JP2008012920A - Manufacturing method for fiber-reinforced composite body - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for accurately and easily manufacturing a fiber-reinforced composite body having a favorable cut surface at a low cost. <P>SOLUTION: A prepreg which is prepared by impregnating a reinforcing fiber with a matrix resin is hardened by using molding dies 2 and 3 which have cavities 20 and 30 in this manufacturing method for the fiber-reinforced composite body. The cavities 20 and 30 of the molding dies 2 and 3 have shapes corresponding to the outer shape of the fiber-reinforced composite body. After cutting off an excessive thickness of the prepreg along the edges (wall surfaces 20c and 30d) of the cavities 20 and 30 with the prepreg pinched by the cavities 20 and 30, the matrix resin is hardened in the manufacturing method. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a method for producing a fiber-reinforced composite accurately and simply at low cost.

  Conventionally, a cured prepreg molded body (fiber reinforced composite) made of carbon fiber reinforced plastic (CFRP) or the like is cured with a surplus thickness in order to ensure dimensional accuracy. It is manufactured by removing surplus with a cutting tool such as an end mill or a router. However, the fiber reinforced composite material is difficult to cut because of its high strength and rigidity, the cutting tool wears quickly, and the useful life of the cutting tool is short. In addition, there is a problem that fibers remain on the cutting surface in a fluffy state or delamination occurs from the cutting surface due to vibration during processing, resulting in a decrease in strength and fatigue failure. As an end mill with improved wear resistance, an end mill has been proposed in which fine diamond particles are electrodeposited on the cutting part. However, the end mill has a short service life because clogging of grinding powder occurs.

  Therefore, Japanese Patent Publication No.59-27827 (Patent Document 1) discloses a cutting method in which the fiber-reinforced composite material is gripped with a jig as a cutting method in which no fluffing or burring occurs on the cutting surface of the fiber-reinforced composite material, and the twist angle at the top and bottom. Have proposed a method of cutting using the overlapping portion of each cutting edge of a router having different cutting edges.

  Japanese Utility Model Publication No. 2-82461 (Patent Document 2) is an end mill that does not cause clogging of grinding powder when grinding fiber reinforced composite materials. An end mill formed on the peripheral surface of the grinding part is proposed.

  JP-A-5-318218 (Patent Document 3) discloses a carbon fiber prepreg laminate and glass fibers provided on both sides thereof as a method of cutting a cured fiber reinforced plastic laminate while preventing delamination and fiber tearing. A method of cutting an end face of a fiber reinforced plastic laminate having the same carbon fiber orientation in both surface layers of the carbon fiber prepreg laminate after heat-curing, the cutter comprising: Proposes a 90-180 ° rake face.

  Japanese Patent Laid-Open No. 2002-283101 (Patent Document 4) is a method for cutting an end face of a rotating fiber reinforced composite material with a tool in order to obtain a good cut surface of the fiber reinforced composite material. A method has been proposed in which the relative movement between the tool and the fiber reinforced composite material per vibration cycle is made to be twice or less the diameter of the reinforcing fiber.

  However, the methods of Patent Documents 1, 2, and 4 have a problem of high cost because they require special tools. Moreover, in the method of patent document 3, the laminated structure of a fiber reinforced plastic laminated board is restricted, and the freedom degree of design is restricted.

Japanese Patent Publication No.59-27827 Japanese Utility Model Publication 2-82461 JP-A-5-318218 JP 2002-283101 A

  Accordingly, an object of the present invention is to provide a method for easily and inexpensively producing a fiber-reinforced composite having a good cut surface.

  As a result of earnest research in view of the above-mentioned object, the present inventors cut the surplus along the edge of the cavity in a state where the prepreg is arranged in the cavity of the mold, and then harden the matrix resin, The present inventors have found that a fiber-reinforced composite having a good cut surface can be accurately and simply manufactured at low cost, and have arrived at the present invention.

  That is, the method of the present invention for producing a fiber reinforced composite from a prepreg in which a reinforced fiber is impregnated with a matrix resin has the prepreg surplus along the edge of the cavity in a state where the prepreg is disposed in the cavity of a mold. The matrix resin is hardened after the material is excised.

  In this method, (1) from the design dimensions of the fiber reinforced composite at room temperature, the linear expansion coefficient of the fiber reinforced composite is used to calculate the dimensions of the fiber reinforced composite at the curing temperature of the prepreg; 2) It is preferable to calculate the room temperature dimension of the cavity of the mold so as to be the same dimension as the fiber-reinforced composite at the curing temperature using the linear expansion coefficient of the mold.

