JP2022114525A - Lamination structure molding method and lamination structure - Google Patents

Abstract

To mold a lamination structure with functional parts while reducing the processing cost.SOLUTION: In a method for molding a lamination structure, unit layers are laminated in a laminating direction to mold the lamination structure. The lamination structure includes a composite material part comprising a composite material including a first resin and reinforcing fibers, and a functional part having a predetermined function provided over the laminating direction of the composite material part. A step of forming the unit layers is repeatedly performed to form the lamination structure. The step of forming the unit layers includes: a step of molding the composite material part using the composite material; and a step of molding the functional part using a second resin that is softer than the composite material.SELECTED DRAWING: Figure 6

Description

The present disclosure relates to a method for forming a laminated structure and a laminated structure.

Conventionally, as a method for forming a laminated structure, a first continuous material containing resin and a second continuous material containing fibers are separately fed to a head having a nozzle, and the first continuous material and the second continuous material are fed. A three-dimensional printing method is known in which printing materials are laminated on a platform to form a structure (see, for example, Patent Document 1). In this three-dimensional printing method, for example, when forming a honeycomb board, the plate-like portion is formed from CFRP (Carbon-fiber-reinforced plastic) or CFRTP (Carbon-fiber-reinforced thermoplastics), and the honeycomb structure portion is formed from resin. formed by

WO2015/065300

By the way, a laminated structure manufactured by a three-dimensional layered manufacturing method such as a three-dimensional printing method is sometimes provided with a through-hole for inserting a fastening member. When the through-holes are provided in the stacking direction of the laminated structure, in the modeling method of Patent Document 1, all layers (unit layers) need to be composite material layers (fiber layers in Patent Document 1).

However, when forming a laminated structure including through holes in which all layers are fiber layers, if the forming accuracy of the through holes is lower than the required accuracy, post-processing to satisfy the required accuracy for the through holes is required. need to do In this case, since the post-processing is to process the composite material layer, there is a problem that the processing cost increases due to the difficulty of the processing.

Accordingly, an object of the present disclosure is to provide a method for forming a laminated structure and a laminated structure capable of forming a laminated structure having a functional site while reducing processing costs.

A method for forming a laminated structure of the present disclosure is a method for forming a laminated structure in which unit layers are laminated in a lamination direction to form a laminated structure, and the laminated structure includes a first resin and reinforcing fibers. The step of forming the unit layer including a composite material part made of a composite material and a functional part having a predetermined function provided over the lamination direction of the composite material part is repeatedly performed to perform the lamination The step of forming a structure and forming the unit layer includes forming the composite material portion using the composite material, and forming the functional portion using a second resin that is softer than the composite material. and molding.

The laminated structure of the present disclosure is a laminated structure formed by laminating unit layers in a lamination direction, wherein the unit layer is a composite material portion formed using a composite material containing a first resin and reinforcing fibers. and a functional portion provided over the stacking direction of the composite material portion, formed using a second resin that is softer than the composite material, and having a predetermined function, the unit layer A boundary is formed between the composite material portion and the functional portion, and the boundaries between the unit layers adjacent in the stacking direction are located at different positions in the in-plane direction of the unit layers. .

According to the present disclosure, it is possible to form a laminated structure having a functional part while reducing processing costs.

FIG. 1 is a perspective view of an example of a laminated structure according to Embodiment 1. FIG. FIG. 2 is a schematic cross-sectional view of the laminated structure according to Embodiment 1. FIG. FIG. 3 is a schematic cross-sectional view of through-holes in a laminated structure. FIG. 4 is a schematic cross-sectional view of an end portion of the laminated structure. FIG. 5 is a schematic cross-sectional view of the covering portion of the laminated structure. 6A and 6B are explanatory diagrams related to the method for forming a laminated structure according to the first embodiment. FIG. 7 is a schematic cross-sectional view of a through-hole of a laminated structure according to Embodiment 2. FIG.

Hereinafter, embodiments according to the present disclosure will be described in detail based on the drawings. In addition, this invention is not limited by this embodiment. In addition, components in the following embodiments include components that can be easily replaced by those skilled in the art, or components that are substantially the same. Furthermore, the components described below can be combined as appropriate, and when there are multiple embodiments, each embodiment can be combined.

[Embodiment 1]
The method for manufacturing the laminated structure 10 according to the first embodiment is a method using a so-called three-dimensional layered structure manufacturing method, in which the laminated structure 10 is formed by stacking the unit layers 11 in the stacking direction. First, a laminated structure 10 to be formed will be described with reference to FIGS. 1 and 2. FIG.

