Adhesive injection method and structure

An adhesive injection method is for injecting an adhesive that bonds an outer plate and a reinforcing member. The reinforcing member has through holes bored through the reinforcing member in a direction intersecting a bonding surface facing the outer plate. The method includes positioning the outer plate and the reinforcing member; disposing a sealing material covering a gap between the outer plate and the reinforcing member; and injecting the adhesive into the through holes in order from one end to the other end of the bonding surface. At the injecting, while the adhesive is injected into the through hole, when the adhesive is recognized through another through hole formed adjacent to the through hole into which the adhesive is being injected, a through hole into which the adhesive is to be injected is shifted from the through hole into which the adhesive is being injected to the other through hole.

FIELD

The present invention relates to a method for injecting an adhesive and a structure manufactured by injecting the adhesive.

BACKGROUND

Various kinds of materials having a light weight and high strength are known, including composite materials obtained by impregnating reinforcing fibers with a resin. Composite materials are used for aircrafts, cars, and ships, for example. Composite materials are bonded to other composite materials and used as structures. Various methods for bonding a plurality of composite materials are known, including methods of applying an adhesive between a plurality of composite materials to be bonded (refer to Japanese Patent Application Laid-open No. 2003-011231 and Japanese Patent Application Laid-open No. 2012-220023).

FIG. 10is a schematic of a conventional structure100of composite materials.FIG. 11is an enlarged schematic of the conventional structure100of the composite materials.FIG. 12is a sectional schematic of an example of one state in a method for injecting an adhesive in manufacturing the conventional structure100of the composite materials.FIG. 13is a sectional schematic of the conventional structure100of the composite materials.FIG. 11is an enlarged view of an area D inFIG. 10.FIGS. 12 and 13are sectional views viewed from the E-E section inFIG. 11.

As illustrated inFIGS. 10 and 11, the conventional structure100of the composite materials includes an outer plate102, a reinforcing member104, and an adhesive106. As illustrated inFIG. 11, to a bonded surface102sof the outer plate102, a bonding surface104sof the reinforcing member104is bonded with the adhesive106interposed therebetween. The bonding surface104sof the reinforcing member104is bonded to the bonded surface102sof the outer plate102with the adhesive106interposed therebetween. The adhesive106is provided to an area between the bonded surface102sof the outer plate102and the bonding surface104sof the reinforcing member104to bond the bonded surface102sof the outer plate102and the bonding surface104sof the reinforcing member104.

If the outer plate102and the reinforcing member104need to be precisely positioned in the structure100of the composite materials, it is necessary to bond the outer plate102and the reinforcing member104by positioning the outer plate102and the reinforcing member104in advance and injecting the liquid adhesive106using an adhesive injector122from a gap between the bonded surface102sof the outer plate102and the bonding surface104sof the reinforcing member104into the area therebetween as illustrated inFIG. 12. In the following description, the area between the bonded surface102sof the outer plate102and the bonding surface104sof the reinforcing member104is referred to as an adhesive injection area. In the following description, the gap between the bonded surface102sof the outer plate102and the bonding surface104sof the reinforcing member104is simply referred to as a gap. In the conventional structure100of the composite materials, it cannot be checked whether air bubbles remain in the adhesive injection area when the liquid adhesive106is injected from the gap. As a result, the adhesive106includes an air bubble107as illustrated inFIG. 13, thereby reducing the bonding strength between the outer plate102and the reinforcing member104.

FIG. 14is a sectional schematic of another example of one state in the method for injecting the adhesive in manufacturing a conventional structure110of the composite materials. In the conventional structure110of the composite materials, as illustrated inFIG. 14, the adhesive106additionally includes tapered portions106tformed in a tapered shape extending from the reinforcing member104to the outer plate102at gap portions. If the gap portions of the adhesive106need to have resistance to external stress in the structure of the composite materials, it is necessary to form the tapered portions106tat the gap portions of the injected adhesive106using a taper former112, such as a taper-forming spatula, like the structure110of the composite material. In the conventional structure110of the composite materials, it cannot be checked whether air bubbles remain in the adhesive injection area when the liquid adhesive106is injected from the gap. As a result, the adhesive106includes air bubbles similarly to the conventional structure100of the composite materials, thereby reducing the bonding strength between the outer plate102and the reinforcing member104.

As described above, in both cases of manufacturing the conventional structure100of the composite materials illustrated inFIG. 13and manufacturing the conventional structure110of the composite materials illustrated inFIG. 14, it cannot be checked whether air bubbles remain in the adhesive injection area when the liquid adhesive106is injected from the gap. As a result, the adhesive106includes air bubbles, thereby reducing the bonding strength between the outer plate102and the reinforcing member104.

In view of the disadvantages described above, the present invention has an object to provide a method for injecting an adhesive and a structure that enable checking that no air bubble remains in an adhesive injection area when the adhesive is injected, reducing the number of air bubbles included in the adhesive, and suppressing reduction in the bonding strength between composite materials.

SUMMARY OF THE INVENTION

To solve the problems described above and achieve the object, an adhesive injection method is a method for injecting an adhesive that bonds an outer plate and a reinforcing member. The reinforcing member has a plurality of through holes bored through the reinforcing member in a direction intersecting a bonding surface facing the outer plate. The adhesive injection method includes a positioning step of positioning the outer plate and the reinforcing member; a sealing material disposing step of disposing a sealing material that covers a gap between the outer plate and the reinforcing member; and an injecting step of injecting the adhesive into the through holes in order from one end to the other end of the bonding surface. At the injecting step, while the adhesive is injected into the through hole, when the adhesive is recognized through another through hole formed adjacent to the through hole into which the adhesive is being injected, a through hole into which the adhesive is to be injected is shifted from the through hole into which the adhesive is being injected to the other through hole.

With this configuration, the adhesive is injected into and fills in the through holes of the reinforcing member. As a result, air bubbles are removed from the other end of the bonding surface, the gap, and the through holes into which the adhesive is not injected. The adhesive is checked from another through hole formed adjacent to the first through hole into which the adhesive is being injected. Consequently, the configuration enables checking that no air bubble remains in an adhesive injection area when the adhesive is injected, reducing the number of air bubbles included in the adhesive, and suppressing reduction in the bonding strength between the composite materials.