  The fiber reinforced composite has a rectangular flat plate portion and at least one flange portion projecting from an end thereof, and the mold cavity has a horizontal portion for supporting the rectangular flat plate portion, and the flange portion. It preferably has at least one vertical part to support.

  A molding die composed of an upper die and a lower die provided with a cavity in at least one of them is used, and the horizontal portions of the upper die and the lower die have holes to be aligned, and the inside of the cavity is formed by a drilling tool inserted into the hole. It is preferable to form a bonding hole in the rectangular flat plate portion of the cured prepreg molded body.

  It is preferable that the vertical part of the upper mold and / or the lower mold has a hole, and a bonding hole is provided in the flange part of the cured prepreg molded body in the cavity by a drilling tool inserted into the hole. It is preferable that a flat tool is inserted into at least one groove provided on the end face of the cavity to detach the fiber reinforced composite from the cavity face.

  The method of the present invention for producing a fiber-reinforced composite having a rectangular flat plate portion and a flange portion protruding from the end portion thereof from a prepreg in which a reinforcing fiber is impregnated with a matrix resin includes an upper die and a lower die provided with a cavity. And a mold having a side mold, and the cavity of the upper mold and the lower mold includes a horizontal portion having a first hole at a position to be aligned, and a vertical portion at least partially having a second hole. (1) placing the prepreg laminate in each of the cavities of the upper mold and the lower mold, and (2) cutting off the surplus of the prepreg laminate along the edge of each cavity, (3) ) After closing the upper mold, the lower mold and the side mold, the matrix resin is cured by heating the prepreg laminate, and (4) the obtained cured prepreg molded body is held in the cavity. Insert into the first hole (5) At least one side surface of the upper mold or the lower mold is aligned with the second hole of the vertical section with a drilling tool provided in the rectangular flat plate portion of the cured prepreg molded body. A jig having a hole is fixed, and a bonding hole is provided in at least one flange portion of the cured prepreg molded body by a drilling tool inserted into the hole.

  According to the present invention, the surplus is removed from the prepreg that can be easily trimmed, so that the fiber-reinforced composite having a good cut surface can be accurately and easily compared with the conventional method of removing surplus from the cured prepreg molded body. Can be manufactured at low cost.

[1] Manufacturing Method of Fiber Reinforced Composite FIG. 1 shows an example of a fiber reinforced composite manufactured by the method of the present invention. This panel-like fiber reinforced composite 1 is formed by curing a prepreg in which a reinforcing fiber is impregnated with a matrix resin, and has a rectangular flat plate portion 10 and flange portions 11 and 11 projecting from one side edge in the transverse direction to one side. And flange portions 12 and 12 projecting from both side edges in the longitudinal direction of the flat plate portion 10, circular holes 13 and 13 for weight reduction provided in the flat plate portion 10, and provided at four corners of the flat plate portion 10. And an arcuate cutout portion 14. One of the flat plate portion 10, the flange portions 11, 11 and the flange portion 12 of the panel-like fiber reinforced composite 1 is provided with a hole 15 for joining to another member by a joining member such as a rivet. Hereinafter, the method for producing the fiber-reinforced composite of the present invention will be described by taking as an example the method of forming the panel-like fiber-reinforced composite 1 shown in FIG.

(1) Mold
(a) Shape FIGS. 2-4 shows an example of the type | mold which shape | molds the panel-like fiber reinforced composite 1 shown in FIG. This mold includes upper and lower molds 2 and 3 having cavities 20 and 30 forming a flat plate portion 10 and flange portions 11, 11, 12 and 12 of the fiber reinforced composite 1, and upper and lower molds 2 and 2. 3 have side molds 4, 4, 5, and 5 that are in close contact with each other.

  The cavity 20 of the upper mold 2 has a horizontal portion 20 a that forms the flat plate portion 10 of the fiber reinforced composite 1 and vertical portions 20 b and 20 b that form the flange portions 12 and 12 of the fiber reinforced composite 1. Fan-shaped convex parts 23a, 23a, 23a, 23a are provided at the four corners of the horizontal part 20a with the arc part inside, and the flat side surface of each fan-shaped convex part 23a projects slightly outward from the vertical parts 20b, 20b. ing. Since each vertical portion 20b extends partway in the thickness direction of the upper mold 2, the root portion (upper portion) of the adjacent fan-shaped convex portion 23a is connected by a horizontal convex portion 23c along the upper surface of the upper die 2. Since the groove 21a for accommodating the resin leak prevention seal 66 is formed along the outer periphery of the cavity 20, the flange portion 22a is formed between the outer peripheral edge of the cavity 20 and the groove 21a.