(Laminate structure)
FIG. 1 is a perspective view of an example of a laminated structure according to Embodiment 1. FIG. FIG. 2 is a schematic cross-sectional view of the laminated structure according to Embodiment 1. FIG. The laminated structure 10 is a structure in which a plurality of unit layers 11 are laminated in the lamination direction, and is, for example, a plate-like member. The laminated structure 10 has a composite material portion 14 made of a composite material and a functional portion 15 made of resin. Therefore, part of the composite material part 14 and the functional part 15 is provided in the predetermined unit layer 11 .

The composite material part 14 is formed using a composite material containing the first resin and reinforcing fibers. The composite material part 14 is formed by laminating a part of the composite material part 14 included in the unit layer 11 . The first resin is, for example, a resin such as a thermoplastic resin or a thermosetting resin. Specifically, the first resin may be PPS (Polyphenylenesulfide), PEI (Polyetherimide), PEEK (Poly Ether Ether Ketone), PAEK (Poly Aryl Ether Ketone), PEKK (Poly Ether Ketone), nylon, or the like. Well, any resin material may be used as long as it is used when molding a composite material by a three-dimensional additive manufacturing method. The reinforcing fiber may be any fiber such as carbon fiber, glass fiber, aramid fiber, etc., and is not particularly limited. The cured composite material is harder than the functional part 15 .

The functional part 15 is a part having a predetermined function, for example, a part having a function to be fastened to which a fastening member is fastened, a part having a function to be processed to be processed, a function to be joined to be joined to another member. and a portion having a covering function to cover the composite material portion 14 . Specifically, in Embodiment 1, the through hole 17 and the end portion 18 are applied as the functional portion 15 .

FIG. 3 is a schematic cross-sectional view of through-holes in a laminated structure. As shown in FIG. 3, the through-hole 17 is a portion having a function to be fastened to which a fastening member is fastened, and is provided through the stacking direction. The through hole 17 has, for example, a hollow cylindrical shape. As shown in FIG. 2 , a bolt as a fastening member is inserted through the through hole 17 .

FIG. 4 is a schematic cross-sectional view of an end portion of the laminated structure. As shown in FIG. 4 , the end portion 18 is the end portion in the in-plane direction perpendicular to the lamination direction of the laminated structure 10 . The end portion 18 serves as a portion having a function to be machined and a portion having a function to be joined. As shown in FIG. 2, this end portion 18 is processed for joining after molding and is joined to another member.

Moreover, the functional part 15 is formed using the second resin. The functional site 15 is formed by laminating a portion of the functional site 15 included in the unit layer 11 . The second resin, like the first resin, is, for example, a resin such as a thermoplastic resin or a thermosetting resin. A different resin from the first resin is used as the second resin. Specifically, the second resin is softer than the cured composite material portion 14 . Here, the softness of the second resin should be lower than that of the cured composite material, and may be lower in Young's modulus. As the second resin, a function may be imparted to the functional portion 15 by selecting the following resins. Heat resistance may be imparted by applying PPS as the second resin. Further, by applying PEEK as the second resin, self-lubricating properties, high hardness, and high strength (low machinability) may be imparted. Furthermore, by applying PEI as the second resin, a function of high coatability may be imparted.

In addition, in Embodiment 1, one type of second resin is used for the functional portion 15, but there is no particular limitation, and a plurality of types may be used.

Also, the functional part 15 may be as shown in FIG. FIG. 5 is a schematic cross-sectional view of the covering portion of the laminated structure. The functional part 15 shown in FIG. 5 is applied as the covering part 19 . The covering portion 19 is a portion having a covering function to cover the composite material portion 14 and is provided to cover the surface of the composite material portion 14 . The covering portion 19 has, for example, a function of absorbing electromagnetic waves, or an insulating function of blocking current conduction.

Next, the unit layer 11 will be described. A predetermined unit layer 11 of the laminated structure 10 is formed by layering a portion of the composite material portion 14 and a portion of the functional portion 15 . In the unit layer 11 in which the composite material portion 14 and the functional portion 15 are formed, a boundary 21 is formed between the composite material portion 14 and the functional portion 15 .

