JP2022125261A - Manufacturing method of composite material structure - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce jig costs and workload, and to enable high-precision molding of a surface shape of a composite material structure, in a case of manufacturing the panel-shaped composite material structure with concave surface.

SOLUTION: A manufacturing method of a composite material structure includes: a first step of forming a laminated unit having a laminated structure including a first plate, a laminate, and a second plate by placing a sheet-like laminate containing a plurality of stacked prepregs on a convex side of the first plate, which is curved in an arc shape when viewed from one direction perpendicular to a plate thickness direction, and placing a second plate, which is curved in an arc shape when viewed from one direction and has a lower stiffness than the first plate, on an opposite side of the laminate from the first plate, with the convex side facing the first plate; and a second step in which the laminate is formed into a predetermined shape and cured while the laminate unit is supported by a base from the second plate side, after the first step.

SELECTED DRAWING: Figure 1

COPYRIGHT: (C)2022,JPO&INPIT

Description

The present invention relates to a method for manufacturing a composite material structure and a jig for manufacturing a composite material structure.

For example, as disclosed in Patent Document 1, a laminate obtained by laminating a plurality of prepregs is stacked on the convex outer surface of a mandrel (male type), and a mold is placed over the laminate. A method of manufacturing a panel-like composite material structure having a concavely curved surface (hereinafter also simply referred to as a concave surface) when viewed from one direction by curing the laminated body while molding it with a mandrel and a mold. (hereinafter referred to as mandrel construction method) is known.

Further, as disclosed in Patent Document 2, for example, a laminate is placed on the concave inner surface of a female mold, and a thin plate is placed on top of this laminate. 2. Description of the Related Art A method of manufacturing a panel-like composite material structure having a concave surface by curing a laminate while molding it (hereinafter referred to as a female mold method) is known. Composite material structures include, for example, aircraft fuselages and the like.

Japanese Patent No. 5576650 JP 2013-18286 A

The mandrel construction method has advantages such as being able to form the concave surface of the composite material structure with high precision using a mandrel. This is preferable in that when the composite material structure is applied to an aircraft fuselage, shim adjustment is not required when various parts are attached to the concave surface corresponding to the inner surface of the fuselage. However, a dedicated mandrel may be required for each different type of composite structure. For example, in a plurality of derived aircraft fuselages with different lengths, the rigidity required for each part is different, so the mandrel shape will be different because the thickness of the fuselage skin is different even though the outer diameter is constant for each model. Therefore, a dedicated mandrel is required for each model. Therefore, when the production rate is high, a plurality of expensive mandrels are required, which causes an increase in jig cost.

In addition, the female mold construction method can be used to manufacture multiple types of composite material structures with a single longest female mold, even if it is a derived aircraft such as an aircraft fuselage. Compared to this, there is no need for a mandrel with a special shape, and there is an advantage that jig costs can be reduced. However, since it is difficult to form the concave surface of the composite material structure (the inner surface of the fuselage in the case of an aircraft) with high accuracy, there is a problem that shim adjustment is required when various parts are attached to the concave surface.
These problems become significant, for example, when the composite material structure to be manufactured is relatively large, such as an aircraft fuselage.

The present invention has been made in view of this problem. The object is to enable the surface shape to be formed with high accuracy.

A method for manufacturing a composite material structure according to an aspect of the present invention is a sheet-like structure including a plurality of laminated prepregs on a convex surface of a first plate curved in an arc when viewed from one direction perpendicular to the plate thickness direction. and a second plate curved in an arc when viewed from the one direction and having lower rigidity than the first plate is formed on the surface of the laminate opposite to the first plate side of the laminate. a first step of forming a laminate unit having a laminate structure including the first plate, the laminate, and the second plate by overlapping a plate with the first plate while aligning the direction of the convex surface; After the first step, a second step of molding and curing the laminate into a predetermined shape while supporting the laminate unit from the second plate side by a base.

According to the above method, in the second step, the convex surface of the first plate, which is more rigid than the second plate, can harden the laminate so as to have a highly precise concave surface. In the second step, by supporting the laminate unit from the second plate on the side of the laminate by the base table, the laminate can be supported while sandwiched between the first plate and the base table. Therefore, the laminate can be stably cured while effectively preventing variations in the thickness dimension of the laminate. Therefore, it is possible to manufacture a panel-shaped composite material structure in which the concave surface is formed with high accuracy.

Further, for example, by bending at least one of the first plate and the second plate, the shapes of the first plate and the second plate can be adjusted. Therefore, a plurality of types of composite material structures can be manufactured from the pair of the first plate and the second plate.

In addition, since the laminate is cured while being shaped by the first plate and the second plate, there is no need to separately prepare dedicated bases and plates each time a different type of composite material structure is manufactured. Also, since the composite material structure can be manufactured using the first plate and the second plate which are relatively light in weight, the handling by the operator can be improved. Therefore, it is possible to reduce the cost of jigs and lighten the work load when manufacturing a composite material structure.