  In the center of the horizontal portion 20a, a pair of circular convex portions 23b, 23b for providing the circular holes 13, 13 of the fiber reinforced composite 1 are provided. A hole 25 into which a pin 65 described later is inserted is provided at the center of each circular protrusion 23b. Between each circular convex part 23b and the annular flange part 22b of the same height provided in the outer periphery, the annular groove 21b which accommodates the resin leak prevention seal 66 is provided.

  The upper mold 2 is provided with a hole 24 into which a drill is inserted in order to provide the hole 15 of the fiber reinforced composite 1. As shown in FIG. 3 (a), the hole 24 has a large diameter portion 24a having a screw thread from the upper side and a small diameter hole portion 24b having no screw thread. The resin leakage prevention plug 62 for the upper mold 2 has a shape complementary to the hole 24 and has a threaded head 62a that is screwed into the large-diameter hole 24a. Since the O-ring (for example, made of silicone rubber, fluorine-containing rubber) 62c is attached to the tip end portion 62b inserted into the small diameter hole portion 24b, resin leakage can be prevented. When the plug 62 is screwed into the hole 24, the distal end surface of the small diameter hole portion 24b is flush with the horizontal portion 20a of the cavity 20.

  As shown in FIG. 4 (a), in order to remove the molded fiber-reinforced composite 1 from the upper mold 2, a flat screwdriver or the like is provided on the inner surface (end surface 20c of the cavity 20) of the flange portion 22a of the upper mold 2. A shallow groove 26 into which a tool is inserted is provided as appropriate.

  The lower mold 3 has a shape corresponding to the upper mold 2. The cavity 30 of the lower mold 3 includes a horizontal portion 30a that forms the flat plate portion 10 of the fiber reinforced composite 1, vertical portions 30b and 30b that form the short direction flange portions 11 and 11 of the fiber reinforced composite 1, and fibers. It has vertical portions 30c, 30c that form longitudinal flange portions 12, 12 of the reinforced composite 1. Fan-shaped convex portions 33a, 33a, 33a, 33a having the same shape as the fan-shaped convex portions 23a, 23a, 23a, 23a of the upper mold 2 are provided at the four corners of the horizontal portion 30a, and each fan-shaped convex portion 33a is flat. The side surfaces protrude slightly outward from the vertical portions 30b, 30b, 30c, 30c. Since each vertical part 30b, 30c extends partway in the thickness direction of the lower mold 2, the root part (lower part) of the adjacent fan-shaped convex part 33a is connected by a horizontal convex part 33c along the lower surface of the lower mold 3. Yes. Since the groove 31a for accommodating the resin leakage prevention seal 66 is formed along the outer periphery of the cavity 30, the gap between the outer peripheral edge of the cavity 30 and the groove 31a is the flange portion 32a.

  A pair of circular convex portions 33b, 33b for providing the circular holes 13, 13 of the fiber reinforced composite 1 are provided in the center of the horizontal portion 30a. An annular groove 31b for accommodating a resin leakage prevention seal 66 is provided between each circular convex portion 33b and an annular flange portion 32b of the same height provided on the outer periphery thereof. A hole 37 into which the pin 65 is inserted is provided at the center of each circular convex portion 33b. Since the pin 65 has a head 65 a having a diameter larger than that of the hole 37, when each pin 65 is inserted into the hole 37, the head 65 a enters the hole 25 of the upper mold 2 without entering the hole 37. As a result, the position of the upper mold 2 with respect to the lower mold 3 is determined.