In this configuration, preferably, the sealing material forms the adhesive injected at the injecting step into a tapered shape tapering from the reinforcing member to the outer plate. This configuration can stabilize the quality of the portion formed in a tapered shape and increase the resistance to external stress at a gap portion of the adhesive. In addition, the configuration requires less work to form the adhesive into a tapered shape.

In the configuration in which the adhesive is formed into the tapered shape, preferably, the sealing material has flexibility and changes its shape in such a manner to swell toward an outside of the gap as the adhesive is injected at the injecting step. This configuration can form the gap portion of the adhesive into a desired tapered shape using shrinkage of the adhesive accompanying curing. The configuration can further stabilize the quality of the portion formed in a tapered shape.

In the configuration in which the adhesive is formed into the tapered shape, preferably, the sealing material is a dam member which is a rigid body and an inside of which is formed in a tapered shape tapering from the reinforcing member to the outer plate. This configuration can form the gap portion of the adhesive into a desired tapered shape corresponding to the inner shape of the dam member. The configuration can further stabilize the quality of the portion formed in a tapered shape.

In the configurations described above, preferably, the sealing material includes a plurality of divided sealing pieces, and at the sealing material disposing step, the sealing pieces are disposed in order from the one end to the other end of the bonding surface, and before the adhesive injected at the injecting step protrudes beyond a range of a previously disposed sealing piece, a sealing piece is additionally disposed. This configuration can maintain the state of being capable of removing air bubbles from the other end of the bonding surface corresponding to an injection state of the adhesive.

In the configurations described above, preferably, at the injecting step, suction is performed through the through hole formed adjacent to the through hole, and when the adhesive is recognized through the through hole formed adjacent to the through hole into which the adhesive is being injected, a through hole through which suction is to be performed is shifted from the through hole through which the suction is being performed to another through hole formed adjacent to the through hole through which the suction is being performed. With this configuration, air bubbles are removed by the suction. Consequently, the configuration enables further reducing the number of air bubbles included in the adhesive and suppressing reduction in the bonding strength between the composite materials.

In the configurations described above, preferably, at the injecting step, a lid member is attached to the through hole on which injection of the adhesive is completed. This configuration can prevent the adhesive from leaking from the through hole on which injection of the adhesive is completed.

In the configuration in which the lid member is attached, preferably, the lid member includes a lid body that covers the through hole; a protrusion extending in a protruding manner in a direction from the lid body toward the outer plate; and a stopper provided at a position of a predetermined length from a front end of the protrusion toward the lid body and that prevents the lid member from coming off from the through hole, and the lid member keeps the thickness of the adhesive at a length defined based on the predetermined length. This configuration can prevent the lid member from coming off from the through hole and keep the thickness of the adhesive at a length defined based on the predetermined length.

In the configurations described above, preferably, the bonding surface extends in a certain direction, the through holes are formed in a pair of two columns extending in the certain direction in a staggered manner, and the sealing material extends in the certain direction and covers the gap formed on both sides. This configuration requires the bonding surface with a smaller area and a smaller number of through holes and can increase the reinforcing effect of the reinforcing member.

In the configuration in which the bonding surface is formed to extend in a certain direction, preferably, the reinforcing member includes a flange extending in a direction along the bonding surface; and a web extending in a direction intersecting the bonding surface and in the certain direction, and the through holes are formed in a pair of two columns in a staggered manner with the web sandwiched therebetween. This configuration requires the bonding surface with a smaller area and a smaller number of through holes and can further increase the reinforcing effect of the reinforcing member.

To solve the problems described above and achieve the object, a structure includes an outer plate; a reinforcing member; and an adhesive that bonds the outer plate and the reinforcing member. The reinforcing member includes a plurality of through holes bored through the reinforcing member in a direction intersecting a bonding surface facing the outer plate, and the adhesive is injected into the through holes.

With this configuration, the adhesive is injected from the through holes of the reinforcing member. As a result, air bubbles are removed from the other end of the bonding surface, the gap, and the through holes into which the adhesive is not injected. The adhesive is checked through another through hole formed adjacent to the first through hole into which the adhesive is being injected. Consequently, the configuration enables checking that no air bubble remains in the adhesive injection area when the adhesive is injected, reducing the number of air bubbles included in the adhesive, and suppressing reduction in the bonding strength between the composite materials.

In this configuration, preferably, the adhesive is formed in a tapered shape tapering from the reinforcing member to the outer plate. This configuration can stabilize the quality of the portion formed in a tapered shape and increase the resistance to external stress at the gap portion of the adhesive. In addition, the configuration requires less work to form the adhesive in a tapered shape.

In the configurations described above, preferably, the structure further includes a lid member attached to the through hole, and the lid member includes a lid body that covers the through hole; a protrusion extending in a protruding manner in a direction from the lid body toward the outer plate; and a stopper provided at a position of a predetermined length from a front end of the protrusion toward the lid body and that prevents the lid member from coming off from the through hole. This configuration can prevent the adhesive from leaking from the through hole. Furthermore, the configuration can prevent the lid member from coming off from the through hole and keep the thickness of the adhesive at the predetermined length.

In the configurations described above, preferably, the bonding surface extends in a certain direction, and the through holes are formed in a pair of two columns extending in the certain direction in a staggered manner. This configuration requires the bonding surface with a smaller area and a smaller number of through holes and can increase the reinforcing effect of the reinforcing member.

In the configuration in which the bonding surface formed to extend in a certain direction, the reinforcing member includes a flange extending in a direction along the bonding surface; and a web extending in a direction intersecting the bonding surface and in the certain direction, and the through holes are formed in a pair of two columns in a staggered manner with the web sandwiched therebetween. This configuration requires the bonding surface with a smaller area and a smaller number of through holes and can further increase the reinforcing effect of the reinforcing member.

Advantageous Effects of Invention

The present invention can provide a method for injecting an adhesive and a structure that enable checking that no air bubble remains in an adhesive injection area when the adhesive is injected, reducing the number of air bubbles included in the adhesive, and suppressing reduction in the bonding strength between composite materials.

DESCRIPTION OF EMBODIMENTS

Embodiments according to the present invention will be described below in detail with reference to the accompanying drawings. The embodiments are not intended to limit the invention. Components according to the embodiments include components easily conceivable and replaceable by those skilled in the art and components substantially identical therewith. Furthermore, the components described below may be appropriately combined.

