JP2015139932A - Method for molding composite material structure, and composite material structure - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for molding a composite material structure, in which air bubbles are prevented from being left behind between a surface protective layer and a metal layer, which layers constitute the composite material structure, by a simple constitution.SOLUTION: The method for molding the composite material structure comprises the steps of: laminating the surface protective layer 2, the metal layer 3 and a fiber-reinforced resin layer 4 in this order on the molding surface 1a of a metal mold 1; and pressurizing and heating these layers to mold the composite material structure 10A. A plurality of deaeration grooves 5, through each of which an air bubble generation area of the molding surface 1a or the surface of the metal layer 3 is communicated with the outer circumferential edge thereof, are formed on at least one of the molding surface 1a of the metal mold 1 and the opposed surface of the metal layer 3 to the molding surface 1a side so that air bubbles to be left behind between the molding surface 1a and the metal layer 3 are removed from the deaeration grooves 5 at the pressurizing and heating step.

Description

  The present invention relates to a method for forming a composite material structure in which a net-like or foil-like metal layer is laminated on a fiber reinforced resin layer such as CFRP or GFRP, and a composite material structure.

  In a composite material structure using a fiber reinforced resin used for an outer surface of a building such as an aircraft or a windmill, a surface protective layer (protection) is disclosed as disclosed in, for example, Patent Document 1 in order to improve lightning resistance. For example, a metal mesh or a metal foil laminated in the vicinity of a resin film or the like.

  Specifically, as shown in FIGS. 4 and 5, a surface protective layer 2 such as a resin film is placed on the molding surface 1a of the mold 1, and a metal such as a metal mesh 3a or a metal foil 3b is formed thereon. Layers are stacked. Further, a plurality of fiber reinforced resin layers 4 such as prepregs are laminated thereon, and these are heated, evacuated and pressurized by an autoclave or the like to be molded into a composite material structure having a predetermined shape.

  When a lightning strike occurs on the composite material structure thus formed, a lightning strike current is guided to a predetermined lightning protection member through the metal layers 3a and 3b, thereby preventing the fiber reinforced resin 4 from being damaged.

JP 2006-219078 A

  However, when a plurality of layers are laminated and molded as described above, bubbles contained between the surface protective layer 2 and the metal layers 3a and 3b can be formed only by evacuation or pressurization during curing in an autoclave or the like. It is difficult to remove completely, and as a result, pits (microholes) or voids (voids) between layers are formed on the outer surface of the composite material structure, resulting in a problem that strength is deteriorated and appearance is deteriorated. In particular, in the case of the foil-like metal layer 3b, unlike the net-like metal layer 3a, the bubbles cannot remain between the metal layer 3b and the surface protective layer 2 because the bubbles cannot pass through the metal layer 3b. Becomes higher.

  In order to solve such problems, for example, as described in JP-A-5-192949, when molding and curing a composite material structure composed of fibers impregnated with a resin, a molding surface ( A forming method is known in which a facing sheet is vibrated by a vibrator.

  However, the molding method in which the molding surface of the mold is vibrated by the vibration exciter as described above merely promotes the natural removal of bubbles, and does not necessarily guarantee complete deaeration. In addition, the installation of the vibrator causes the mold structure to become complicated, which also increases the unit manufacturing cost of the molded product.

  The present invention has been made in view of such circumstances, and it is possible to prevent bubbles from remaining between the surface protective layer and the metal layer constituting the composite material structure with a simple configuration. An object of the present invention is to provide a method for forming a composite material structure and a composite material structure.

In order to solve the above problems, the present invention employs the following means.
In the first aspect of the method for molding a composite material structure according to the present invention, a surface protective layer, a metal layer, and a fiber reinforced resin layer are sequentially laminated on a molding surface of a mold, A method of forming a composite material structure by heating, wherein at least one of the molding surface or the surface of the metal layer on the molding surface side is from an area where bubbles are generated on the surface of the molding surface or the metal layer. A plurality of deaeration grooves communicating to the outer peripheral edge are formed, and bubbles remaining between the molding surface and the metal layer are degassed from the deaeration grooves during the pressurization and heating. .

According to the above molding method, when the surface protective layer, the metal layer, and the fiber reinforced resin layer laminated on the molding surface of the mold are pressed while being heated, the surface protective layer and the metal layer are Air bubbles contained therebetween are easily discharged to the outside through the deaeration groove. That is, the bubbles flow in the material of the surface protective layer that is softened during molding, and reach the deaeration groove formed on at least one of the molding surface of the mold and the surface of the metal layer. Since the deaeration groove communicates from the bubble generating area to the outer peripheral edge of the molding surface or the metal layer surface, the bubble is pushed out from the end of the deaeration groove to the outside by the pressure during molding.
As described above, bubbles remain between the surface protective layer and the metal layer constituting the composite material structure by a very simple method of forming a deaeration groove on the molding surface of the mold or the surface of the metal layer. This can be effectively prevented.