  The lower mold 3 has a hole 34 vertically aligned with the hole 24 of the upper mold 2 in the horizontal part 30a, and has a hole 34 'in one vertical part 30b and both vertical parts 30c, 30c. The holes 34 and 34 'have the same diameter, and a drill for forming the hole 15 of the fiber reinforced composite 1 is inserted. As shown in FIG. 3 (b), the hole 34 has a small diameter portion 34a and a large diameter portion 34b from the upper side. The resin leakage prevention plug 63 for the lower mold 3 includes a small diameter portion 63a that is in close contact with the small diameter hole portion 34a, and a large diameter portion 63b that enters the large diameter hole portion 34b. Although not shown, the large-diameter portion 63b may be screwed into the large-diameter hole portion 34b as necessary to prevent the plug 63 during molding from falling off. The tip surface of the plug 63 mounted in the holes 34 and 34 ′ is in the same plane as the horizontal portion 30a or the vertical portions 30b and 30c of the cavity 30. A groove 38 for removing the plug 63 from the hole 34 ′ after the matrix resin is cured is provided on the lower surface of the lower mold 3 along the vertical portions 30 b and 30 c of the cavity 30.

  As shown in FIG. 4B, a shallow tool for removing the molded fiber-reinforced composite 1 from the lower mold 3 is also inserted into the inner surface (end surface 30d of the cavity 30) of the flange portion 32a of the lower mold 3. A groove 36 is provided.

  Since the cured fiber reinforced composite 1 tends to be thickened by about 0.1 mm after the mold is opened, the cavity formed by the upper mold 2 and the lower mold 3 cavities 20 and 30 should be thinned by about 0.1 mm in advance. preferable.

(b) Material Examples of the material constituting the upper mold 2 and the lower mold 3 include cast iron, steel (for example, JIS SS400), carbon steel (for example, JIS S45C-H), and the like. As the cast iron, one having a low linear expansion coefficient marketed under the trade name “Novinite” from Enomoto Casting Co., Ltd. is preferable. Examples of the material constituting the side molds 4 and 5 include aluminum.

  Examples of the material of the plugs 62 and 63 and the pin 65 include alloy steel (for example, JIS SCM435H). The material of the seal 66 is a rubber having heat resistance that can withstand the curing temperature, and examples thereof include fluorine-containing rubber such as polytetrafluoroethylene (PTFE), silicone rubber, and the like. As a commercial product of PTFE seal, GORE-TEX No.3300 (manufactured by Japan Gore-Tex Co., Ltd.) can be mentioned.

(2) Manufacturing process
(a) Prepreg Lamination Step Resin leakage prevention plugs 62 and 63 are inserted into the hole 24 of the upper mold 2 and the holes 34 and 34 ′ of the lower mold 3 in advance. A plurality of rectangular cloth prepregs having four corners cut out in a fan shape are stacked on the upper die 2 and the lower die 3. As shown in FIGS. 5 (a) and 5 (b), the prepreg laminates 1a and 1b on the upper mold 2 and the lower mold 3 each have a surplus.

  The cloth-like prepreg is obtained by impregnating a matrix resin into a cloth made of reinforcing fibers. The reinforcing fiber is not particularly limited and is appropriately selected from carbon fiber, aramid fiber, glass fiber, boron fiber, and the like according to the use. The matrix resin is preferably a thermosetting resin, and is appropriately selected from an epoxy resin, a polyurethane, an unsaturated polyester, a bismaleimide resin, a phenol resin, and the like according to applications. When the panel-like fiber reinforced composite 1 is used as an aircraft fuselage member, the reinforcing fiber is preferably a carbon fiber, and the matrix resin is preferably an epoxy resin.

(b) Surplus cutting process As shown in FIGS. 5 (c) and 5 (d), the surplus of the prepreg laminate 1a is made along the end surface 20c of the cavity 20 of the upper mold 2 by a trimming tool 72 such as a cutter. 12a is cut (trimmed), and surplus thicknesses 11b and 12b of the prepreg laminate 1b are cut along the end face 30d of the cavity 30 of the lower mold 3. Seals 66 are attached to the grooves 21a and 21b of the upper mold 2 and the grooves 31a and 31b of the lower mold 3. Silicone sheets are packed into the groove 26 of the upper mold 2 and the groove 36 of the lower mold 3. The pins 65 are inserted into the holes 37 of the lower mold 3 and their heads 65a are inserted into the holes 25 of the upper mold 2 so that the prepreg laminates 1a and 1b are in contact with each other as shown in FIG. The upper mold 2 is placed on the mold 3. As shown in FIGS. 5 (f) and 5 (g), the lower mold 3 is placed in a state where the prepreg laminated body 1 a placed on the upper mold 2 is hung on the prepreg laminated body 1 b placed on the lower mold 3. Along with the end face 30d of the cavity 30, the longitudinal surplus 11a of the prepreg laminate 1a is cut off. Trimming is usually performed at room temperature.

