforementioned additional elements and d) continuing to evacuate the sealed chamber (5), an additional element is heated, characterized in that the additional element or the above-mentioned material include continuous or chopped fibers, are mechanically robust, organized or unorganized that placed on the bottom of the defect (1a) separately or appropriately in relation to the fibers of the aforementioned element or the aforementioned material, the first resin is placed, for the step (d) a polymeric matrix, wherein said fibers are distributed replacing cancellous portion is, for example, in a cellular material, and b) placed on the outer portion of the spongy part (24) with the second resin is at least one element (2) of fabric continuous or chopped fibers, wherein the second resin is applied separately or appropriately in relation to the aforementioned fibers element, wherein the radiation source (6), which was heated an additional element comprising the infrared is placed in relation to the defect (1a) so as to irradiate the sheath (4) for discharging the gases released from the polymer matrix and with the proviso that above-mentioned light source acts on the other side of the spongy (24).

2. Method according to claim 1, characterized in that it is carried out in one step.

3. Method according to claim 2, characterized in that the first resin requires a processing temperature of less significant than the processing temperature of the second resin.

4. Method according to claim 1, characterized in that the method is carried out in two stages, namely a first step during which the bottom of the defect (1a) are placed the resin sponge is inserted into the above-mentioned substitute part (24), for example of honeycomb material and proceed to step (d) and (e), and a second step whereby the upper outer surface of the cancellous portion (24) is applied to the resin and again proceed to step (d) and (e).

5. Method according to claim 1, characterized in that the element (2) of fabric is a composite, for example a prepreg, as it comprises the second resin forming a polymeric matrix in which the continuous or distributed chopped fibers.

6. Method according to claim 1, characterized in that each resin is a polymeric material termosshivaemy.

7. Method according to claim 1, characterized in that each resin is a thermoplastic resin material.

8. Method according to claim 1, characterized in that the infrared radiation comprises a radiation range included between 1 and 10 microns.

9. Method according to claim 1, characterized in that the radiation source (6) comprises at least one catalytic burner (7).

10. Method according to claim 1, characterized in that the degassing membrane (4) is obtained on the basis of at least one material relatively transparent with respect to infrared radiation.

11. Method according to claim 1, characterized in that the resin is first placed on the bottom of the defect (1) with at least one other element (23) made of cloth with continuous or chopped fibers.

12. Method according to claim 1, characterized in that the other element (23) of fabric is a composite, for example a prepreg, as it comprises the first resin forming the resin matrix in which are distributed continuous or chopped fibers.

13. Method according to claim 1, characterized in that the composite article is an article such as "sandwich", and comprises a spongy portion (24) between two monolithic layers (21) and (22).

14. Method according to claim 1, characterized in that the spongy layer (22) and replaces a part (24) made of spongy material, for example, structural foam, such as an epoxy resin.

15. Method according to claim 1, characterized in that the means (3) for draining the gases constituting the mesh, such as metal.

Safety during repair

During the repair of structures arise from PCM dangerous and harmful production factors, namely:

excessive dust and fumes in the air of the working area; an increased current value to the power supply circuit of the heating device and the heating device for the repair area;

local vibration and noise exceeding the allowable value when working with pneumatic tools;

workplace location at heights;

deviation of microclimate parameters in the production room from the optimal values;

inadequate lighting in the workplace; occurrence of static electricity; toxic vapors;

Unusual fire and explosion hazards of some of the materials used.

Characteristics of substances used for toxicological indicators lam, hazard class and the maximum permissible concentration of harmful substances in the air are in tabl. 3

During repair work, be sure to observe the requirements of OST 1.42199-84 "SSBT. Works adhesive. General requirements for safety, "Safety and industrial sanitation when working with epoxy resins and materials based on these and other legal materials, acting on the aviation industry.

Tabl. 3

Characteristics, the substances in the air of the working area

Substance	Harmful components	Phisical state	mg/m	Class of Danger	Toxicological characteristic
1	2	3	4	5	6
Petrol	Petrol	fume	100	4	The drug, acts on respiratory system
Solvent R-5	Xylol	Fume	50	3	The drug, acts on blood, irritates mucous
Ethyl acetate	Ethyl-acetate	fume	50	3	Drug, irritate mucous, act on blood
Fiberglass	Dustglass	Dust	4	4	Irritability, fibrogenic effect, causes of eczema, dermatitis.
Hexaflurio-selecate	Sodium ftuoride	Couples, aerosol	0,5	2	Irritability skin, mucous membrane of the eyes, upper respiratory tract
Aluminium powder	Aluminium powder	Dust	2	4

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