In the above forming method, the deaeration groove may be formed at the same time when the metal layer is rolled or at the time of surface treatment after the rolling.
By doing so, a dedicated process for forming a deaeration groove in the metal layer can be omitted, and bubbles can be prevented from remaining between the surface protective layer and the metal layer with a simple configuration.

  In a second aspect of the method for molding a composite material structure according to the present invention, a surface protective layer, a metal layer, and a fiber reinforced resin layer are sequentially laminated on a molding surface of a curved mold, and these are added. A method of forming a composite material structure by pressing and heating, wherein the metal layer is pre-curved according to the curved shape of the molding surface and then laminated on the surface protective layer. .

According to the above molding method, the metal layer placed on the molding surface of the curved mold via the surface protective layer is curved in accordance with the curved shape of the molding surface of the mold. Is well adapted to the molding surface of the mold, and air bubbles are prevented from remaining between the surface protective layer and the metal layer after molding.
In this way, it is possible to prevent bubbles from remaining between the surface protective layer and the metal layer by a very simple method of bending the metal layer in advance according to the curved shape of the mold forming surface. .

In the above-described forming method, the curvature of the metal layer is preferably set smaller than the curvature of the forming surface.
In this way, when the surface protective layer, the metal layer, and the fiber reinforced resin layer are pressed, the metal layer having a smaller curvature than the molding surface of the mold is formed on the surface from the central portion toward both sides. Adheres to the protective layer. For this reason, it becomes difficult for bubbles to remain between the surface protective layer and the metal layer.

The composite material structure according to the present invention is characterized by being formed by the composite material structure forming method according to any one of the above aspects.
According to this composite material structure, since no bubbles remain between the surface protective layer and the metal layer, there are no defects that cause pits (micro holes) or voids (voids) between layers on the outer surface, and good strength. And appearance can be obtained.

As described above, according to the method for molding a composite material structure according to the present invention, air bubbles are prevented from remaining between the surface protective layer and the metal layer constituting the composite material structure with a simple configuration. be able to.
In addition, according to the composite material structure of the present invention, no bubbles remain between the surface protective layer and the metal layer, and there is no problem of generating pits (micro holes) or voids (voids) between the layers on the outer surface. Good strength and appearance can be obtained.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a mold, a surface protective layer, a metal layer, and a fiber reinforced resin layer showing a first embodiment of a method for forming a composite material structure according to the present invention. It is a perspective view of a metal mold | die, a surface protective layer, a metal layer, and a fiber reinforced resin layer which shows 2nd Embodiment of the shaping | molding method of the composite material structure which concerns on this invention. It is side views, such as a metal mold | die, a surface protective layer, a metal layer, a fiber reinforced resin layer, which shows 3rd Embodiment of the shaping | molding method of the composite material structure which concerns on this invention. It is a perspective view of the metal mold | die, surface protection layer, metal layer, and fiber reinforced resin layer which show the prior art. It is a perspective view of the metal mold | die, surface protection layer, metal layer, and fiber reinforced resin layer which show the prior art.

  Hereinafter, embodiments of the present invention will be described.

[First Embodiment]
FIG. 1 is a perspective view of a mold 1, a surface protective layer 2, a metal layer 3, and a fiber reinforced resin layer 4 showing a first embodiment of a method for forming a composite material structure according to the present invention. In this embodiment, a surface protective layer 2 such as a resin film is placed on the molding surface 1a of the mold 1 and a foil-like metal layer 3 is laminated thereon, as in FIG. . Further, a plurality of fiber reinforced resin layers 4 such as prepregs are laminated thereon, and these are heated, evacuated, and pressurized by an autoclave or the like to form a composite material structure 10A having a predetermined shape.

  The difference from the prior art is that a plurality of deaeration grooves 5 are formed on the molding surface 1 a of the mold 1. These deaeration grooves 5 are formed in a straight line that communicates from the area (for example, the central region) where air bubbles easily occur on the molding surface 1a to the outer peripheral edge, but pass through the area where air bubbles easily occur and the molding surface 1a. It is preferable to form so as to communicate from one end to the other end. Further, the deaeration groove 5 may be a curved or random groove. The deaeration groove 5 is formed over the entire molding surface 1a by machining, chemical processing such as etching, or the like.