  In the present invention, surplus cuts are cut from the uncured prepreg laminates 1a and 1b that can be easily trimmed, so that a fiber-reinforced composite having a good cut surface can be easily compared with the conventional method of trimming a cured prepreg molded body. Can be manufactured.

(c) Flange prepreg laminating step As shown in FIGS. 5 (h) and 5 (i), in order to reinforce the flanges 12 and 12, the band-like prepreg 1c is filled with reinforcing fibers and matrix resin. The prepreg laminates 1a and 1b are laminated on the flange portions 12a and 12b via the material 1d. In this way, a prepreg assembly 1 ″ obtained by integrating the prepreg laminates 1a and 1b, the strip-shaped prepreg 1c, and the filler 1d is obtained.

(d) Curing Step As shown in FIG. 6, the side molds 4, 4, 5, and 5 are attached to the side surfaces of the combined upper mold 2 and lower mold 3 to support the flange portion of the prepreg assembly 1 ″. As shown in FIG. 7, the entire mold is placed on a base 80 and covered with a bag film 81. The inside of the bag film 81 is depressurized through a tube 82 connected to a vacuum pump. The bag film 81 is adhered to the upper surface of the substrate 80 with an adhesive tape 83 so that the vacuum state can be maintained.

  The bag film 81 is heated while being kept in a vacuum state (see FIG. 8) to cure the matrix resin. Although heating can be performed in an oven or the like, it is preferably performed while pressurizing in an autoclave. The heating temperature varies slightly depending on the type of thermosetting resin, but is preferably 120 to 180 ° C. When using an autoclave, it is preferable to pressurize to about 3-6 MPa.

(e) Drilling step After cooling to room temperature, the side molds 4, 4, 5, and 5 are removed, and as shown in FIG. 9, the shoulder bolt 64 is attached to the plate-shaped drilling jigs 6, 6, 7, and 7. The plate-shaped drilling jigs 6, 6, 7, and 7 are attached to the lower mold 3 by screwing into the holes 35 through the holes 61 and 71. The drilling jigs 6 and 7 are respectively provided with holes 60 and 70 for inserting a drilling tool in order to provide the holes 15 of the fiber reinforced composite 1 in the mold. The drilling jigs 6 and 7 can be formed of aluminum or the like. The shoulder bolt 64 can be formed of alloy steel (for example, JIS SCM435H).

  The resin leakage prevention plugs 62, 63 are removed from the holes 24, 34, 34 'of the molds 2, 3. As shown in FIG. 9, a cylindrical guide plug 67 having a hole 67a is inserted into the holes 24, 60 and 70 of the upper mold 2 and the drilling jigs 6 and 7. As shown in FIG. 10, the guide plug 67 has a large diameter portion 67b that is in close contact with the large diameter portion 24a of the hole 24 and a small diameter portion 67c that is in close contact with the small diameter hole portion 24b of the hole 24. Since the holes 60 and 70 of the jigs 6 and 7 have the same shape as the hole 24 except that they do not have threads, the guide plug 67 is engaged.

  As shown in FIG. 11, a drilling tool 73 such as an NC drill is inserted into the hole 67a of the guide plug 67 to drill a cured prepreg molded body 1 ′ obtained by curing the prepreg assembly 1 ″. In order to improve the accuracy of the hole 15 of the fiber reinforced composite 1 obtained by drilling, it is preferable that the diameter of the hole 67a of the guide plug 67 is greater than the diameter D of the drilling tool 73 to D + 50 μm or less. The guide plug 67 is fixed in the holes 24, 60, and 70, and the cured prepreg molded body 1 ′ is vertically drilled. In this way, drilling is performed using the drilling jigs 6 and 7 having the holes 24, 34, 34 ', 60 and 70 in a state where the cured prepreg molded body 1' is held in the molds 2 and 3, The joining hole 15 can be accurately and efficiently formed.

(f) Demolding process The molds 2 and 3 and the drilling jigs 6 and 7 are removed from the obtained fiber-reinforced composite 1. As shown in FIG. 12, the hole 25 of the upper mold 2 is provided with a thread. The upper die 2 and the lower die 3 can be easily separated by screwing a bolt 74 into the threaded hole 25 and pushing the head 65a of the pin 65 at its tip. A flat tool 75 such as a flat-blade screwdriver is inserted into the groove 26 provided in the flange portion 22a of the upper mold 2 to separate the fiber reinforced composite 1 from the upper mold 2. As shown in FIG. 13, a flat tool 75 is also inserted into the groove 36 provided in the flange portion 32a of the lower mold 3, and the fiber-reinforced composite 1 is lifted from the lower mold 3 and separated.

