JP2000052440A - Molding method for fiber reinforced composite material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a molding method for a fiber reinforced composite material in which a manufacturing process can be simplified and carried out easily, by which the manufacturing cost thereof can be reduced. SOLUTION: In a manufacturing method for a fiber reinforced composite material, a prepreg formed of a fiber reinforced composite material is formed into the endless shape, and then a pair of bar-shaped shaping molds 12 and 14 are inserted into the endless prepreg 8 and drawn out to both sides to be formed into the endless plane shape, and then the endless plane-shaped prepreg 8 is pressed to a molding tool 20 and formed into the intermediate shape while a pair of bar-shaped shaping molds 12 and 14 are drawn to both sides, and a pair of bar-shaped shaping molds 12 and 14 are removed from the endless prepreg 8 formed into the intermediate shape, and then the endless prepreg 8 is molded into the given shape. For instance, an almost L-shaped structural member can be molded simply and easily by the molding method.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for molding a fiber-reinforced composite material, which can easily produce various structural materials formed from the fiber-reinforced composite material.

[0002]

2. Description of the Related Art Structural members for aircraft, vehicles and the like are required to have impact resistance and toughness, as well as light weight. Attention has been paid to fiber-reinforced composite materials to satisfy such requirements, and structural members formed from the composite materials have been used.

Conventionally, such a structural member is formed, for example, as follows. First, a prepreg in which fibers are impregnated with resin is cut into a predetermined shape (cutting step),
Next, a predetermined number of cut prepregs are laminated on a molding die to form a predetermined shape (lamination step). Thereafter, the prepreg having a predetermined shape is placed in a heating and pressurizing furnace and subjected to a heat and pressure treatment to cure the prepreg in a laminated state. Thereafter, both ends of the cured molded structural member (these ends are irregular in order to stack the sheet-like prepreg) are cut into a required shape (cutting step), and the cut ends are further cut. The part is finished with sandpaper (finishing process).

[0004]

In the above-mentioned molding method, firstly, the work involved in the cutting step and the laminating step is complicated and the production cost is increased. That is, in the cutting step, the roll-shaped prepreg needs to be cut into a predetermined shape, and the number of cuts must be cut to the number of layers to be laminated. In the laminating step, the cut prepregs must be laminated one by one. In such a cutting step and a laminating step, handling of a prepreg becomes complicated when a structural member to be manufactured becomes large.

Second, there is a problem in that the work involved in the cutting step and the finishing step after the heating and pressurizing treatment is complicated, and the production cost is increased. That is, since the sheet-like prepregs are laminated when the structural member is molded, both ends of the structural member after the molding are irregular. Therefore, in order to solve this problem, irregular parts must be cut, and cutting alone may cause the fibers to flake or peel off, which causes poor appearance and poor quality. Therefore, after finishing, it is necessary to perform further finishing treatment,
Thus, the number of manufacturing steps for manufacturing the structural member increases.

[0006] It is an object of the present invention to provide a method of molding a fiber-reinforced composite material, which can simplify and facilitate the production process and thereby reduce the production cost.

[0007]

According to the present invention, there is provided a winding step of winding a prepreg formed of a fiber-reinforced composite material around a winding die to form an endless prepreg, and forming the winding die from the endless prepreg. Removing the mold removing step, inserting a pair of rod-shaped molds into the endless prepreg from which the winding mold has been removed, and pulling on both sides to form an endless planar shape; and forming the pair of rod-shaped molds. Pressing the endless flat prepreg against the mold while pulling the prepreg on both sides to form an intermediate shape, and removing the pair of rod-shaped molds from the endless prepreg formed in the intermediate shape. And a finishing shape forming step of forming the endless prepreg into a predetermined shape after removing the pair of rod-shaped molds.

According to the present invention, an endless prepreg is formed using a winding die, and a pair of rod-shaped molds are inserted into the endless prepreg and pulled on both sides. It has no upper deflection. Then, since the endless prepreg is pressed to the mold while being pulled to both sides by a pair of rod-shaped molds and formed into an intermediate shape, it can be formed into an intermediate shape without bending. After that, since a pair of rod-shaped molds are removed to form a predetermined shape, the prepreg of the final predetermined shape has no fibers exposed at both ends, and both ends are aligned. A cutting step for cutting both ends is not required.

The present invention also provides a winding step of winding a prepreg formed of a fiber-reinforced composite material around a winding mold to form an endless prepreg, and a demolding step of removing the winding mold from the endless prepreg. And a tensioning step of passing the pair of string-shaped members through the endless prepreg from which the winding mold is removed and pulling the pair of string-shaped members to form an endless planar shape by pulling the pair of string-shaped members to both sides. A shaping step of pressing the prepreg into a mold to form a predetermined shape,
A method for molding a fiber-reinforced composite material, comprising:

According to the present invention, an endless prepreg is formed using a winding die, and the endless prepreg is pulled to both sides through a pair of string-like members, so that the formed endless planar prepreg is substantially bent. Will not be. Then, the endless prepreg is formed into a predetermined shape by pressing against a forming die while being pulled to both sides by a pair of string-shaped members, so that it can be formed into a final predetermined shape without bending. By using the same material as that of the prepreg for the string-like members, in this case, the final shape is formed without removing the pair of string-like members, so that the manufacturing process is further simplified and the number of steps is reduced. Can be. Further, the prepreg formed in the final shape has no fibers exposed at both ends and has both ends aligned, so that a cutting step of cutting both ends as in the conventional case is unnecessary.