First Embodiment

FIG. 1is a schematic of a structure10of composite materials according to a first embodiment. As illustrated inFIG. 1, the structure10of the composite materials includes an outer plate12, a reinforcing member14, and an adhesive16. To a bonded surface12sof the outer plate12, a bonding surface14sof the reinforcing member14is bonded with the adhesive16interposed therebetween. The bonding surface14sof the reinforcing member14is bonded to the bonded surface12sof the outer plate12with the adhesive16interposed therebetween. The outer plate12and the bonded surface12sface the reinforcing member14and the bonding surface14sin a direction orthogonal to the surfaces. In the present embodiment, a member to be reinforced is referred to as the outer plate12, and a member that reinforces the member to be reinforced is referred to as the reinforcing member14for convenience of detailed explanation. The combination of members bonded by the adhesive16is not limited thereto and may include combinations of any members having shapes capable of being bonded. The adhesive16is provided to an area between the bonded surface12sof the outer plate12and the bonding surface14sof the reinforcing member14to bond the bonded surface12sof the outer plate12and the bonding surface14sof the reinforcing member14. In the following description, the area provided with the adhesive16between the bonded surface12sof the outer plate12and the bonding surface14sof the reinforcing member14is referred to as an adhesive injection area.

The outer plate12is a plate of the composite material extending in a direction along a plane including the bonded surface12sand includes the bonded surface12s. The reinforcing member14is a T-shaped member extending in a longitudinal direction along the bonding surface14s, that is, a Z-direction inFIG. 1. As illustrated inFIG. 1, the reinforcing member14includes a flange15aand a web15b. The flange15aextends in a direction along the bonding surface14s. The web15bextends in a direction intersecting the bonding surface14sand along the Z-direction. The reinforcing member14includes a first member14a, a second member14b, a third member14c, and a fourth member14d. The first and second members14aand14bare L-shaped members of the composite material extending along the Z-direction. The third member14cis a plate of the composite material extending in a direction along a plane including the bonding surface14sand includes the bonding surface14s. The fourth member14dis a triangular prismatic member of the composite material extending along the Z-direction.

A first outside surface of the first member14aforming the L-shape is bonded to a second outside surface of the second member14bforming the L-shape. A second outside surface of the first member14aforming the L-shape is bonded to a first part of the third member14cwith respect to a center line along the Z-direction on the surface opposite to the bonding surface14s. A first outside surface of the second member14bforming the L-shape is bonded to a second part of the third member14cwith respect to the center line along the Z-direction on the surface opposite to the bonding surface14s. The second outside surface of the second member14bforming the L-shape is bonded to the first outside surface of the member14aforming the L-shape. The first part of the third member14cwith respect to the center line along the Z-direction on the surface opposite to the bonding surface14sis bonded to the second outside surface of the first member14aforming the L-shape. The second part of the third member14cwith respect to the center line along the Z-direction on the surface opposite to the bonding surface14sis bonded to the first outside surface of the second member14bforming the L-shape. The fourth member14dis disposed so as to fill a space formed by a curve on the outside surface of the first member14aforming the L-shape, a curve on the outside surface of the second member14bforming the L-shape, and a part of the third member14cnear the center line along the Z-direction on the surface opposite to the bonding surface14s. The fourth member14dis bonded to the members14a,14b, and14c. The members14a,14b,14c, and14dmay be bonded by curing of a resin included in the composite materials, which will be described later, or by the adhesive for bonding the composite materials.

The flange15aincludes a part of the first member14aincluding the second surface forming the L-shape, a part of the second member14bincluding the first surface forming the L-shape, and the third member14c. The web15bincludes a part of the first member14aincluding the first surface forming the L-shape and a part of the second member14bincluding the second surface forming the L-shape.

The reinforcing member14includes a plurality of through holes bored therethrough in a direction intersecting the bonding surface14s. The through holes are a through hole18a, a through hole18b, a through hole18c, a through hole18d, a through hole18e, a through hole18f, a through hole18g, a through hole18h, a through hole18i, and a through hole18j(refer toFIGS. 3 and 4on the through holes18b,18d,18f,18h, and18j). The through holes18ato18jare formed in this order from one end of the bonding surface14s, that is, the end in the −Z-direction inFIG. 1to the other end of the bonding surface14s, that is, the end in the +Z-direction inFIG. 1.

Specifically, the through holes18ato18jare bored through the flange15aincluded in the reinforcing member14in a direction orthogonal to the bonding surface14s. More specifically, the through holes18a,18c,18e,18g, and18iare bored through the part of the first member14aincluding the second surface forming the L-shape and the third member14cincluded in the reinforcing member14, and are formed in a line in the direction along the Z-direction. The through holes18b,18d,18f,18h, and18jare bored through the part of the second member14bincluding the first surface forming the L-shape and the member14cand are formed in a line in a direction along the Z-direction. In other words, the through holes18ato18jare formed in a pair of two columns in a staggered manner with the web15bsandwiched therebetween from the end in the −Z-direction to the end in the +Z-direction in the flange15a.

The through holes18ato18jare formed side by side successively from the end in the −Z-direction to the end in the +Z-direction. In other words, the through hole18aand the through hole18bare formed adjacent to each other, the through hole18band the through hole18care formed adjacent to each other, the through hole18cand the through hole18dare formed adjacent to each other, the through hole18dand the through hole18eare formed adjacent to each other, the through hole18eand the through hole18fare formed adjacent to each other, the through hole18fand the through hole18gare formed adjacent to each other, the through hole18gand the through hole18hare formed adjacent to each other, the through hole18hand the through hole18iare formed adjacent to each other, and the through hole18iand the through hole18jare formed adjacent to each other.

The adhesive16is injected into and fills in the through holes18ato18j. The adhesive16injected into and filling in the through holes18ato18jare integrated with the adhesive16in the adhesive injection area.