(3) Other Embodiments FIG. 14 shows another example of a fiber reinforced composite produced by the method of the present invention. This panel-like fiber reinforced composite 1 has the fiber reinforcement shown in FIG. 1 except that flanges 12 and 12 provided on the side edges in the longitudinal direction protrude only on one side and do not have circular holes 13 and 13. Same as Complex 1. FIG. 15 shows an example of a mold for molding the fiber-reinforced composite 1 shown in FIG. This molding die is the same as the molding die shown in FIGS. 2 to 4 except that it comprises an upper die 2 having no cavity and a lower die 3 having no circular convex portion 33b. Since the molding method using this mold is essentially the same as described above, the description thereof is omitted.

(4) Mold size setting In order to prevent deterioration of dimensional accuracy due to thermal expansion during heat curing, fiber reinforced composite 1 (prepreg assembly 1 ″, cured prepreg molded body 1 ′) and mold are It is preferable to have a linear expansion coefficient as close as possible. Specifically, the linear expansion coefficient of CFRP used for the fiber reinforced composite 1 is about 2.6 × 10 ⁻⁶ / ° C., so novinite grade CS-5 [linear expansion coefficient: 2.5 × 10 ⁻⁶ / ° C. (200 ° C)] or CN-5 [linear expansion coefficient: 2.7 × 10 ⁻⁶ / ° C. (200 ° C.)]. However, when the difference in linear expansion coefficient between the two is relatively large, it is preferable to determine the room temperature dimensions of the cavities of the molds 2 and 3 so as to have the same dimensions as the cured prepreg molded body 1 ′ at the curing temperature.

The accuracy of the dimensions of the flat portion 10 of the fiber-reinforced composite 1 is important to the design length and W _1, the length of the cavity in which the design length is obtained as W _2. When the temperature rises from room temperature to the curing temperature, as shown in FIG. 16, the length W ₁ of the flat plate portion 10 becomes W ₁ + ΔW ₁ (= α ₁ · W ₁ · ΔT), and the cavity length W ₂ becomes W ₂ + ΔW. ₂ (= α ₂ · W ₂ · ΔT). Here, α ₁ is the linear expansion coefficient of the fiber reinforced composite 1, α ₂ is the linear expansion coefficient of the lower mold 3, and ΔT is the difference (° C.) between the room temperature and the curing temperature. At the curing temperature, the length of the flat plate portion 10 is the same as the length of the cavity, so that W ₁ + α ₁ · W ₁ · ΔT = W ₂ + α ₂ · W ₂ · ΔT holds. Therefore, W ₂ is represented by the following formula (1).
W ₂ = W ₁ × (1 + α ₁ · ΔT) / (1 + α ₂ · ΔT) (1)

  When the fiber reinforced composite 1 is removed from the molds 2 and 3, the angle between the flat plate portion 10 and the flange portion 11 of the fiber reinforced composite 1 tends to slightly decrease, so that only a decrease (for example, about 0.5 to 1.5 °). It is preferable that the angle formed by the horizontal portions 20a and 30a and the vertical portions 30a and 30b of the cavities 20 and 30 is larger than the angle in the final product.

[2] fuselage structure The fiber-reinforced composite obtained by the manufacturing method as described above is suitable as a member constituting the aircraft fuselage structure because it is lightweight and has high strength. FIG. 18 shows an example in which an aircraft fuselage structure is configured using a fiber reinforced composite produced by the method of the present invention. The fiber reinforced composite 1 is joined by a rivet 90. The structure shown in FIG. 18 can be used as a structure for an aircraft fuselage floor, for example. In this example, the fiber reinforced composites 1 are bonded to each other, but the present invention is not limited to this, and may be bonded to another member such as an aluminum alloy member. In the example shown in FIG. 18, the fiber reinforced composites 1 having the same shape are joined. However, the present invention is not limited to this, and fiber reinforced composites 1 having different shapes may be combined.