The present invention also provides a winding step of winding a prepreg formed of a fiber-reinforced composite material around a winding die to form an endless prepreg, and a demolding step of removing the winding die from the endless prepreg. And a shaping and tensioning step of inserting a pair of rod-shaped molds into the endless prepreg from which the winding mold has been removed and pulling on both sides to form an endless flat shape, while pulling the pair of bar-shaped molds on both sides An intermediate shaping step of forming an intermediate shape by an upper mold and a lower mold, a demolding step of removing the pair of rod-shaped molds from the endless prepreg formed in the intermediate shape, and the pair of rod-shaped molds A finishing shape forming step of forming an endless prepreg into a predetermined shape by the upper mold and the lower mold after removing,
A method for molding a fiber-reinforced composite material, comprising:

According to the present invention, an endless prepreg is formed by using a winding die, and a pair of rod-shaped molds is inserted into the endless prepreg and pulled on both sides. It has no upper deflection. Then, the endless prepreg is formed in an intermediate shape by the upper mold and the lower mold while being pulled to both sides by a pair of rod-shaped molds, so that the prepreg can be formed in an intermediate shape without bending. After that, since a pair of rod-shaped molds are removed and the upper mold and the lower mold are formed into a predetermined shape,
In the prepreg having the final predetermined shape, the fiber is not exposed at both ends and both ends are aligned, so that a cutting step for finally cutting both ends as in the conventional case is unnecessary.

[0013] The present invention also provides a winding step of winding a prepreg formed from a fiber-reinforced composite material around a winding mold to form an endless prepreg, and a demolding step of removing the winding mold from the endless prepreg. And a tensioning step of passing the pair of string-shaped members through the endless prepreg from which the winding mold is removed to pull the pair of string-shaped members into an endless planar shape, and forming the upper molding die while pulling the pair of string-shaped members to both sides. And a finishing shape forming step of forming an endless planar prepreg into a predetermined shape by a lower forming die.

According to the present invention, an endless prepreg is formed using a winding die, and the endless prepreg is pulled to both sides through a pair of string members, so that the formed endless planar prepreg is substantially bent. Will not be. Since the endless prepreg is formed into a predetermined shape by the upper and lower molds while being pulled to both sides by a pair of cord-like members, it can be formed into a final predetermined shape without bending. By using the same material as that of the prepreg for the string-like members, in this case, the final shape is formed without removing the pair of string-like members, so that the manufacturing process is further simplified and the number of steps is reduced. Can be. Further, the prepreg formed in the final shape has no fibers exposed at both ends and has both ends aligned, so that a cutting step of cutting both ends as in the conventional case is unnecessary. Also,
Since the upper mold and the lower mold are used at the time of molding, it can be formed into a desired shape, and can be conveniently applied to molding, for example, a Z-shaped structural member.

The present invention also provides a winding step of winding a prepreg formed of a fiber-reinforced composite material on a winding die having a triangular cross section to form an endless prepreg, and winding the prepreg from the endless prepreg. Removing the mold, removing the winding mold, inserting the string member through the three corners of the endless prepreg, and using the inserted string member and the forming mold, A forming step of forming a substantially inverted T-shape so that a portion where each string-shaped member is present is an end portion.

According to the present invention, an endless prepreg is formed by using a winding die having a triangular cross section, and a string member is passed through each of three corners of the endless prepreg to form a string member. Since the prepreg is formed into a substantially inverted T-shaped predetermined shape using a mold, the formed prepreg has no substantially inverted T-shaped deflection. In addition, the portion where the string-shaped member is located is the end of the substantially inverted T-shaped prepreg, and since these ends are endless, the fibers are not exposed at these ends and the ends are aligned. This eliminates the need for a conventional cutting step for cutting both ends. Further, since the three T-shaped members and the forming die are formed in a substantially inverted T shape, the inverted T-shaped structural member can be formed easily and easily.

Further, according to the present invention, in the shaping step,
A triangular filler material is interposed at the joint of the endless prepreg formed in a substantially inverted T shape, and is cured by heating.

Further, the present invention provides a winding step of winding a prepreg formed of a fiber-reinforced composite material on a winding die having a rectangular cross section to form an endless prepreg, and winding the prepreg from the endless prepreg. Removing the mold, removing the winding mold, inserting the string member through the four corners of the endless prepreg, and using the inserted string member and the forming mold, And a shaping step of forming a substantially H-shape such that a portion where each cord-like member exists is an end.

According to the present invention, an endless prepreg is formed by using a winding die having a square cross section, and a string-shaped member is passed through each of the four corners of the endless prepreg, and Since the prepreg is formed into a substantially H-shaped predetermined shape using a molding die, the formed prepreg has no substantially H-shaped deflection. Also, the portion where the string-like member is located is the end of the substantially H-shaped prepreg, and since these ends are endless, the fibers are not exposed at these ends, and the ends are aligned. This eliminates the need for a conventional cutting step for cutting both ends. In addition, approximately H due to the four cord members and the forming die
Therefore, the inverted H-shaped structural member can be easily and easily formed.

Further, the present invention is characterized in that, in the shaping step, a triangular filler material is interposed at each joint of the endless prepreg formed in a substantially H shape, and is cured by heating.

[0021]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A method for forming a fiber-reinforced composite according to the present invention will be described below with reference to the accompanying drawings.

FIG. 1 is a perspective view showing a first example of a structural member molded according to the molding method of the present invention. Referring to FIG. 1, the illustrated structural member 2 has an L-shaped cross section. This structural member 2 is formed by forming a prepreg of a fiber-reinforced composite material into an L shape, and heating and curing the L-shaped prepreg. The molding method will be described later.
The fiber-reinforced composite material is formed by impregnating a fiber with a resin. For example, carbon fiber, glass fiber, or the like is used as the fiber, and an epoxy resin or a phenol resin is used as the resin to be impregnated.