The composite materials used for the structure10, the outer plate12, and the reinforcing member14are materials used for aircrafts, cars, and ships, for example. The composite materials include reinforcing fibers that reinforce the composite material and a resin impregnated into the reinforcing fibers, for example. The reinforcing fiber is a bundle of the order of several hundred to several thousand base fibers in a range of equal to or larger than 5 μm and equal to or smaller than 7 μm, for example. The base fibers constituting the reinforcing fibers are carbon fibers, for example. The base fibers constituting the reinforcing fibers are not limited thereto and may be other plastic fibers, glass fibers, or metal fibers, for example. While the resin impregnated into the reinforcing fibers is preferably a thermosetting resin, it may be a thermoplastic resin. Examples of the thermosetting resin include, but are not limited to, epoxy resin, etc. Examples of the thermoplastic resin include, but are not limited to, polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyphenylenesulfide (PPS), etc. The resin impregnated into the reinforcing fibers is not limited thereto and may be other resins.

The adhesive16may be any kind of adhesive as long as it can bond the composite materials. The adhesive16is preferably integrated with the composite materials and include the resin used for the composite materials, for example. The use of the resin can increase the bonding strength between the composite materials.

The structure10has a gap between the bonded surface12sof the outer plate12and the bonding surface14sof the reinforcing member14. Through the gap, the adhesive16is exposed from the outer plate12and the reinforcing member14. In the following description, the gap between the bonded surface12sof the outer plate12and the bonding surface14sof the reinforcing member14is simply referred to as a gap. The gaps extend in the Z-direction on both sides of the bonding surface14sbecause the outer plate12and the reinforcing member14of the structure10extend in the Z-direction.

The structure10may include a sealing material (i.e., a seal)20that covers the gaps formed on both (opposite) sides of the bonding surface14s. The sealing material (seal)20is a discrete element with respect to the adhesive (i.e., is not simply a portion of the adhesive), and is disposed in a method of injecting the adhesive16, which will be described later. One side of the sealing material (seal)20is fixed to the reinforcing member14, and the other side thereof is fixed to the outer plate12, thereby covering the gap. As illustrated inFIG. 1, the sealing material (seal)20includes a plurality of divided pieces, that is, a sealing piece (first seal member)20a, a sealing piece (second seal member)20b, a sealing piece (third seal member)20c, and a sealing piece (fourth seal member)20d. The sealing material20and the sealing pieces20ato20dmay be tape-like members made of a flexible material or dam members made of a rigid material.

One side of each of the sealing pieces20aand20cis fixed to the part of the member14aof the reinforcing member14including the second surface forming the L-shape without covering the through holes18a,18c,18e,18g, and18i. The sealing piece20aand the sealing piece20care disposed in this order from the end in the −Z-direction to the end in the +Z-direction. The sealing pieces20aand20ccover the gap formed on one side and can be connected to and separated from each other. The first sides of the sealing pieces20band20dare fixed to the part of the member14bof the reinforcing member14including the first surface forming the L-shape without covering the through holes18b,18d,18f,18h, and18j. The sealing piece20band the sealing piece20dare disposed in this order from the end in the −Z-direction to the end in the +Z-direction. The sealing pieces20band20dcover the gap formed on the other side and can be connected to and separated from each other.

The structure10has the configuration described above. Because the adhesive16is injected into and fills in the through holes18ato18jof the reinforcing member14, air bubbles are removed from the end in the +Z-direction corresponding to the other end of the bonding surface14s, the gaps, and the through holes into which the adhesive16is not injected. The adhesive16is checked through an adjacent second one of the through holes formed adjacent to a first through hole into which the adhesive16is being injected. Consequently, the structure10enables checking that no air bubble remains in the adhesive injection area when the adhesive16is injected, reducing the number of air bubbles included in the adhesive16, and suppressing reduction in the bonding strength between the composite materials.

In the structure10, the bonding surface14sextends in the Z-direction, and the through holes18ato18jare formed in a pair of two columns extending in the Z-direction in a staggered manner. Consequently, the structure10requires the bonding surface14swith a smaller area and a smaller number of through holes18ato18jand can increase the reinforcing effect of the reinforcing member14.

In the structure10, the through holes18ato18jare formed in a pair of two columns extending in the Z-direction in a staggered manner with the web15bsandwiched therebetween in the flange15a. Consequently, the structure10requires the bonding surface14swith a smaller area and a smaller number of through holes18ato18jand can increase the reinforcing effect of the reinforcing member14.

Because the structure10includes the sealing material (seal)20that covers the gaps, it can protect gap portions of the adhesive16from the outside. In the structure10, the sealing material20that covers the gaps includes a plurality of divided pieces, that is, the sealing pieces20a,20b,20c, and20d. With this configuration, appropriate replacement of the sealing pieces20a,20b,20c, and20dcan suitably protect the gap portions of the adhesive16from the outside.

The sealing material (seal) does not necessarily have the structure of the sealing material20described above and may extend toward the through holes18ato18j. This structure is preferably employed because the through holes18ato18jcan be covered with the part of the sealing material extending toward the through holes18ato18jafter the adhesive16is injected thereinto.

The sealing material (seal) may have through holes. The through holes may be formed at desired positions in the sealing material or at the boundaries between the sealing pieces constituting the sealing material, for example. In this case, the through holes formed in the reinforcing member14and the through holes formed in the sealing material (seal)20are successively used to remove air bubbles, check that no air bubble remains, and inject the adhesive16. Consequently, this structure requires a smaller number of through holes formed in the reinforcing member14, thereby further increasing the reinforcing effect of the reinforcing member14. Alternatively, the sealing material (seal) may have through holes, and the reinforcing member14may have no through hole. Also in this case, the through holes formed in the sealing material are successively used to remove air bubbles, check that no air bubble remains, and inject the adhesive16. Consequently, this structure requires no through hole formed in the reinforcing member14, thereby further increasing the reinforcing effect of the reinforcing member14.

FIG. 2is a flowchart of the method for injecting the adhesive16according to the first embodiment.FIG. 3is a schematic configuration diagram of one state in the method for injecting the adhesive16according to the first embodiment.FIG. 4is a schematic configuration diagram of another state in the method for injecting the adhesive16according to the first embodiment.FIGS. 3 and 4are schematics viewed from the A-A direction inFIG. 1. The following describes the method for injecting the adhesive16according to the first embodiment with reference toFIGS. 1 to 4. As illustrated inFIG. 2, the method for injecting the adhesive16includes a positioning step (Step S12), a sealing material disposing step (Step S14), and an injecting step (Step S16).