The base may have a support surface that supports the stacked unit by contacting the stacked unit from the second plate side while maintaining the convex surface of the first plate in a predetermined shape. As a result, the lamination unit can be well supported by the supporting surface of the base table, so that a composite material structure in which the concave surface is formed with high accuracy can be manufactured.

In the second step, after the lamination unit is airtightly covered with a bag film independently of the base, a high-temperature and high-pressure gas is used to press the lamination unit while the lamination unit is supported by the base. may be cured while heating and applying pressure from both sides in the thickness direction.

According to the above method, the laminate is brought into close contact with the first plate and the second plate by using the bag film and the high-temperature and high-pressure gas while reducing the jig cost and the work load. By applying pressure from both sides in the thickness direction and curing, a composite material structure in which concave surfaces are formed with high accuracy can be manufactured.

A maximum thickness dimension of the first plate may be thicker than a maximum thickness dimension of the second plate. This makes it easier to increase the rigidity of the first plate more than the rigidity of the second plate.

In the first step, the first plate is arranged so that the upper surface is the convex surface and the lower surface is the concave surface, and the first plate is moved from the lower surface side while maintaining the convex surface of the first plate in a predetermined shape. a first substep of supporting with a support member; after the first substep, a second substep of arranging the stack on the top surface of the first plate; after the second substep, the second substep; and a third sub-step of vertically inverting the first plate and the laminate together with the supporting member while the first plate is supported by the supporting member.

According to the above method, in the first sub-step, the convex surface of the first plate is maintained in a predetermined shape by the supporting member, and in the second sub-step, the laminate is stacked on the upper surface of the first plate in an appropriate shape. can be placed. Further, in the third sub-step, while the first plate is supported by the support member, the first plate and the stack are turned upside down together with the support member, thereby maintaining the shapes of the first plate and the stack. , the transition from the third sub-step to the second step can be performed smoothly.

A jig according to one aspect of the present invention is a jig for manufacturing a composite material structure for molding and curing a sheet-like laminate including a plurality of laminated prepregs into a predetermined shape, and a first plate curved in an arc when viewed from a direction perpendicular to the direction perpendicular to the direction, and having the laminate stacked on a convex surface; a second plate that is curved inward and that is superimposed on the surface of the laminate opposite to the first plate while aligning the direction of the convex surface with that of the first plate; the first plate and the laminate; , and a base that supports a laminated unit having a laminated structure including the second plate from the second plate side.

According to the above configuration, by using the convex surface of the first plate, which has higher rigidity than the second plate, the laminate can be cured so as to have a highly accurate concave surface. In addition, by supporting the laminated unit from the second plate on the side of the laminated body by the base, the laminated body can be supported while being sandwiched between the first plate and the base. while the laminate can be cured. Therefore, it is possible to manufacture a composite material structure in which the concave surface is formed with high accuracy.

Further, for example, by bending at least one of the first plate and the second plate, the shapes of the first plate and the second plate can be adjusted. Therefore, a plurality of types of composite material structures can be manufactured from the pair of the first plate and the second plate. Moreover, since the laminate can be formed by the first plate and the second plate, there is no need to prepare a dedicated base stand or plate each time a different type of composite material structure is manufactured. Also, since the composite material structure can be manufactured using the first plate and the second plate which are relatively light in weight, the handling by the operator can be improved. Therefore, it is possible to reduce the cost of jigs and lighten the work load when manufacturing a composite material structure.

The base may have a support surface that supports the stacked unit by contacting the stacked unit from the second plate side while maintaining the convex surface of the first plate in a predetermined shape.

Thus, by supporting the laminated unit from the second plate side by the support surface of the base while maintaining the convex surface of the first plate in a predetermined shape, it is possible to reduce the cost of jigs and the work load while reducing the concave surface. Precisely formed composite structures can be manufactured.

The first plate is supported from the concave surface side while the convex surface of the first plate is maintained in a predetermined shape, and the first plate is arranged so as to be reversible in the plate thickness direction while the first plate is supported. A support member may also be provided.

According to the above configuration, the convex surface of the first plate can be maintained in a predetermined shape by the supporting member. By inverting the thickness direction of the first plate together with the plate, the laminated body can be placed on the second plate in a favorable manner.

According to each aspect of the present invention, when manufacturing a composite material structure, it is possible to reduce the jig cost and work load, and to form the surface shape of the composite material structure with high accuracy.

1 is a partial view of an aircraft fuselage constructed from composite material structures according to embodiments; FIG. FIG. 2 is a perspective view of a manufacturing jig used when manufacturing the composite material structure of FIG. 1; 1 is a flow diagram of a method for manufacturing a composite material structure according to an embodiment; FIG. 4A to 4D are diagrams for explaining each step in FIG. 3; FIG. It is a figure for demonstrating the hardening step by the conventional scalpel construction method.

Hereinafter, embodiments will be described with reference to the drawings.

(embodiment)
[Composite structure]
FIG. 1 is a partial view of an aircraft fuselage made up of a composite material structure 20 (hereinafter referred to as structure 20) according to an embodiment. The structure 20 has a panel shape, and is, for example, a skin panel that constitutes an aircraft fuselage. The structure 20 is a curved plate that curves in an arc and extends in the longitudinal direction (one direction described later) of the aircraft fuselage.