The L-shaped structural member 2 is, for example, shown in FIGS.
It is formed by a first molding method shown in FIG. First,
The winding step shown in FIG. 2 is performed. In this example, a winding mold 4 (see also FIG. 3) is used in the winding step,
A sheet-shaped prepreg 6 is wound around the winding mold 4, and an endless prepreg 8 is formed by winding in this manner. As will be understood from the description below, the number of stacked prepregs after molding is twice the number of turns around the cylindrical mold 4. By forming it endless in this way, it is not necessary to stack sheets one by one, and the prepreg can be easily stacked.
The winding around the winding die 4 may be performed by winding a sheet-like elongated prepreg 6 or a plurality of sheets of a certain size may be wound as required. The winding die 4 may be a cylindrical or cylindrical one having a circular cross section, and is not limited to this, and may be one having an elliptical cross section.

After the winding step, a demolding step shown in FIG. 3 is performed. In the demolding step, the winding die 4 is pulled from the endless prepreg 8 in the direction indicated by the arrow 10, and the winding die 4 is removed from the endless prepreg 6.
Thus, the endless prepreg 8 is formed from the sheet-shaped prepreg 4.

After the demolding step, a shaping and tensioning step shown in FIG. 4 is performed. In the shaping and tensioning step, a pair of bar-shaped shaping members 12 and 14 are used, and the bar-shaped shaping members 12 and 14 may be elongated bar-shaped members. The shaping and tensioning step is performed by inserting a pair of shaping molds 12 and 14 into the endless prepreg 8 and pulling the inserted shaping molds 12 and 14 to both sides as indicated by arrows 16 and 18. By pulling the pair of molds 12 and 14 in this manner, the endless prepreg 8 becomes flat and substantially free from bending, and can be formed into an L shape as described later.

Thereafter, an intermediate shaping step shown in FIGS. 5 and 6 is performed. In the intermediate shaping step, a molding die 20 having a right upper triangular shape is used. In this step, first, the central part of the endless planar prepreg 8 is pressed against the top part 20 a of the molding die 20 while pulling the pair of moldings 12 and 14 to both sides as shown by arrows 22 and 24. Thereafter, as shown in FIG. 6, the pair of forming molds 12 and 14 are moved downward toward the forming mold 20 as indicated by arrows 26 and 28 while being pulled to both sides, and are moved in this manner to obtain the endless prepreg 8.
Is bent into a substantially L shape using the molding die 20. In this way, the endless planar prepreg 8 is formed in a substantially L-shaped intermediate shape. In the intermediate shaping step, a pair of moldings 12,
Since 14 is formed in a substantially L shape while being pulled to both sides, it can be formed in an intermediate shape without bending or the like.

Thereafter, a demolding step is performed. In the demolding step, the pair of moldings 12 and 14 are pulled out of the intermediate prepreg 8 and removed. In this manner, the intermediate prepreg 8 is formed on the molding die 20.

Thereafter, a finish shaping step is performed. In this finishing shape forming step, both ends of the prepreg 8 after removing the pair of molds 12 and 14 are pressed with a pressing tool (not shown).
It is performed by pressing with. When pressed by the pressing tool in this way, as shown in FIGS. 7 and 8, the endless prepreg 8 is formed in a substantially L shape as a final predetermined shape in a state of being placed on the molding die 20.

Since the substantially L-shaped prepreg 8 at the stage before the structural member 2 as a product is formed as described above, both ends of the prepreg 8 having a predetermined shape are endless,
Therefore, the fibers of the composite material are not exposed at both ends, and both ends are neatly aligned.

The prepreg 8 thus formed is then heated and cured by a method known per se. At the time of heating and curing, the mold 20 and the prepreg 8 having a predetermined shape are vacuum bagged by a resin sheet (not shown) or the like, and housed in a heating furnace (or a heating and pressing furnace) in a vacuum bagged state. (Or a heating and pressurizing furnace) to be heated (or heated and pressed) and cured as required, thus forming the structural member 2 as shown in FIG. 1 as required. When the structural member 2 is formed in this manner, both ends are formed endlessly and aligned, so there is no need to cut and align as in the conventional case.
This cutting step and the steps related thereto can be omitted, whereby the manufacturing steps can be simplified and facilitated, and the manufacturing costs can be significantly reduced.

FIG. 9 is a perspective view showing a second example of a structural member molded according to the molding method of the present invention. Referring to FIG. 9, the illustrated structural member 32 is formed as a channel material having a U-shaped cross section. This structural member 32
Is formed by forming a prepreg of a fiber-reinforced composite material into a U-shape, and heat-curing the U-shaped prepreg.

The U-shaped structural member 32 is formed, for example, by the following second molding method. To form the structural member 32, like the L-shaped structural member 2,
The winding step, the demolding step, and the forming / pulling step are performed in this order.
Is used to form an endless planar prepreg 38.
The winding step, the demolding step, and the shaping and tensioning step are the same as those described above, and therefore, the details thereof are omitted.

Thereafter, an intermediate shaping step shown in FIGS. 10 and 11 is performed. In the intermediate shaping step, a molding die 40 having a rectangular upper end is used. In this step, first, the center of the endless planar prepreg 38 is pressed against the top 40a of the molding die 40 while pulling the pair of moldings 34, 36 to both sides as shown by arrows 42, 44 (FIG. 10). Then, as shown in FIG. 11, while pulling the pair of molds 34, 36 to both sides, the molding dies 4 as shown by arrows 46, 48.
It is moved downward toward zero, and the center of the endless prepreg 38 is bent into a substantially U-shape using a molding die 40. Thus, the endless planar prepreg 38 is formed in a substantially U-shaped intermediate shape. In the intermediate shaping step, a pair of moldings 34, 3
6 is formed in a substantially U-shape while being pulled to both sides, so that it can be formed in an intermediate shape without bending or the like.

Thereafter, similarly to the above, the pair of molds 34, 36 are pulled out of the intermediate prepreg 38 and removed (demolding step). Thereafter, both ends of the prepreg 38 from which the pair of molds 34 and 36 have been removed are pressed by a pressing tool (not shown) to finish to a final predetermined shape (finish shape forming step). As shown in FIG. 12, an endless prepreg 38 is formed in a substantially U shape as a final predetermined shape in a state where the prepreg 38 is placed on a molding die 40.