  The depth of the deaeration groove 5 is desirably about 0.05 mm. If the depth is greater than that, there is a concern that defects such as swells may occur in the composite material structure 10A after completion of molding. Moreover, although the space | interval (pitch) of the deaeration groove | channel 5 can illustrate about 2 mm, for example, it can set suitably according to conditions, such as a magnitude | size and thickness of a molded article, or a pressurization pressure, heating temperature.

  When the composite material structure 10A is molded by pressurizing and heating the surface protective layer 2, the metal layer 3, and the fiber reinforced resin layer 4, between the molding surface 1a of the mold 1 and the metal layer 3, that is, Air bubbles remaining on both surfaces of the surface protective layer 2 are degassed from the deaeration groove 5.

  That is, the bubbles flow through the material of the surface protective layer 2 that is softened during molding, and are pushed out into the deaeration grooves 5 formed on the molding surface 1 a of the mold 1. Since the deaeration groove 5 communicates from the area (for example, the central area) where bubbles are easily generated on the molding surface 1a to the outer peripheral edge, the air bubbles pushed out to the deaeration groove 5 flow along the deaeration groove 5 and are removed. The air is discharged from the end of the air groove 5 to the outside.

  In this manner, bubbles remain between the surface protective layer 2 and the metal layer 3 constituting the composite material structure 10A by a very simple method of forming the deaeration groove 5 on the molding surface 1a of the mold 1. This can be effectively prevented.

  In the composite material structure 10A molded in this way, no bubbles remain between the surface protective layer 2 and the metal layer 3, so that pits (microholes) are formed on the outer surface (the outer surface of the surface protective layer 2). ) Or interstitial voids (voids), and good strength and appearance can be obtained.

[Second Embodiment]
FIG. 2 is a perspective view of a mold 1, a surface protective layer 2, a metal layer 3, and a fiber reinforced resin layer 4 showing a second embodiment of the method for forming a composite material structure according to the present invention. In the first embodiment described above, the deaeration groove 5 is formed on the molding surface 1a of the mold 1, but in this second embodiment, the surface of the metal layer 3 on the molding surface 1a side (here, the lower surface). ), A plurality of deaeration grooves 5 having a depth of about 0.05 mm are formed. Since the other configuration is the same as that of the first embodiment (FIG. 1), the same reference numerals are given to the respective parts and the description thereof is omitted.

  The deaeration groove 5 is formed in a straight line on the lower surface of the metal layer 3 so as to communicate from an area where bubbles are likely to be generated (for example, a central region) to an outer peripheral edge. 3 is preferably formed so as to communicate from one end to the other end of the lower surface. The deaeration groove 5 may be curved or random.

  The deaeration groove 5 is formed on the lower surface of the metal layer 3 by machining, chemical processing such as etching, or the like. Or you may make it form the deaeration groove | channel 5 simultaneously at the time of the rolling process of the metal layer 3, or the surface treatment after a rolling process. The depth of the deaeration groove 5 is preferably about 0.05 mm. Moreover, the space | interval (pitch) of the deaeration groove | channel 5 can illustrate about 2 mm, for example.

  When molding the composite material structure 10B by pressurizing and heating the surface protective layer 2, the metal layer 3, and the fiber reinforced resin layer 4, it is between the molding surface 1a of the mold 1 and the metal layer 3, that is, the surface protection. Bubbles remaining on both surfaces of the layer 2 flow in the material of the surface protective layer 2 that softens during molding, and are pushed out into the deaeration grooves 5 formed on the lower surface of the metal layer 3. Since the deaeration groove 5 communicates from the area (for example, the central region) where bubbles are easily generated on the lower surface of the metal layer 3 to the outer peripheral edge, the bubbles pushed out to the deaeration groove 5 follow the deaeration groove 5. The air is discharged from the end of the deaeration groove 5 to the outside.

  In this way, the very simple configuration of forming the deaeration groove 5 in the metal layer 3 prevents bubbles from remaining between the surface protective layer 2 and the metal layer 3 constituting the composite material structure 10B. can do.

  In addition, by forming the deaeration groove 5 at the same time when the metal layer 3 is rolled, a dedicated process for forming the deaeration groove 5 in the metal layer 3 can be omitted, and the surface protection layer 2 and the metal can be formed with a simple configuration. It is possible to prevent bubbles from remaining between the layer 3 and the layer 3.

  In the composite material structure 10B molded in this way, no bubbles remain between the surface protective layer 2 and the metal layer 3, so that pits (microholes) or voids (voids) between the layers are formed on the outer surface. There is no problem that causes the problem, and good strength and appearance can be obtained.