First, the positions of the outer plate12and the reinforcing member14to be bonded by the adhesive16are determined (Step S12). Specifically, the position of the reinforcing member14with respect to the outer plate12is determined. More specifically, the positions of the bonding surface14sof the reinforcing member14and the bonded surface12sof the outer plate12facing the bonding surface14sin the direction orthogonal thereto, the angle between the bonding surface14sand the bonded surface12s, and the space between the bonding surface14sand the bonded surface12sare determined. As a result, the adhesive injection area and the gaps are formed between the bonding surface14sand the bonded surface12s.

Subsequently, the sealing material (seal)20that covers the gaps is disposed (Step S14). Specifically, one side of the sealing material (seal)20is fixed to a predetermined position on the reinforcing member14, and the other side thereof is fixed to a predetermined position on the outer plate12. Other parts of the sealing material20are not necessarily fixed, or the whole part other than the part facing the gaps may be fixed. As a result, the adhesive injection area serves as a space with its gaps covered. As illustrated inFIG. 3, for example, the sealing pieces (seal members)20a,20b,20c, and20dare disposed at once to cover the gaps extending in the Z-direction.

Subsequently, the adhesive16before cured is successively injected into the through holes18ato18jfrom a first end in the −Z-direction to the second end in the +Z-direction using an adhesive injector22illustrated inFIG. 4(Step S16). Specifically, the adhesive16is injected into the through hole18aformed closest to the end in the −Z-direction. Subsequently, the adhesive16is injected into the through hole18bformed second closest to the end in the −Z-direction. Similarly, the adhesive16is injected into the through holes18c,18d,18e,18f,18g,18h,18i, and18jin order. As a result, the adhesive16is successively injected into the adhesive injection area from the end in the −Z-direction to the end in the +Z-direction.

At Step S16, as illustrated inFIG. 4, while the adhesive16is being injected into a first through hole18a, when the adhesive16can be recognized through a second through hole18bformed adjacent to the first through hole18ainto which the adhesive16is being injected, the through hole into which the adhesive16is to be injected is shifted from the first through hole18ato the second through hole18b. As illustrated inFIG. 4, the stage when the adhesive16can be recognized through the through hole18bindicates a stage when the adhesive16can be visually recognized through the second through hole18b, that is, a stage when the adhesive16reaches the penetrating direction of the second through hole18b. Alternatively, the stage when the adhesive16can be recognized through the second through hole18bmay be a stage when the adhesive16starts protruding from the second through hole18b. At this stage, it is determined that injection of the adhesive16into the first through hole18ais completed.

Similarly, at Step S16, the through hole into which the adhesive16is to be injected is shifted from the end in the −Z-direction to the end in the +Z-direction, that is, the through holes18c,18d,18e,18f,18g,18h,18i, and18jin order subsequently to the through holes18aand18b. As a result, the adhesive16is injected into the adhesive injection area from the end in the −Z-direction to the end in the +Z-direction.

At Step S16, when the adhesive16is being injected into the first through hole18a, air bubbles are removed from the gaps on the end in the +Z-direction and the remaining through holes18bto18jinto which the adhesive16has not yet been injected. When the adhesive16is being injected into the second through hole18b, air bubbles are removed from the gaps on the end in the +Z-direction and the remaining through holes18cto18jinto which the adhesive16is not injected. Similarly, when the adhesive16is being injected into any one of the through holes, air bubbles are removed from the gaps on the end in the +Z-direction and the through holes into which the adhesive16is not injected. As a result, the adhesive injection area is cleared of the air bubbles and filled with the adhesive16.

After the adhesive16injected at Step S16is solidified, the sealing material (seal)20may be removed from the gaps. In this case, the sealing material (seal)20can be reused.

The method for injecting the adhesive16according to the first embodiment has the configuration described above. Because the adhesive16is injected through the through holes18ato18jof the reinforcing member14, air bubbles are removed from the end in the +Z-direction, the gaps, and the through holes into which the adhesive16is not injected. The adhesive16is checked through a through hole formed adjacent to a through hole into which the adhesive16is being injected. Consequently, the method enables checking that no air bubble remains in the adhesive injection area when the adhesive16is injected, reducing the number of air bubbles included in the adhesive16, and suppressing reduction in the bonding strength between the composite materials.

The method for injecting the adhesive16according to the first embodiment includes the sealing material (seal) disposing step, which is processing of disposing the sealing material20that covers the gaps. Consequently, the method can prevent the adhesive16from flowing out through the gaps, thereby precisely forming the injected adhesive16within the adhesive injection area.

In the method for injecting the adhesive16according to the first embodiment, the bonding surface14sextends in the Z-direction, and the through holes18ato18jare formed in a pair of two columns extending in the Z-direction in a staggered manner. Consequently, the method requires the bonding surface14swith a smaller area and a smaller number of through holes18ato18jand can increase the reinforcing effect of the reinforcing member14.

In the method for injecting the adhesive16according to the first embodiment, the through holes18ato18jare formed in a pair of two columns extending in the Z-direction in a staggered manner with the web15bsandwiched therebetween in the flange15a. Consequently, the method requires the bonding surface14swith a smaller area and a smaller number of through holes18ato18jand can increase the reinforcing effect of the reinforcing member14.

The method for injecting the adhesive16according to the first embodiment may perform the processing at Step S14corresponding to the state at Step S16. Specifically, at Step S14, the sealing pieces (seal members) are disposed in order from the end in the −Z-direction to the end in the +Z-direction. In other words, the seal member20aand the seal member20care disposed in order at the gap on the first side, and the seal member20band the seal member20dare disposed in order at the gap on the second side. At Step S14, the sealing pieces20aand20bat the end in the −Z-direction are disposed first. Preferably, before the adhesive16injected at Step S16protrudes beyond the range of the sealing pieces20aand20bdisposed first, the sealing pieces20cand20dare additionally disposed adjacent to the sealing pieces20aand20b, respectively, at the end in the +Z-direction. Alternatively, after a slight amount of the adhesive16protrudes, the sealing pieces20cand20dmay be added and disposed adjacent to the sealing pieces20aand20b, respectively, at the end in the +Z-direction. If the adhesive injection area further extends in the Z-direction, additional sealing pieces are successively added and disposed at the end in the +Z-direction corresponding to the range of the adhesive16injected at Step S16reaching in the +Z-direction.