The substantially U-shaped prepreg 38 thus formed is then heated and cured in the same manner as described above. At the time of heating and curing, the mold 40 and the prepreg 38 having a predetermined shape are vacuum bagged by a resin sheet (not shown) or the like, and housed in a heating furnace (or a heating and pressing furnace) in a vacuum bagged state. (Or a heating and pressurizing furnace) to heat (or heat and press) and harden as required, thus forming the structural member 32 as a channel material as shown in FIG. 9 as required. . When the structural member 32 is formed in this manner, both ends are formed endlessly and aligned, so that it is not necessary to cut and align as in the conventional case, and this cutting step and steps related thereto are omitted. As a result, the manufacturing process can be simplified and facilitated, and the manufacturing cost can be significantly reduced.

FIG. 13 is a perspective view showing a third example of a structural member formed according to the forming method of the present invention. FIG.
3, the illustrated structural member 52 has a Z-shaped cross section. The structural member 52 is formed by forming a prepreg of a fiber-reinforced composite material into a Z shape, and heating and curing the Z-shaped prepreg.

The Z-shaped structural member 52 is formed, for example, by the following third molding method. In forming the structural member 52, similarly to the L-shaped structural member 2,
The winding step, the demolding step, and the shaping pulling step are performed in this order, and thus a pair of rod-shaped shaping 54, 56
Is used to form an endless planar prepreg 58.
The winding step, the demolding step, and the shaping and tensioning step are the same as those described above, and therefore, the details thereof are omitted.

Thereafter, an intermediate shaping step shown in FIGS. 14 and 15 is performed. In the intermediate shaping step, a lower molding die 60 having a Z-shaped upper end and an upper molding die 62 having a Z-shaped lower end are used, and the shapes of the lower molding die 60 and the upper molding die 62 are structural members to be molded. 52 corresponds to the shape. In this step, first, a pair of moldings 54, 56 are indicated by arrows 64, 66.
As shown in FIG. 14, the endless planar prepreg 58 is pressed against the upper part of the lower mold 60 while being pulled to both sides (FIG. 14). Then, as shown in FIG. 15, the upper mold 62 is lowered toward the lower mold 60 in the direction indicated by the arrow 68 while loosening the tension of the pair of molds 54 and 56, and the lower mold 60 and the upper mold 60 are lowered. 62 forms a substantially Z-shaped intermediate shape. In the intermediate shaping step, the endless planar prepreg 58 is held in a state of being pulled to both sides by the pair of molds 54 and 56 and is formed in a substantially Z shape, so that an intermediate shape without deflection or the like can be formed.

Thereafter, the pair of molds 54 and 56 are pulled out of the intermediate prepreg 58 and removed (demolding step). Thereafter, the upper molding die 62 is further lowered, and the intermediate prepreg 58 is pressed by the lower molding die 60 and the upper molding die 62 to finish it into a substantially Z-shaped final predetermined shape (finish shape forming step). As shown in FIGS. 16 and 17, the endless prepreg 58 is formed into a substantially Z shape as a final predetermined shape by the lower molding die 60 and the upper molding die 62.

The substantially Z-shaped prepreg 58 thus formed is then heated and cured in the same manner as described above. At the time of heat curing, as shown in FIG. 17, the upper molding die 62 is removed, and the prepreg 58 is placed on the lower molding die 60, and the lower molding die 60 and the prepreg 38 having a predetermined shape are bonded to a resin sheet (FIG. 17). (Not shown) or the like, and housed in a heating furnace (or a heating and pressing furnace) in a vacuum bagged state, and heated (or heated and pressed) by a heating furnace (or a heating and pressing furnace) as required. Thus, the structural member 52 as a channel material as shown in FIG. 13 is formed as required. When the structural member 52 is formed in this manner, since both ends are formed endlessly and aligned, there is no need to cut and align as in the conventional case, and this cutting step and steps related thereto are omitted. As a result, the manufacturing process can be simplified and facilitated, and the manufacturing cost can be significantly reduced.

FIG. 18 is a perspective view showing a fourth example of a structural member formed according to the forming method of the present invention. FIG.
8, the illustrated structural member 72 has a substantially T-shaped cross section, and has a plate-shaped first portion 74 and a substantially vertically upward portion from the center in the width direction of the first portion 74. Extending second
And a portion 76. The structural member 72 is formed by forming a prepreg of a fiber-reinforced composite material into a substantially inverted T shape, and heat-curing the prepreg having the inverted T shape.

The inverted T-shaped structural member 72 is formed by, for example, a fourth molding method as shown in FIGS. First, the winding step shown in FIG. 19 is performed.
In this example, a winding mold 78 having a triangular cross section is used in the winding process (see also FIG. 20).
8 is wound around a sheet-shaped prepreg 80, and the endless prepreg 82 (FIG.
0) is formed.

As will be understood from the following description, in this case as well, the number of laminated prepregs after forming is twice the number of windings on the winding mold 78. By forming it endless in this way, it is not necessary to stack sheets one by one, and the prepreg can be easily stacked. The winding around the winding die 78 may be performed by winding an elongated prepreg 80 in the form of a sheet, or a plurality of sheets of a certain size may be wound as required. It should be noted that a triangular prism shape or a triangular cylindrical shape can be used as the winding mold 78.

After the winding step, a demolding step shown in FIG. 20 is performed. In the demolding step, the winding mold 78 is pulled from the endless prepreg 82, and the winding mold 78 is removed from the endless prepreg 82. By doing so, the endless prepreg 82 is formed from the sheet-shaped prepreg 80.