Here, the boundaries 21 between the unit layers 11 adjacent in the stacking direction are at different positions in the in-plane direction of the unit layers 11 . For example, as shown in FIG. 3, the functional portion 15 as the through-hole 17 is shaped to the composite material portion 14 as an uneven shape having a stepped portion 25 in order to improve the bondability to the composite material portion 14. there is Specifically, in the case of the uneven shape shown in FIG. , is positioned closer to the through hole 17 in the in-plane direction. By alternately laminating one and the other of the adjacent unit layers 11, the shape of the functional portion 15 on the composite material portion 14 side becomes a corrugated shape wavy along the lamination direction. In other words, the shape of the composite material portion 14 on the side of the functional portion 15 has an uneven shape that is wavy along the stacking direction, and has a complementary shape to the functional portion 15 . In other words, the step portion 25 is formed by the intersection of the boundary between the unit layers 11 and the interface between the unit layers 11 . Here, the stepped portion 25 has a length of 0.2 mm or more between one boundary of the adjacent unit layer 11 and the other boundary of the adjacent unit layer 11 in the in-plane direction. In addition, the length between one boundary of the adjacent unit layer 11 and the other boundary of the adjacent unit layer 11 may be 0.2 mm or more and 3 mm or less.

(Method for forming laminated structure)
Next, a method for forming the laminated structure 10 described above will be described with reference to FIG. 6A and 6B are explanatory diagrams related to the method for forming a laminated structure according to the first embodiment. In this modeling method, the step of forming the unit layers 11 is repeated to form the laminated structure 10 . Further, in FIG. 6, the through holes 17 are applied as the functional parts 15 .

In the step of forming the unit layer 11, a step S11 of forming the composite material portion 14 and a step S12 of forming the functional portion 15 are executed. Depending on the unit layer 11 to be modeled, only the composite material part 14 or only the functional part 15 may be formed. The step S12 of shaping the sexual part 15 is not always executed.

In step S11 for modeling the composite material part 14, the ejection nozzle 31 provided in the modeling apparatus (not shown) is moved in the in-plane direction perpendicular to the stacking direction, and the composite material 26 is ejected from the ejection nozzle 31 to form the unit layer. 11 (part of) the composite material part 14 is shaped. In addition, in step S<b>11 for modeling the composite material part 14 , the moving speed in the in-plane direction may be faster than in step S<b>12 for modeling the functional part 15 .

In step S12 of forming the functional part 15, the ejection nozzle 31 or the ejection nozzle 32 different from the ejection nozzle 31 is moved in the in-plane direction orthogonal to the stacking direction, and the second resin 27 is discharged from the ejection nozzles 31 and 32 while the ejection nozzle 32 is moved in the in-plane direction. is discharged to form (part of) the functional site 15 in the unit layer 11 . Note that the discharge nozzles 31 and 32 may be a single nozzle as long as the composite material 26 and the second resin 27 can be switched and discharged, or a plurality of nozzles for discharging the composite material 26 and the second resin 27 respectively. A nozzle may be used. In addition, in step S<b>12 of modeling the functional part 15 , the moving speed in the in-plane direction may be slower than in step S<b>11 of modeling the composite material part 14 . In step S<b>12 for modeling the functional part 15 , by slowing down the moving speed, it is possible to make the functional part 15 more precise than the composite material part 14 .

Here, the order of step S11 for modeling the composite material part 14 and step S12 for modeling the functional part 15 will be described. The order of performing step S11 for modeling the composite material portion 14 and step S12 for modeling the functional portion 15 is determined based on the melting temperature of the resin. Specifically, in the step of forming the unit layer, of the melting temperature of the first resin and the melting temperature of the second resin, the step using the resin having the lower melting temperature is performed first, and the step using the resin having the higher melting temperature is performed. A step with resin is performed later. For example, when the melting temperature of the first resin is higher than the melting temperature of the second resin, step S12 of modeling the functional portion 15 is performed first, and then step S11 of modeling the composite material portion 14 is performed. On the other hand, for example, when the melting temperature of the second resin is higher than the melting temperature of the first resin, step S11 of modeling the composite material part 14 is executed first, and then step S12 of modeling the functional part 15 is executed. do.

In addition, in the method for forming the laminated structure 10, when the step of forming the unit layers 11 described above is repeatedly executed, the boundaries 21 between the unit layers 11 adjacent in the stacking direction are different in the in-plane direction of the unit layers 11. The unit layer 11 is shaped so as to be positioned. As shown in FIGS. 3 and 6 , in the method for forming the laminated structure 10 , one boundary between adjacent unit layers 11 is formed so as to be positioned farther from the through-hole 17 in the in-plane direction. After that, in the method for forming the laminated structure 10 , the other boundary between the adjacent unit layers 11 is formed so as to be positioned closer to the through hole 17 in the in-plane direction. In the method for forming the laminated structure 10, by alternately laminating one and the other of the adjacent unit layers 11, the laminated structure 10 shown in FIG. 3 can be formed.