If the sealing pieces are added and disposed in order from the end in the −Z-direction to the end in the +Z-direction at Step S14corresponding to the state at Step S16, the method for injecting the adhesive16according to the first embodiment does not excessively cover, with the sealing material20, an area into which the adhesive16is not injected and keeps the gaps open. Consequently, the method can maintain the state of being capable of removing air bubbles from the end in the +Z-direction corresponding to an injection state of the adhesive16.

If the sealing material (seal) extends toward the through holes18ato18j, the method for injecting the adhesive16according to the first embodiment is preferably employed because the through holes18ato18jcan be covered with the portion of the sealing material extending toward the through holes18ato18jafter the adhesive16is injected thereinto at Step S16.

In a case where the sealing material (seal) has through holes, the method for injecting the adhesive16according to the first embodiment successively uses the through holes formed in the reinforcing member14and the through holes formed in the sealing material to remove air bubbles, check that no air bubble remains, and inject the adhesive16at Step S16. Consequently, the method requires a smaller number of through holes formed in the reinforcing member14, thereby further increasing the reinforcing effect of the reinforcing member14. In the case where the sealing material (seal) has through holes, and the reinforcing member14has no through hole, the method for injecting the adhesive16according to the first embodiment successively uses the through holes formed in the sealing material to remove air bubbles, check that no air bubble remains, and inject the adhesive16at Step S16. Consequently, the method requires no through hole formed in the reinforcing member14, thereby further increasing the reinforcing effect of the reinforcing member14.

Second Embodiment

FIG. 5is a schematic configuration diagram of one state in the method for injecting the adhesive16according to a second embodiment.FIG. 6is a schematic configuration diagram of a structure30of the composite materials and another state in the method for injecting the adhesive16according to the second embodiment.FIGS. 5 and 6are schematics viewed from a section direction corresponding to a direction of the B-B section inFIG. 1. The B-B section is a plane connecting two sections along a plane direction orthogonal to the Z-direction between the members14aand14bdiscontinuously. The B-B section passes through the center of the through hole18gin the member14aand passes through the center of the through hole18hin the member14b. The structure30is different from the structure10in that tapered portions16tare formed at the gap portions of the adhesive16. The method for injecting the adhesive16according to the second embodiment is different from the method for injecting the adhesive16according to the first embodiment in that the tapered portions16tare formed at the gap portions of the injected adhesive16by the sealing material (seal)20. In the description of the second embodiment, components similar to those of the first embodiment are denoted by like reference numerals, and detailed explanation thereof is omitted.

As illustrated inFIG. 6, the structure30includes the outer plate12, the reinforcing member14, and the adhesive16. The adhesive16has the tapered portions16ttapering from the reinforcing member14to the outer plate12and formed at the gap portions, that is, the portions exposed from the outer plate12and the reinforcing member14. The tapered portions16teach cover the side surface of the flange15aof the reinforcing member14on the gap side and have a tapered shape tapering from the surface of the flange15aof the reinforcing member14on the web15bside to the bonded surface12sof the outer plate12. In other words, the portions of the adhesive16protruding from the respective gaps serve as the tapered portions16thaving a tapered shape the thickness of which becomes thinner from the reinforcing member14toward the outer plate12.

As illustrated inFIG. 6, the structure30may include the sealing material (seal)20that covers the gaps formed on both sides of the bonding surface14s. The sealing material (seal)20included in the structure30extends along the tapered portions16t.

In a case where the sealing material20is a tape-like member made of a flexible material, portions of the sealing material20facing the respective tapered portions16tchange their shapes to correspond to the respective tapered portions16tin such a manner to swell into a tapered shape tapering from the reinforcing member14to the outer plate12toward the outside of the gaps. Alternatively, the sealing material20may change its shape in such a manner to swell into a tapered shape tapering from the reinforcing member14to the outer plate12toward the outside of the gaps while being separated from the tapered portions16t.

In a case where the sealing material20is a dam member made of a rigid material, the inside portions of the sealing material20facing the respective tapered portions16tare formed in a tapered shape corresponding to the respective tapered portions16tfrom the reinforcing member14to the outer plate12.

The structure30has the configuration described above. Because the adhesive16includes the tapered portions16tformed in a tapered shape tapering from the reinforcing member14to the outer plate12, the structure30has higher resistance to external stress at the gap portions of the adhesive16.

In the conventional structures100and110of the composite materials, the injected liquid adhesive106protrudes from the gaps, thereby deforming. As a result, the bonding strength between the outer plate102and the reinforcing member104is reduced. By contrast, the structure30includes the sealing material20, thereby suppressing protrusion of the injected adhesive16from the gaps and deformation of the adhesive16. Consequently, the structure30can stabilize the quality of the tapered portions16tand suppress reduction in the bonding strength between the outer plate12and the reinforcing member14. In addition, the structure30requires less work to form the tapered portions16t.

Similarly to the method for injecting the adhesive16according to the first embodiment, the method for injecting the adhesive16according to the second embodiment includes the positioning step (Step S12), the sealing material disposing step (Step S14), and the injecting step (Step S16). Step S12in the method for injecting the adhesive16according to the second embodiment is the same as that according to the first embodiment.

Step S14in the method for injecting the adhesive16according to the second embodiment is different from that according to the first embodiment in the way of disposing the sealing material (seal)20in detail. Specifically, at Step S14in the method for injecting the adhesive16according to the second embodiment, one side of the sealing material (seal)20is fixed to a predetermined position on the reinforcing member14, and the other side thereof is fixed to a predetermined position on the outer plate12. In addition, other parts of the sealing material20are disposed so as to form the gap portions of the adhesive16into the tapered portions16t.

Specifically, in a case where the sealing material (seal)20is a tape-like member made of a flexible material, at Step S14in the method for injecting the adhesive16according to the second embodiment, the parts of the sealing material (seal)20facing the gap portions are not fixed. The parts are capable of changing their shapes in such a manner to swell into a tapered shape tapering from the reinforcing member14to the outer plate12toward the outside of the gaps as the adhesive16is injected.