It is a perspective view which shows an example of the fiber reinforced composite body manufactured by the method of this invention. It is a disassembled perspective view which shows an example of the type | mold which shape | molds the fiber reinforced composite of FIG. It is the top view which shows the upper mold | type of Fig.2 (a), a longitudinal direction side view, a transversal direction side view, and a bottom view. It is the top view which shows the lower mold | type of Fig.2 (a), a longitudinal direction side view, a transversal direction side view, and a bottom view. It is a fragmentary sectional view which shows the pin mechanism provided in the upper mold | type. It is a fragmentary sectional view which shows the pin mechanism provided in the lower mold | type. FIG. 3 is an enlarged perspective view showing a portion A in FIG. It is an expansion perspective view which shows the B section of Fig.2 (a). It is a side view which shows the state which mounted the prepreg laminated body in the upper mold | type. It is a side view which shows the state which mounted the prepreg laminated body in the lower mold | type. It is a side view which shows a mode that the transverse direction surplus of the prepreg laminated body mounted in the upper mold | type is excised. It is a side view which shows a mode that the transverse direction surplus of the prepreg laminated body mounted in the lower mold | type is excised. It is the top view and side view which show the state in which the prepreg laminated body which cut off the surplus thickness was accommodated in the cavity of the lower mold | type. It is a side view which shows a mode that the longitudinal direction surplus of the prepreg laminated body (it hangs on the prepreg laminated body mounted in the lower mold | type) mounted in the upper mold | type is excised. It is CC partial sectional drawing of FIG.5 (f). It is a side view which shows the state which laminated | stacked the strip | belt-shaped prepreg on the flange part of the prepreg laminated body clamped by the upper mold | type and the lower mold | type. FIG. 6 is an enlarged cross-sectional view showing a portion D in FIG. It is a side view which shows the state which attached the side type | mold to the side surface of the integrated upper mold | type and lower mold | type of FIG.5 (i). It is sectional drawing which shows a mode that a prepreg assembly and a shaping | molding die are coat | covered with a bag film, and it deaerates. It is sectional drawing which shows the state which hold | maintained the prepreg assembly and the shaping | molding die under the vacuum. It is a disassembled perspective view which shows an example of the jig | tool used in order to perforate a hardening prepreg molded object. It is a fragmentary sectional view which shows the state which inserted the guide plug in the hole of the upper mold | type. It is a fragmentary sectional view which shows a mode that the hardening prepreg molded object is punched. It is a fragmentary sectional view which shows a mode that a volt | bolt is screwed in the hole of an upper mold | type in order to isolate | separate an upper mold | type and a lower mold | type. It is a fragmentary perspective view which shows a mode that a flat tool is inserted in the groove | channel provided in the flange part of the lower mold | type in order to isolate | separate a fiber reinforced composite body from a lower mold | type. It is a perspective view which shows another example of the fiber reinforced composite body manufactured by the method of this invention. FIG. 15 is a perspective view showing an example of a mold for molding the fiber-reinforced composite of FIG. It is sectional drawing which shows the dimension in the curing temperature of a lower mold | type and a fiber reinforced composite. It is a graph which shows the dimensional change by the temperature change of a fiber reinforced composite and a shaping | molding die. It is a perspective view which shows a part of example of the structure for aircraft fuselages formed by assembling a fiber reinforced composite.