After the releasing step, an inserting step shown in FIG. 21 is performed. In this insertion step, the three string-like members 8 are connected in association with the formation of the endless triangular prepreg 82.
4, 86, 88 are used.
6, 88 are located at corresponding corners of the endless prepreg 82, respectively. As the string members 84, 86, 88, for example, a thin string (dry cloth) such as carbon fiber or glass fiber can be used.
86 and 88 become a part of the structural member 72 as described later.

Thereafter, a shaping step shown in FIGS. 22 to 24 is performed. In the shaping step, as shown in FIG. 22, the three string-like members 84, 86, 88 are pulled outward to hold the endless prepreg 82 in a triangular shape, and the prepreg 82 is bent by holding in this manner. Can be maintained without any Then, FIG. 23 and FIG.
As shown in the figure, the lower molding die 90 and the pair of upper holding dies 9
The prepreg 82 having a triangular shape is formed into a substantially inverted T-shape by using 2,94. In this molding, the triangular prepreg 82 is placed on the lower molding die 90, and the pair of upper pressing dies 92, 94 are obliquely downwardly moved from both sides as shown by arrows 96, 98 in the state of the placement. The pressing is performed toward the molding die 90. At this time, the three cord members 84, 86,
This is performed while loosening the tension state by 88, so that it is possible to form a substantially inverted T-shaped predetermined shape while preventing the occurrence of bending. In order to form the inverted T-shaped joint (joint between the first portion 74 and the second portion 76 after molding) into a predetermined shape, a triangular elongated filler material 100 is interposed inside the joint. . Filler material 100
Need to be molded.

As described above, the substantially inverted T-shaped prepreg 82 can be easily formed by using the lower molding die 90, the pair of upper pressing dies 92, 94, and the three cord members 84, 86, 88. The inverted T-shaped prepreg 82 is formed in a substantially T shape as a final predetermined shape in a state of being placed on the lower mold 90.

Since the substantially inverted T-shaped prepreg 82 at the stage before the structural member 72 as a product is formed as described above, the portion where the string-shaped members 84, 86, 88 are located is formed in the inverted T-shaped. It becomes the end of the prepreg 82 and the prepreg 82
Are endless, so that no fibers of the composite material are exposed at those ends and that the ends are neatly aligned.

The prepreg 82 thus formed is
Heat cured as required. At the time of heating and curing, the prepreg 82 is vacuum bagged by a resin sheet (not shown) together with the lower molding die 90 and the pair of upper pressing dies 92 and 94, and the prepreg 82 is heated in a heating furnace (or heated and pressed) in a vacuum bagged state. Furnace), heated (or heated and pressed) by a heating furnace (or a heating and pressurizing furnace), and cured as required. The endless prepreg 82
The string-like members 84, 86, 88 inserted into the fibers are not removed and the resin impregnates the fibers during curing, and remains as a part of the fibers in the structural member 72. Thus, the structural member 7
When molding No. 2, since both ends are formed endlessly and aligned, there is no need to cut and align as in the conventional case, and this cutting step and related steps can be omitted, thereby manufacturing The process can be simplified and facilitated, and the manufacturing cost can be significantly reduced. In addition, the string-shaped members 84, 86, 88 are
, And remains inside thereof, so there is no need to remove them, and the manufacturing process can be simplified and facilitated.

The shaping step can be performed as shown in FIGS. 25 and 26. Referring to FIGS. 25 and 26, three string members 84, 8 are formed in the same manner as described above.
6, 88 are pulled outward to hold the endless prepreg 82 in a triangular shape. Next, the triangular prepreg 82 is formed into a substantially inverted T shape using the pair of forming dies 102 and 104.
In this molding, the top, which is one corner of the prepreg 82, is inserted between the pair of molding dies 102 and 104 while pulling the cord-like member 88 upward in the direction indicated by the arrow 106, and the remaining two cord-like pieces are formed. The members 84 and 86 are indicated by arrows 108 and 1
Mold 102, 1 while pulling in both directions in the direction indicated by 10
This is performed by moving the prepreg 82 toward the corresponding molds 102 and 104 by moving the prepreg 82 to the other two corners. Even in this manner, as described above, the substantially inverted T-shaped prepreg 82 having no bending can be formed as required. Also in this case, a triangular elongated filler material 112 is interposed inside the inverted T-shaped joint (the joint between the first portion 74 and the second portion 76 after molding).

As described above, the substantially inverted T-shaped prepreg 82 can be easily formed by using the lower molding die 90, the pair of upper pressing dies 92, 94 and the three cord members 84, 86, 88. The inverted T-shaped prepreg 82 is formed in a substantially T shape as a final predetermined shape in a state of being placed on the lower mold 90.

FIG. 27 is a perspective view showing a fifth example of a structural member formed according to the forming method of the present invention. FIG.
7, the structural member 122 shown includes first and second portions 124 and 126 having a substantially inverted H-shaped cross section and extending substantially parallel to each other, and the first and second portions 12
4, 126 connecting the center portions in the width direction. The structural member 122 is formed by forming a prepreg of a fiber-reinforced composite material into a substantially H shape, and heat-curing the H-shaped prepreg.

The substantially H-shaped structural member 122 is, for example,
It is formed by a fifth molding method as shown in FIGS. First, the winding step shown in FIG. 28 is performed. In this example, a winding mold 130 having a square cross section is used in the winding step (see also FIG. 29), and a sheet-shaped prepreg 132 is wound around the winding mold 130, and the winding is performed in this manner. Thereby, an endless square prepreg 134 (see FIG. 29) is formed. Also in this case, the number of laminated prepregs after forming is twice the number of windings on the winding die 130. By forming it endless in this way, it is not necessary to stack sheets one by one, and the prepreg can be easily stacked. It is to be noted that a square pillar or a square cylinder can be used as the winding mold 130.

After the winding step, a demolding step shown in FIG. 29 is performed. In the demolding step, the winding die 130 is pulled from the endless prepreg 134 and the winding die 130 is removed from the endless prepreg 134. In this way, an endless prepreg 134 is formed from the sheet prepreg 132.