[Third Embodiment]
FIG. 3 is a side view of a mold 11, a surface protective layer 2, a metal layer 3, a fiber reinforced resin layer 4 and the like showing a third embodiment of the method for molding a composite material structure according to the present invention. The mold 11 shown here has a molding surface 11a curved in a concave shape, and molds the curved composite material structure 10C.

  That is, a surface protective layer 2 such as a resin film is placed on the molding surface 11a of the mold 11, a foil-like metal layer 3 is laminated thereon, and a plurality of fibers such as prepregs are laminated thereon. The reinforced resin layer 4 is laminated, and these are heated, evacuated, and pressurized by an autoclave or the like to be molded into a composite material structure 10C having a predetermined curved shape.

  After the metal layer 3 is pulled out from the roll 30 and cut into a predetermined size by the cutter 6, the metal layer 3 is matched with the curved shape of the molding surface 11 a of the mold 11 by, for example, a roller-type curved molding machine 7 or manual work. Then, the film is preliminarily curved and laminated on the surface protective layer 2. Here, it is preferable to set the curvature rate R2 of the metal layer 3 slightly smaller than the curvature rate R1 of the molding surface 11a.

  As described above, the metal layer 3 is preliminarily curved according to the curved shape of the molding surface 11a of the mold 11, and then laminated on the surface protective layer 2, so that the metal layer 3 is well adapted to the molding surface 11a. Therefore, bubbles are prevented from remaining between the surface protective layer 2 and the metal layer 3 after molding.

  Thus, it is possible to prevent bubbles from remaining between the surface protective layer 2 and the metal layer 3 by a very simple method of bending the metal layer 3 in advance according to the curved shape of the molding surface 11a. Can do.

  Further, when the metal layer 3 is curved in advance, the surface protection layer 2, the metal layer 3, and the fiber reinforced resin layer 4 are pressure-molded by setting the curvature rate R2 to be smaller than the curvature rate R1 of the molding surface 11a. In doing so, the metal layer 3 is in close contact with the surface protective layer 2 from the central portion toward both sides (left and right as viewed in FIG. 3). For this reason, it becomes the aspect by which the bubble interposed between the surface protective layer 2 and the metal layer 3 is extruded on both sides, and a bubble becomes difficult to remain.

  Thus, in the composite material structures 10A, 10B, and 10C formed by the composite material structure forming method according to the first to third embodiments, no bubbles remain between the surface protective layer 2 and the metal layer 3. Therefore, there is no problem of generating pits (micro holes) or voids (voids) between layers on the outer surface, and good strength and appearance can be obtained.

  It should be noted that the present invention is not limited to the configuration of the embodiment described above, and can be appropriately modified or improved within the scope not departing from the gist of the present invention. The form is also included in the scope of the right of the present invention. For example, it is good also as a shaping | molding method which combined the 1st-3rd embodiment suitably.

DESCRIPTION OF SYMBOLS 1,11 Mold 1a, 11a Molding surface 2 Surface protective layer 3 Metal layer 4 Fiber reinforced resin layer 5 Deaeration groove 6 Cutter 7 Curve molding machine 10A, 10B, 10C Composite material structure 30 Roll R1 Curvature ratio R2 of molding surface Metal layer curvature

Claims (5)

A method of forming a composite material structure by laminating a surface protective layer, a metal layer, and a fiber reinforced resin layer in order on a molding surface of a mold, and pressurizing and heating them.
Forming at least one of the molding surface or the surface of the metal layer on the molding surface side, a plurality of deaeration grooves communicating from the bubble generating area to the outer periphery of the surface of the molding surface or the metal layer;
A method for molding a composite material structure, wherein bubbles remaining between the molding surface and the metal layer are deaerated from the deaeration groove during the pressurization and heating.   2. The method for forming a composite material structure according to claim 1, wherein the deaeration groove is formed simultaneously with rolling of the metal layer or during surface treatment after rolling. A method of forming a composite material structure by laminating a surface protective layer, a metal layer, and a fiber reinforced resin layer in order on a molding surface of a curved mold, and pressurizing and heating them.
A method for forming a composite material structure, comprising: bending the metal layer in advance according to the curved shape of the molding surface, and then laminating the metal layer on the surface protective layer.   4. The method for molding a composite material structure according to claim 3, wherein a curvature rate of the metal layer is set smaller than a curvature rate of the molding surface.   A composite material structure formed by the method for forming a composite material structure according to any one of claims 1 to 4.

Images