Explanation of symbols

1 ... Fiber-reinforced composite
10 ... flat plate
11, 12 ... Flange
13 ... Round hole
14 ... Notch
15 ... hole
1a, 1b ... Prepreg laminate
1c ・ ・ ・ Strip prepreg
1d ・ ・ ・ Filler
1 '・ ・ ・ Hardened prepreg molding
10 '... flat plate
11 '・ ・ ・ Flange part
12 '・ ・ ・ Flange part
1 '' ・ ・ ・ Prepreg assembly
10 '' ... flat plate
11 ”・ ・ ・ Flange part 2 ・ ・ ・ Upper mold
20 ... cavity
20a ・ ・ ・ Horizontal part
20b ・ ・ ・ Vertical part
20c ・ ・ ・ End face
21a, 21b ... groove
22a ・ ・ ・ Flange part
22b ・ ・ ・ Annular flange
23a ・ ・ ・ Fan convex
23b ・ ・ ・ Circular convex part
23c ・ ・ ・ Horizontal convex part
24 ... hole
24a ・ ・ ・ Large diameter part
24b ・ ・ ・ Small diameter part
25 ... hole
26 ... Groove 3 ... Lower mold
30 ... cavity
30a ・ ・ ・ Horizontal part
30b, 30c ・ ・ ・ Vertical part
30d ・ ・ ・ End face
31a, 31b ... groove
32a ・ ・ ・ Flange part
32b ・ ・ ・ Annular flange
33a ... Fan-shaped convex part
33b ・ ・ ・ Circular convex part
33c ・ ・ ・ Horizontal convex part
34 ... hole
34a ・ ・ ・ Small diameter part
34b ・ ・ ・ large diameter part
34 ', 35, 37 ... holes
36 ・ ・ ・ Groove
38 ... groove 4 ... side mold 5 ... side mold 6 ... drilling jig
60, 61 ... Hole 7, 7 '... Drilling jig
70, 71 ... hole
62 ... Plug for preventing resin leakage
62a ・ ・ ・ Head
62b ・ ・ ・ Tip
62c ・ ・ ・ O-ring
63 ... Resin leakage prevention plug
64 ... shoulder bolt
65 ・ ・ ・ Pin
65a ・ ・ ・ Head
66 ・ ・ ・ Seal for preventing resin leakage
67 ... Guide plug
67a ... hole
67b ・ ・ ・ large diameter part
67c ・ ・ ・ Small diameter part
72 ・ ・ ・ Trimming tool
73 ... Drilling tool
73a ... Drill blade
74 ... Bolt
75 ・ ・ ・ Flat tool
80 ・ ・ ・ Base
81 ... Bag film
82 ... Suction tube
83 ・ ・ ・ Adhesive tape
90 ... Rivets

Claims (7)

A method for producing a fiber-reinforced composite from a prepreg in which a reinforced fiber is impregnated with a matrix resin, and with the prepreg being disposed in a cavity of a mold, an excess of the prepreg is cut along an edge of the cavity Thereafter, the matrix resin is cured. In the manufacturing method of the fiber reinforced composite of Claim 1, (1) From the design dimension of the said fiber reinforced composite in room temperature, using the linear expansion coefficient of the said fiber reinforced composite, the said in the hardening temperature of the said prepreg Calculate the dimensions of the fiber reinforced composite, and (2) use the linear expansion coefficient of the mold to calculate the room temperature dimension of the mold cavity so that it is the same size as the fiber reinforced composite at the curing temperature. A method characterized by: 3. The method of manufacturing a fiber reinforced composite according to claim 1, wherein the fiber reinforced composite has a rectangular flat plate portion and at least one flange portion protruding from an end portion thereof, and the cavity of the mold. Comprises a horizontal portion supporting the rectangular flat plate portion and at least one vertical portion supporting the flange portion. The method for producing a fiber-reinforced composite according to any one of claims 1 to 3, wherein a molding die comprising an upper die and a lower die provided with a cavity in at least one is used, and the horizontal portion of the upper die and the lower die. Has a matching hole, and a bonding hole is formed in the rectangular flat plate portion of the cured prepreg molded body in the cavity by a drilling tool inserted into the hole. 5. The method of manufacturing a fiber-reinforced composite according to claim 4, wherein the vertical portion of the upper mold and / or the lower mold has a hole, and a flange of the cured prepreg molded body in the cavity is formed by a drilling tool inserted into the hole. A bonding hole is provided in the part. 6. The method for producing a fiber reinforced composite according to claim 1, wherein a flat tool is inserted into at least one groove provided on an end surface of the cavity to remove the fiber reinforced composite from the cavity surface. A method characterized by separating. A method for producing a fiber-reinforced composite having a rectangular flat plate portion and a flange portion protruding from an end portion thereof from a prepreg in which a reinforcing fiber is impregnated with a matrix resin, the upper die and the lower die provided with a cavity; The upper mold and the lower mold cavity have a horizontal portion having a first hole at a position to be aligned, and a vertical portion at least partially having a second hole. And (1) placing the prepreg laminate in each of the cavities of the upper mold and the lower mold, (2) cutting off the surplus of the prepreg laminate along the edge of each cavity, (3) The matrix resin is cured by heating the prepreg laminate after closing the upper mold, the lower mold, and the side mold, and (4) while the obtained cured prepreg molded body is held in the cavity, Inserted into the first hole A hole for bonding is provided in the rectangular flat plate portion of the cured prepreg molded body by a drilling tool, and (5) a hole is formed at a position aligned with the second hole of the vertical portion on at least one side surface of the upper die or the lower die. And fixing a jig with a hole, and forming a bonding hole in at least one flange portion of the cured prepreg molded body by a drilling tool inserted into the hole.

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