After the release step, an insertion step shown in FIG. 30 is performed. In this insertion step, the four string-like members 1 are connected in association with the formation of the endless square prepreg 134.
36138, 140 and 142 are used, and these string-like members 136 to 142 are respectively positioned at the corresponding corners of the endless prepreg 134. String members 136-1
As described above, for example, a thin string of carbon fiber, glass fiber, or the like can be used as 42, and the string members 136 to 142 become a part of the structural member 72 as described later.

Thereafter, a shaping process shown in FIGS. 31 to 33 is performed. In the shaping step, as shown in FIG. 31, the four string-like members 136 to 142 are pulled outward to hold the endless prepreg 134 in a square shape, and the prepreg 134 is not bent by holding in this manner. Can be kept in a state. Next, four rod-shaped molds 1
The quadrangular prepreg 134 is formed into a substantially H shape by using 44, 146, 148, and 150. Rod-shaped molds 144-15
As 0, for example, an elongated one having a rectangular cross section can be used. In this molding, first, as shown in FIG. 31, one side portion of the rectangular prepreg 134 (FIGS.
3, a pair of rod-shaped molds 144 and 144
146, and the remaining pair of rod-shaped molds 148, 15 at the center of the other side (upper part in FIGS. 31 to 33) of the prepreg 134 facing the one side.
Position 0. Next, as shown in FIG. 32, while holding the four cord-like members 136 to 142 in a square shape, a pair of moldings 144 and 146 and a pair of moldings 14 opposed to each other.
8, 150 in the direction approaching each other with arrows 152, 154
In the direction shown by, and as shown in FIG.
34 are moved until the one side and the other side of 34 contact each other. Since the substantially H-shaped structural member 122 is formed, the amount of movement of the molds 144 and 146 in the direction indicated by the arrow 152 is substantially equal to the amount of movement of the other molds 148 and 150 in the direction indicated by the arrow 154. Is set. Thereafter, as shown in FIG. 33, the molds 144, 148 on one side (the right side in FIGS. 31 to 34) are moved in the direction indicated by the arrow 156 (to the right in FIGS. 32 and 33).
Shaping 146, 1 on the other side (left side in FIGS. 31 to 33)
50 is moved in the direction indicated by the arrow 158 (to the left in FIGS. 32 and 33), and thus the four cord-like members 1 are moved.
36 to 142 and four shapings 144 to 150 to convert the rectangular prepreg 134 to the substantially H-shaped prepreg 13.
4 can be formed. At this time, the pulling is performed while loosening the tension by the four string-like members 136 to 142, thereby forming a substantially H-shaped predetermined shape while preventing the occurrence of bending. In addition, in order to form the joint portion of the H-shaped prepreg 134 (the joint portion between the first portion 124 and the connecting portion 128 after molding, and the joint portion between the second portion 126 and the connecting portion 128) in a predetermined shape, Similarly, a triangular elongated filler material 1
60 is interposed.

As described above, the substantially H-shaped prepreg 134 can be easily formed by using the four molds 144 to 150 and the four string-shaped members 136 to 142. It is held in a predetermined shape by a shape holding member (not shown) as necessary.

Since the substantially H-shaped prepreg 134 at the stage before the structural member 122 is formed as described above,
The site where the string-like members 136 to 142 are located is the end of the H-shaped prepreg 134, and each end of the prepreg 134 is endless, so that the fibers of the composite material are not exposed at those ends, Also, both ends are neatly aligned.

The prepreg 134 thus formed
Is heat cured as required, as described above,
Thus, a structural member 122 as shown in FIG. 28 is formed. The string-like members 136 to 142 remain as part of the structural member 122 without being removed. When the structural member 122 is molded in this manner, both ends are formed endlessly and aligned, so there is no need to cut and align as in the conventional case, and this cutting step and steps related thereto are omitted. As a result, the manufacturing process can be simplified and facilitated, and the manufacturing cost can be significantly reduced. In addition, since the string-like members 136 to 142 become a part of the structural member 72 and remain therein, there is no need to remove them, and the manufacturing process thereof can be simplified and facilitated.

Although the molding method according to the present invention has been described above, the present invention is not limited to the above-described method, and various modifications and corrections can be made without departing from the scope of the present invention.

For example, when forming the substantially L-shaped structural member shown in FIG. 1, the substantially U-shaped structural member shown in FIG. 9, or the substantially Z-shaped structural member shown in FIG. Instead of the mold, a string-shaped member used when forming the substantially inverted T-shaped structural member in FIG. 18 can be used. In such a case, a pair of string members is inserted into the endless prepreg after the releasing step (insertion step), and the string members are pulled outward in the inserted state to form an endless planar prepreg ( Tensile process). The substantially L-shaped or substantially U-shaped structural member is formed into a predetermined shape by pressing an endless flat prepreg against a molding die while pulling a pair of string-shaped members to both sides (shaping step). ) After the heat curing, the string-shaped member remains as a part of the structural member. Also,
The substantially Z-shaped structural member is formed into a predetermined shape by a lower mold and an upper mold while pulling a pair of string members outward (shaping step). It remains as part of the structural member. When the string-shaped member is used as described above, the manufacturing process of the structural member can be made simpler and easier, and the manufacturing cost can be reduced.

[0062]

According to the molding method of the first aspect of the present invention,
An endless prepreg is formed using a winding die, and a pair of rod-shaped molds is inserted into the endless prepreg and pulled to both sides, so that the formed endless planar prepreg has substantially no deflection. Then, since the endless prepreg is pressed to the mold while being pulled to both sides by a pair of rod-shaped molds and formed into an intermediate shape, it can be formed into an intermediate shape without bending. After that, since a pair of rod-shaped molds are removed to form a predetermined shape, the prepreg of the final predetermined shape has no fibers exposed at both ends, and both ends are aligned. A cutting step for cutting both ends is not required.