Although the positions of the boundaries 21 in the in-plane direction of the unit layer 11 are different in the first embodiment, they may be the same positions.

[Embodiment 2]
Next, a laminated structure 40 according to Embodiment 2 will be described with reference to FIG. In order to avoid redundant description, in the second embodiment, portions different from those in the first embodiment will be described, and portions having the same configuration as in the first embodiment will be described with the same reference numerals. FIG. 7 is a schematic cross-sectional view of a through-hole of a laminated structure according to Embodiment 2. FIG.

(Laminate structure)
In the laminated structure 40 of the second embodiment, the boundaries 21 of the unit layers 11 have different positions in the in-plane direction depending on the load distribution applied to the functional regions 15 . Specifically, when the functional part 15 is the through-hole 17 to which the fastening member is fastened, the load is large on the outer layer side of the laminated structure 40, and the load is small on the inner layer side. In this case, in order to form a load path, on the outer layer side of the laminated structure 40, the boundary 21 of the unit layer 11 is on the functional part 15 side, and on the inner layer side of the laminated structure 40, the boundary 21 of the unit layer 11 is A laminated structure 40 is shaped so as to be on the composite material part 14 side. That is, in the laminated structure 40, the ratio of the functional sites 15 in the unit layer 11 on the outer layer side is high, and the ratio of the functional sites 15 in the unit layer 11 on the inner layer side is low.

As described above, the method for forming the laminated structures 10 and 40 and the laminated structures 10 and 40 described in the present embodiment are understood as follows, for example.

A method for forming the laminated structures 10 and 40 according to the first aspect is a method for forming the laminated structures 10 and 40 by laminating the unit layers 11 in the lamination direction to form the laminated structures 10 and 40. The laminated structures 10 and 40 include a composite material portion 14 made of a composite material containing a first resin and reinforcing fibers, and a functional portion 15 having a predetermined function provided over the lamination direction, and the unit The steps of forming the layered structure 40 and forming the unit layers 11 by repeatedly performing the step of forming the layers 11 include step S11 of forming the composite material portion 14 using the composite material, and and a step S12 of modeling the functional part 15 using a second resin that is softer than the composite material.

According to this configuration, the functional part 15 can be modeled using the second resin that is softer than the composite material. Therefore, the deformation of the functional portion 15 can allow the required accuracy of the functional portion 15, which eliminates the need for post-processing, thereby reducing the processing cost. In addition, even if the accuracy required for the functional part 15 is higher, the functional part 15 is easy to process, so that post-processing becomes easy, and the processing cost can be reduced. can be done. As described above, it is possible to form the laminated structures 10 and 40 having the functional parts 15 while reducing the processing cost.

As a second aspect, the first resin and the second resin are different.

According to this configuration, the first resin suitable for molding the composite material portion 14 can be used, and the second resin suitable for molding the functional portion 15 can be used. Therefore, the functional part 15 made of resin softer than the composite material can be favorably shaped.

As a third aspect, in the unit layer 11, a boundary 21 between the composite material portion 14 and the functional portion 15 is formed. The unit layers 11 are formed such that the boundaries 21 between the unit layers 11 are located at different positions in the in-plane direction of the unit layers 11 .

According to this configuration, the joint between the composite material portion 14 and the functional portion 15 can be made strong.

As a fourth aspect, the functional portion includes a portion having a function to be fastened to which a fastening member is fastened, a portion having a function to be processed to be processed, a portion having a function to be joined to be joined to another member, It has at least one of the functions of covering the composite material portion.

According to this configuration, it can be applied to the functional part 15 having various functions, and can be highly versatile.

As a fifth aspect, the functional part 15 is a through hole 17 that penetrates in the stacking direction.

According to this configuration, the laminated structures 10 and 40 having the through holes 17 can be formed while reducing the processing cost.

As a sixth aspect, the functional site is an end portion of the laminated structure.

According to this configuration, the laminated structures 10 and 40 having the end portion 18 can be shaped while reducing the processing cost.

As a seventh aspect, the functional portion is a covering portion that covers the composite material portion.

According to this configuration, the laminated structures 10 and 40 having the covering portion 19 can be formed while reducing the processing cost.