In a case where the sealing material (seal)20is a dam member made of a rigid material, at Step S14in the method for injecting the adhesive16according to the second embodiment, the inside portions of the sealing material20facing the gap portions are formed in a tapered shape corresponding to the respective tapered portions16tfrom the reinforcing member14to the outer plate12.

Step S16in the method for injecting the adhesive16according to the second embodiment is different from that according to the first embodiment in that it further includes forming the tapered portions16tat the respective gap portions of the adhesive16. Specifically, at Step S16in the method for injecting the adhesive16according to the second embodiment, the tapered portions16tare formed at the portions of the sealing material20facing the respective gaps, that is, at the respective gap portions of the adhesive16.

Specifically, in a case where the sealing material20is a tape-like member made of a flexible material, at Step S16in the method for injecting the adhesive16according to the second embodiment, the sealing material20changes its shape in such a manner to swell toward the outside of the gaps as illustrated inFIG. 6from the state illustrated inFIG. 5as the adhesive16is injected. As a result, the gap portions of the adhesive16swell in a protruding manner larger than the respective tapered portions16tby the sealing material20. Subsequently, the adhesive16shrinks as it cures, thereby forming the gap portions into the tapered portions16t.

In a case where the sealing material20is a dam member made of a rigid material, at Step S16in the method for injecting the adhesive16according to the second embodiment, the injected adhesive16is formed into a shape extending along the inside portion of the sealing material20facing the respective gap portions as illustrated inFIG. 6. Subsequently, the adhesive16cures, thereby forming the gap portions into the tapered portions16t.

The method for injecting the adhesive16according to the second embodiment has the configuration described above. The method suppresses protrusion of the injected adhesive16from the gaps and deformation of the adhesive16with the sealing material20. Consequently, the method can stabilize the quality of the tapered portions16tand suppress reduction in the bonding strength between the outer plate12and the reinforcing member14. In addition, the method requires less work to form the tapered portions16t.

In a case where the sealing material20is a tape-like member made of a flexible material, the method for injecting the adhesive16according to the second embodiment can form the gap portions of the adhesive16into a desired tapered shape using shrinkage of the adhesive16accompanying curing.

In a case where the sealing material20is a dam member made of a rigid material, the method for injecting the adhesive16according to the second embodiment can form the gap portions of the adhesive16into a desired tapered shape corresponding to the shape of the inside portion of the dam member.

Third Embodiment

FIG. 7is a schematic configuration diagram of one state in the method for injecting the adhesive16according to a third embodiment.FIG. 8is a schematic configuration diagram of a structure40of the composite materials and another state in the method for injecting the adhesive16according to the third embodiment.FIG. 9is a schematic configuration diagram of a lid member46included in the structure40of the composite materials according to the third embodiment.FIGS. 7 and 8are schematics viewed from a section direction corresponding to a direction of the C-C section inFIG. 1. The C-C section is a plane orthogonal to the outer plane12and connecting two sections along the Z-direction. One of the sections passes through the center of the through hole18a, and the other thereof passes through the center of the through hole18b.FIGS. 7 and 8do not illustrate the area positioned in the +Z-direction with respect to the through hole18c.

The structure40is different from the structure10in that it further includes the lid member46attached to a through hole. The method for injecting the adhesive16according to the third embodiment is different from the method for injecting the adhesive16according to the first embodiment in that it further includes performing suction through a through hole formed adjacent to a through hole into which the adhesive16is being injected and attaching the lid member46to a through hole on which injection of the adhesive16is completed. In the description of the third embodiment, components similar to those of the first embodiment are denoted by like reference numerals, and detailed explanation thereof is omitted.

As illustrated in a part closer to the end in the −Z-direction inFIG. 8, the structure40includes the outer plate12, the reinforcing member14, the adhesive16, and the lid member46. The lid member46is attached to the through hole18ainFIG. 8. The lid members46may be attached to all or some of the through holes18ato18j.

As illustrated inFIG. 9, the lid member46includes a lid body47, protrusions48, and stoppers49. The lid member46integrates the lid body47, the protrusions48, and the stoppers49and may be made of the same material as that of the adhesive16. The lid body47is a disc-like plate that covers a through hole and has a diameter larger than that of the through hole. The lid body47is not limited to a disk-like plate and may have any desired shape as long as it is a plate having a size large enough to sufficiently cover the through hole. The protrusions48extend in a protruding manner in a direction from the lid body47toward the outer plate12. The stoppers49prevent the lid member46from coming off from the through hole. The stoppers49are each provided at a position of a predetermined length l from the front end of the protrusion48toward the lid body47. As illustrated inFIG. 8, the predetermined length l keeps the gap between the bonded surface12sof the outer plate12and the bonding surface14sof the reinforcing member14, that is, the width of the adhesive injection area and the thickness of the adhesive16at a length defined based on the predetermined length l.

In a case where the lid member46is attached perpendicularly to the bonded surface12s, the predetermined length l is equal to the gap between the bonded surface12sof the outer plate12and the bonding surface14sof the reinforcing member14, that is, the width of the adhesive injection area and the thickness of the adhesive16. In contrast, in a case where the lid member46is attached obliquely to the bonded surface12s, the relation between the predetermined length l and the gap between the bonded surface12sof the outer plate12and the bonding surface14sof the reinforcing member14, that is, the width of the adhesive injection area and the thickness of the adhesive16is determined based on the attachment angle.

The lid member46does not necessarily have the shape described above. The lid member, for example, may include one or a plurality of needle members provided to the lid body47and capable of being stuck and inserted into the injected adhesive16. In this case, the needle member of the lid member preferably has a stopper that prevents the lid member from coming off from the through hole. The stopper is preferably provided at a position of the predetermined length l from the front end of the needle member toward the lid body47. With this structure, the thickness of the adhesive16can be kept at a length defined based on the predetermined length l.

Alternatively, the lid member may include one or a plurality of spring members provided to the lid body47and capable of being inserted into the injected adhesive16. In this case, the spring member of the lid member preferably has a stopper that prevents the lid member from coming off from the through hole. The stopper is preferably provided at a position of the predetermined length l from the front end of the spring member toward the lid body47. With this structure, the thickness of the adhesive16can be kept at a length defined based on the predetermined length l.

The structure40has the configuration described above. Consequently, the structure40can prevent the adhesive16from leaking from the through holes to which the lid members46are attached. In addition, the structure40can prevent the lid members46from coming off from the through holes and keep the thickness of the adhesive16at a length defined based on the predetermined length l.