According to the molding method of the second aspect of the present invention, an endless prepreg is formed by using a winding die, and the endless prepreg is pulled to both sides through a pair of string-like members. The planar prepreg is substantially free of deflection. Then, the endless prepreg is formed into a predetermined shape by pressing against a forming die while being pulled to both sides by a pair of string-shaped members, so that it can be formed into a final predetermined shape without bending. In this case, since the final shape is formed without removing the pair of string-shaped members, the manufacturing process can be further simplified and the number of processes can be reduced. Further, the prepreg formed in the final shape has no fibers exposed at both ends and has both ends aligned, so that a cutting step of cutting both ends as in the conventional case is unnecessary.

According to the molding method of the third aspect of the present invention, an endless prepreg is formed by using a winding die, and a pair of rod-shaped dies is inserted into the endless prepreg and pulled on both sides. The resulting endless planar prepreg has substantially no deflection. Then, the endless prepreg is formed in an intermediate shape by the upper mold and the lower mold while being pulled to both sides by a pair of rod-shaped molds, so that the prepreg can be formed in an intermediate shape without bending. Then, since a pair of rod-shaped molds are removed and the upper and lower molds are used to form a predetermined shape, the prepreg having the final predetermined shape has no fibers exposed at both ends and has both ends aligned. This eliminates the need for a cutting step for finally cutting both ends as in the conventional case.

According to the molding method of the fourth aspect of the present invention, an endless prepreg is formed by using a winding die, and the endless prepreg is pulled to both sides through a pair of string-like members. The planar prepreg is substantially free of deflection. Since the endless prepreg is formed into a predetermined shape by the upper and lower molds while being pulled to both sides by a pair of cord-like members, it can be formed into a final predetermined shape without bending. In this case, since the final shape is formed without removing the pair of string-shaped members, the manufacturing process can be further simplified and the number of processes can be reduced. Further, the prepreg formed in the final shape has no fibers exposed at both ends and has both ends aligned, so that a cutting step of cutting both ends as in the conventional case is unnecessary. Further, since the upper mold and the lower mold are used at the time of molding, it can be formed into a desired shape, and can be conveniently applied to, for example, molding a Z-shaped structural member.

According to the molding method of the fifth aspect of the present invention, an endless prepreg is formed by using a winding die having a triangular cross section, and a string-shaped member is formed at each of three corners of the endless prepreg. The prepreg is formed into a substantially inverted T-shaped predetermined shape using a string-shaped member and a forming die, so that the formed prepreg has substantially no inverted T-shaped deflection. Also, the portion where the string-shaped member is located is the end of the substantially inverted T-shaped prepreg,
Since these ends are endless, the fibers are not exposed at these ends and the ends are aligned, so that a cutting step for cutting both ends as in the conventional case is unnecessary. Further, since the three T-shaped members and the forming die are formed in a substantially inverted T shape, the inverted T-shaped structural member can be formed easily and easily.

According to the molding method of the sixth aspect of the present invention, the triangular filler is interposed at the joint of the prepreg when the prepreg is formed in a substantially inverted T shape. Can be formed.

According to the molding method of the present invention, an endless prepreg is formed by using a winding die having a rectangular cross section, and a string is formed on each of the four corners of the endless prepreg. The prepreg is formed into a substantially H-shaped predetermined shape by using the string-shaped member and the forming die through the member, so that the formed prepreg has no substantially H-shaped deflection. Also, the portion where the string-like member is located is the end of the substantially H-shaped prepreg, and since these ends are endless, the fibers are not exposed at these ends, and the ends are aligned. This eliminates the need for a conventional cutting step for cutting both ends. In addition, since the four H-shaped members and the forming die are formed in a substantially H shape, the inverted H-shaped structural member can be formed easily and easily.

Further, according to the molding method of claim 8 of the present invention, the triangular filler is interposed in each of the joints of the prepreg when forming the joint into a substantially H shape, so that the joints can be accurately formed into a predetermined shape. Can be formed.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a first example of a structural member formed by a forming method according to the present invention.

FIG. 2 is a simplified perspective view for explaining a winding step in a first molding method for molding the structural member of FIG. 1;

FIG. 3 is a simplified perspective view for explaining a demolding step of the first molding method.

FIG. 4 is a simplified perspective view for explaining a molding and tensioning step of the first molding method.

FIG. 5 is a simplified front view for explaining a part of the intermediate shaping step of the first molding method.

FIG. 6 is a simplified front view for explaining another part of the intermediate shaping step of the first molding method.

FIG. 7 is a front view schematically showing a state after a finish shaping step of the first molding method.

FIG. 8 is a perspective view showing a state after a finish shaping step of the first molding method.

FIG. 9 is a perspective view showing a second example of the structural member formed by the forming method according to the present invention.

10 is a simplified front view for explaining a part of an intermediate shaping step in a second molding method for molding the structural member of FIG. 9;

FIG. 11 is a simplified front view for explaining another part of the intermediate shaping step of the second molding method.

FIG. 12 is a front view schematically showing a state after a finish shaping step of the second molding method.

FIG. 13 is a perspective view showing a third example of the structural member formed by the forming method according to the present invention.

FIG. 14 is a simplified front view for explaining a part of an intermediate shaping step in a third forming method for forming the structural member of FIG. 13;

FIG. 15 is a simplified front view for explaining another part of the intermediate shaping step of the third molding method.

FIG. 16 is a front view schematically showing a state after a finish shaping step of the third molding method.

FIG. 17 is a perspective view showing a state after a finish shaping step of the third molding method.

FIG. 18 is a perspective view showing a fourth example of the structural member formed by the forming method according to the present invention.

FIG. 19 is a simplified perspective view for explaining a winding step in a fourth forming method of forming the structural member of FIG. 18;

FIG. 20 is a simplified perspective view for explaining a demolding step of a fourth molding method.