As an eighth aspect, in the step of forming the unit layer, the step of using a resin having a lower melting temperature than the melting temperature of the first resin and the melting temperature of the second resin is performed first, A step using a resin with a higher melting temperature is performed later.

According to this configuration, the resin having a high melting temperature can be easily dissolved in the resin having a low melting temperature, so that the bonding between the composite material portion 14 and the functional portion 15 can be strengthened. .

As a ninth aspect, in the step of forming the unit layer, the movement speed for modeling in step S11 of modeling the composite material portion 14 is the same as the movement speed for modeling in step S12 of modeling the functional portion 15. faster than speed.

According to this configuration, in step S11 for modeling the composite material part 14, by increasing the moving speed, it is possible to form the reinforcing fibers so as to extend in the fiber direction. Therefore, the composite material part 14 can be appropriately shaped. Further, in step S12 for modeling the functional region 15, by slowing down the movement speed, the functional region 15 can be formed with high accuracy.

A laminated structure according to a tenth aspect is a laminated structure formed by laminating unit layers in a lamination direction, wherein the unit layers are composites formed using a composite material containing a first resin and reinforcing fibers. and a functional portion provided over the lamination direction and formed using a second resin that is softer than the composite material and having a predetermined function, and the unit layer includes , a boundary is formed between the composite material portion and the functional portion, and the boundaries between the unit layers adjacent in the stacking direction are at different positions in the in-plane direction of the unit layers.

According to this configuration, it is possible to form the laminated structures 10 and 40 in which the joint between the composite material portion 14 and the functional portion 15 is strengthened.

As an eleventh aspect, the boundary is positioned in the in-plane direction according to the load distribution applied to the functional site.

According to this configuration, the laminated structures 10 and 40 suitable for the load distribution applied to the functional portion 15 can be formed.

REFERENCE SIGNS LIST 10 laminated structure 11 unit layer 14 composite material site 15 functional site 17 through hole 18 end 19 covering section 21 boundary 25 stepped section 26 composite material 27 second resin

Claims (11)

A laminated structure forming method for forming a laminated structure by laminating unit layers in a lamination direction,
The laminated structure includes a composite material part made of a composite material containing a first resin and reinforcing fibers, and a functional part having a predetermined function provided over the lamination direction,
forming the laminated structure by repeating the step of forming the unit layer;
The step of forming the unit layer includes:
shaping the composite material part using the composite material;
and forming the functional portion using a second resin that is softer than the composite material. 2. The method for modeling a laminated structure according to claim 1, wherein the first resin and the second resin are different. A boundary between the composite material portion and the functional portion is formed in the unit layer,
In the step of forming the unit layer,
3. The method for forming a laminated structure according to claim 1, wherein the unit layers are formed such that the boundaries between the unit layers adjacent in the stacking direction are located at different positions in the in-plane direction of the unit layers. . The functional part includes a part having a function to be fastened to which a fastening member is fastened, a part having a function to be processed to be processed, a part having a function to be joined to be joined to another member, and a coating covering the composite material part. 4. The method for manufacturing a laminated structure according to any one of claims 1 to 3, wherein at least one of the functional parts has a function. 5. The method of forming a laminated structure according to claim 4, wherein the functional portion is a through hole that penetrates in the lamination direction. 5. The method for modeling a laminated structure according to claim 4, wherein the functional portion is an end portion of the laminated structure. 5. The method for forming a laminated structure according to claim 4, wherein the functional portion is a covering portion that covers the composite material portion. In the step of forming the unit layer,
Between the melting temperature of the first resin and the melting temperature of the second resin, the step using the resin with the lower melting temperature is performed first, and the step using the resin with the higher melting temperature is performed later. Item 8. The method for forming a laminated structure according to any one of Items 1 to 7. In the step of forming the unit layer,
9. The moving speed for shaping in the step of shaping the composite material part is higher than the moving speed for shaping in the step of shaping the functional part according to any one of claims 1 to 8. A method for forming a laminated structure. In a laminated structure formed by laminating unit layers in the lamination direction,
The unit layer is
a composite material portion formed using a composite material including a first resin and reinforcing fibers;
A functional part provided over the lamination direction, formed using a second resin that is softer than the composite material, and having a predetermined function,
A boundary between the composite material portion and the functional portion is formed in the unit layer,
The laminated structure, wherein the boundaries between the unit layers adjacent in the lamination direction are located at different positions in the in-plane direction of the unit layers. 11. The laminated structure according to claim 10, wherein the boundary is positioned in the in-plane direction according to the load distribution applied to the functional site.

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