Similarly to the method for injecting the adhesive16according to the first embodiment, the method for injecting the adhesive16according to the third embodiment includes the positioning step (Step S12), the sealing material disposing step (Step S14), and the injecting step (Step S16). Step S12and Step S14in the method for injecting the adhesive16according to the third embodiment are the same as those according to the first embodiment.

Step S16in the method for injecting the adhesive16according to the third embodiment is different from that according to the first embodiment in that it further includes performing suction through a through hole formed adjacent to a through hole into which the adhesive16is being injected and attaching the lid member46to a through hole on which injection of the adhesive16is completed.

At Step S16in the method for injecting the adhesive16according to the third embodiment, the adhesive16before cured is successively injected into the through holes18ato18jfrom the end in the −Z-direction to the end in the +Z-direction using an adhesive injector42illustrated inFIGS. 7 and 8. Simultaneously with the injection, at Step S16in the method for injecting the adhesive16according to the third embodiment, suction is successively performed through the through holes18bto18jfrom the end in the −Z-direction to the end in the +Z-direction with a sucker44illustrated inFIG. 7.

Specifically, at Step S16in the method for injecting the adhesive16according to the third embodiment, the adhesive16is injected into the through hole18aformed closest to the end in the −Z-direction as illustrated inFIG. 7. Simultaneously with this, suction is performed through the through hole18bformed adjacent to the through hole18a. At this time, only air bubbles or a mixture of the adhesive16and air bubbles are sucked through the through hole18b. When the adhesive16with no air bubble starts to be sucked through the through hole18b, it can be determined that the portion closer to the end in the −Z-direction than the through hole18bis filled with the adhesive16. Consequently, it is determined that the adhesive16can be recognized through the through hole18bformed adjacent to the through hole18ainto which the adhesive16is being injected when the adhesive16is being injected into the through hole18a. In other words, it is determined that injection of the adhesive16into the through hole18ais completed. At this stage, the through hole into which the adhesive16is to be injected is shifted from the through hole18ato the through hole18b. Simultaneously with this, the through hole through which suction is to be performed is shifted from the through hole18bto the through hole18c.

At Step S16in the method for injecting the adhesive16according to the third embodiment, the lid member46is attached to the through hole18aon which injection of the adhesive16is completed after the through hole into which the adhesive16is to be injected is shifted from the through hole18ato the through hole18band before the adhesive16sufficiently cures.

Similarly, at Step S16in the method for injecting the adhesive16according to the third embodiment, the through hole into which the adhesive16is to be injected is shifted from the end in the −Z-direction to the end in the +Z-direction, that is, the through holes18c,18d,18e,18f,18g,18h, and18iin order subsequently to the through holes18aand18b. Simultaneously with this, the through hole through which suction is to be performed is shifted from the end in the −Z-direction to the end in the +Z-direction, that is, the through holes18d,18e,18f,18g,18h,18i, and18jin order subsequently to the through holes18band18c. As the through hole into which the adhesive16is to be injected is shifted, the lid members46are successively attached to the through holes18bto18ion which injection of the adhesive16is completed.

At Step S16in the method for injecting the adhesive16according to the third embodiment, when injection of the adhesive16into the through hole18iis completed, the through hole into which the adhesive16is to be injected is shifted to the through hole18j, and suction performed through the through hole is finished. When injection of the adhesive16into the through hole18jis completed, and the lid member46is attached to the through hole18jon which injection of the adhesive16is completed, Step S16in the method for injecting the adhesive16according to the third embodiment is finished. As a result, the adhesive16is injected into the adhesive injection area from the end in the −Z-direction to the end in the +Z-direction.

At Step S16in the method for injecting the adhesive16according to the third embodiment, when the adhesive16is being injected into the through hole18a, air bubbles are removed from the gaps on the end in the +Z-direction and the through holes18cto18jinto which the adhesive16is not injected. In addition, the air bubbles are actively sucked and removed through the through hole18b. When the adhesive16is being injected into the through hole18b, air bubbles are removed from the gaps on the end in the +Z-direction and the through holes18dto18jinto which the adhesive16is not injected. In addition, the air bubbles are actively sucked and removed through the through hole18c. Similarly, except when the adhesive16is being injected into the through hole18jformed closest to the end in the +Z-direction, air bubbles are actively sucked and removed through a through hole formed adjacent to a through hole into which the adhesive16is being injected. As a result, the adhesive injection area is cleared of the air bubbles more reliably and filled with the adhesive16.

At Step S16in the method for injecting the adhesive16according to the third embodiment, the lid members46may be attached to all or some of the through holes18ato18j. At Step S16in the method for injecting the adhesive16according to the third embodiment, the lid member46is attached to at least one through hole. Consequently, the method can prevent the adhesive16from leaking from the through holes to which the lid members46are attached. In addition, the method can prevent the lid members46from coming off from the through holes and keep the thickness of the adhesive16at the predetermined length l.

The method for injecting the adhesive16according to the third embodiment has the configuration described above. The adhesive16is checked based on the state of suction performed through a through hole formed adjacent to a through hole into which the adhesive16is being injected. Consequently, the method enables checking that no air bubble remains in the adhesive injection area when the adhesive16is injected. Furthermore, air bubbles are removed by suction. Consequently, the method enables further reducing the number of air bubbles included in the adhesive16and suppressing reduction in the bonding strength between the composite materials.

In the method for injecting the adhesive16according to the third embodiment, the lid member46is attached to a through hole on which injection of the adhesive16is completed. Consequently, the method can prevent the adhesive16from leaking from the through hole on which injection of the adhesive16is completed.

In the method for injecting the adhesive16according to the third embodiment, the lid member46attached to a through hole on which injection of the adhesive16is completed has the stoppers49. Consequently, the method can prevent the lid member46from coming off from the through hole. In the method for injecting the adhesive16according to the third embodiment, the stoppers49are each provided at a position of the predetermined length l from the front end of the protrusion48toward the lid body47in the lid member46attached to the through hole on which injection of the adhesive16is completed. Consequently, the method can keep the thickness of the adhesive16at a length defined based on the predetermined length l.

REFERENCE SIGNS LIST