FIG. 21 is a simplified perspective view for explaining an insertion step of a fourth molding method.

FIG. 22 is a simplified front view for explaining a part of the intermediate shaping step of the fourth molding method.

FIG. 23 is a simplified front view for explaining another part of the intermediate shaping step of the fourth molding method.

FIG. 24 is a simplified front view for explaining still another part of the intermediate shaping step of the fourth molding method.

FIG. 25 is a simplified front view showing a part of a modification of the intermediate shaping step.

FIG. 26 is a simplified front view showing another part of the modification of the intermediate shaping step.

FIG. 27 is a perspective view showing a fifth example of the structural member formed by the forming method according to the present invention.

FIG. 28 is a simplified perspective view for explaining a winding step in a fifth forming method for forming the structural member of FIG. 28.

FIG. 29 is a simplified perspective view for explaining a demolding step of the fifth molding method.

FIG. 30 is a simplified perspective view for explaining an insertion step of a fifth molding method.

FIG. 31 is a simplified front view for explaining a part of the intermediate shaping step of the fifth molding method.

FIG. 32 is a simplified front view for explaining another part of the intermediate shaping step of the fifth molding method.

FIG. 33 is a simplified front view for explaining still another part of the intermediate shaping step of the fifth molding method.

[Explanation of symbols]

2,32,52,72,122 Structural member 4,78,130 Wound type 6,80,132 Sheet prepreg 8,38,58,82,134 Endless prepreg 12,14,34,36,54, 56 Molding 20, 40, 60, 62, 90, 102, 104 Mold 84, 86, 88, 136, 138, 140, 142
String-shaped member 92,94 Upper holding mold 100,112,160 Filler material 144,146,148,150 Bar-shaped mold

 ──────────────────────────────────────────────────続 き Continuing from the front page (72) Inventor Yukio Hamaguchi 1002-1, Matsuo-cho, Toba-shi, Mie Prefecture F-term (reference) 4F205 AA37 AA39 AD16 AH47 HA02 HA08 HA23 HA33 HA35 HA45 HB02 HC16 HC17 HF04 HG04 HK03 HK04 HK05 HK24 HK31 HK37 HL02 HL19 HL24 4F209 AA37 AA39 AD16 AH47 NA01 NA16 NB02 NG03 NH18 NK01 NK10 NW05 NW21

Claims (8)

[Claims] A winding step of winding a prepreg formed of a fiber-reinforced composite material around a winding die to form an endless prepreg; a removing step of removing the winding die from the endless prepreg; A pair of rod-shaped molds are inserted into the endless prepreg from which the winding mold has been removed, and a pair of rod-shaped molds are inserted and pulled to both sides to form an endless planar shape. An intermediate shaping step of pressing the prepreg of the present invention into a molding die to form an intermediate shape; a demolding step of removing the pair of rod-shaped moldings from the endless prepreg formed in the intermediate shape; and the pair of rod-shaped moldings. And forming the endless prepreg into a predetermined shape after removing the prepreg. 2. A winding step of winding a prepreg formed from a fiber-reinforced composite material around a winding mold to form an endless prepreg; a removing step of removing the winding mold from the endless prepreg; A tensioning step of passing a pair of string members through the endless prepreg from which the winding mold is removed and pulling the pair of string members to both sides to form an endless plane, and pulling the pair of string members to both sides to form an endless flat prepreg. Forming a fiber-reinforced composite material into a predetermined shape by pressing against a forming die. 3. A winding step of winding a prepreg formed of a fiber-reinforced composite material around a winding die to form an endless prepreg; a removing step of removing the winding die from the endless prepreg; A molding and drawing step of inserting a pair of rod-shaped molds into the endless prepreg from which the winding mold has been removed and pulling on both sides to form an endless flat shape; and And an intermediate shaping step of forming an intermediate shape by a lower mold, a demolding step of removing the pair of rod-shaped molds from the endless prepreg formed in the intermediate shape, and removing the pair of rod-shaped molds And forming the endless prepreg into a predetermined shape using the upper mold and the lower mold. 4. A winding step of winding a prepreg formed of a fiber-reinforced composite material around a winding die to form an endless prepreg; a removing step of removing the winding die from the endless prepreg; A tensioning step of passing a pair of string-shaped members through the endless prepreg from which the winding mold is removed and pulling the pair of string-shaped members to form an endless planar shape; A forming step of forming an endless planar prepreg into a predetermined shape by a mold, and a method of forming a fiber-reinforced composite material. 5. A winding step of winding a prepreg formed of a fiber-reinforced composite material on a winding die having a triangular cross section to form an endless prepreg, and removing the winding die from the endless prepreg. Removing the removing mold, inserting the string-shaped members through the three corners of the endless prepreg from which the winding mold has been removed, and using the inserted string-shaped members and the forming dies to form the respective strings. A forming step of forming the member in a substantially inverted T shape such that a portion where the member is located is an end portion. 6. A shaping step, wherein a triangular filler material is interposed at a joint portion of an endless prepreg formed in a substantially inverted T-shape, and heat-cured.
A method for molding the fiber-reinforced composite material according to the above. 7. A winding step of winding a prepreg formed of a fiber-reinforced composite material on a winding die having a square cross section to form an endless prepreg, and removing the winding die from the endless prepreg. Removing the removing mold, inserting the string-shaped members through the four corners of the endless prepreg from which the winding mold has been removed, and using the inserted string-shaped members and the forming dies to form the respective strings. A shaping step of forming the member in a substantially H-shape such that a portion where the member is located is an end portion. 8. The method according to claim 7, wherein in the shaping step, a triangular filler material is interposed at each joint of the endless prepreg formed in a substantially H shape, and is heated and cured.
A method for molding the fiber-reinforced composite material according to the above.