The structure 20 is manufactured from a composite material obtained by curing a sheet-like laminate 15 including a plurality of laminated prepregs, as will be described later. A prepreg includes a fiber sheet and a resin impregnated in the fiber sheet. Structure 20 has an FPR structure. Although this FRP structure is made of carbon fiber reinforced plastic (CFRP) in this embodiment, it may be made of other fiber reinforced plastics.

In an aircraft, for example, four structures 20 are combined side by side in the circumferential direction of the fuselage. The concave surface 20b, which is a concave surface when viewed in the longitudinal direction of the aircraft fuselage, is the inner peripheral surface of the fuselage. A plurality of stringers (hat-shaped stringers) 20c (see FIG. 4(d)) extending in the same direction are formed on the concave surface 20b so as to be spaced apart from each other in the circumferential direction of the body. The convex surface 20a, which is a convex surface when viewed from the longitudinal direction of the aircraft fuselage, is formed smoothly.

BACKGROUND OF THE INVENTION An aircraft fuselage is required to have a plurality of parts (structural parts such as frames and floor beams that make up the fuselage structure) accurately attached to the inner peripheral surface at predetermined positions. Therefore, the concave surface 20b of the structure 20 is required to be formed with high accuracy. The structure 20 is manufactured using the manufacturing jig 1 described below, so that the concave surface 20b is formed with high accuracy.

[Manufacturing jig]
FIG. 2 is a perspective view of the manufacturing jig 1 used when manufacturing the structure 20 of FIG. FIG. 2 shows a state in which the frame member 6 is arranged with the distal end side of the arm portion 6b (the contact side of the arm portion 6b with the first plate 2) directed downward. Also, for the sake of explanation, the laminate 15 arranged between the first plate 2 and the second plate 3 is indicated by a virtual line (a chain double-dashed line).

The manufacturing jig 1 is a jig for manufacturing the structure 20 by molding and curing a sheet-like laminate 15 (manufacturing intermediate of the structure 20) including a plurality of laminated prepregs into a predetermined shape. be.

As shown in FIG. 2 , the manufacturing jig 1 includes a first plate 2 , a second plate 3 , a support member 4 and a base 5 . The first plate 2 and the second plate 3 are arranged so as to sandwich the laminate 15 in the plate thickness direction. Thus, when manufacturing the structure 20, the laminate unit 16 having a laminate structure including the first plate 2, the laminate 15, and the second plate 3 is formed. The laminated unit 16 is plate-shaped as a whole, and is subjected to high-temperature and high-pressure (autoclave) processing in an autoclave while being supported by the base table 5 .

The first plate 2 and the second plate 3 are curved plates that curve in an arc and extend in one direction when viewed from one (X) direction (hereinafter simply referred to as one direction) perpendicular to the plate thickness direction. be. A concave portion 2c is formed on a convex surface 2a, which is a convex surface when viewed from one direction of the first plate 2. As shown in FIG. The recessed portion 2c is formed so as to be recessed in the plate thickness direction of the first plate 2 and extend in one direction. The recessed portion 2c is used as a mold portion for forming the stringer 20c of the structure 20. As shown in FIG.

The first plate 2 and the second plate 3 of this embodiment are made of the same material. As an example, the first plate 2 and the second plate 3 have an FRP structure. Although this FRP structure is made of carbon fiber reinforced plastic (CFRP) in this embodiment, it may be made of other fiber reinforced plastics. If the structure 20 is a part of an aircraft fuselage, the first plate 2 and the second plate 3 are ideally made of a material having the same thermal expansion as the structural material of the aircraft fuselage.

Since the first plate 2 and the second plate 3 have a relatively lightweight FRP structure, the operator's work load when handling the first plate 2 and the second plate 3 is reduced, and the transportation for transportation is reduced. Cars and peripheral equipment are relatively inexpensive. Further, by forming the first plate 2 and the second plate 3 from the same material, the physical properties of the first plate 2 and the second plate 3 can be made uniform, and the physical properties of both surfaces of the structure 20 can be easily made uniform. can be done. Note that the first plate 2 and the second plate 3 may be made of different materials.

The second plate 3 has lower rigidity than the first plate 2 . The second plate 3 is curved in an arc shape when viewed from one direction, and the direction of the first plate 2 and the convex surfaces 2a and 3a (here, as an example, are stacked while aligning the orientations in the X, Y, and Z directions.

The maximum plate thickness dimension of the first plate 2 is thicker than the maximum plate thickness dimension of the second plate 3 . As a result, the first plate 2 is less likely to be bent or distorted than the second plate 3 . Therefore, in the laminate 15, when the resin viscosity of the prepreg decreases during autoclave curing, the surface (concave surface 15b) on the first plate 2 side, which has higher rigidity than the surface (convex surface 15a) on the second plate 3 side, The shape is determined by the process, and it is molded with high precision.

As an example, the plate thickness dimensions of the first plate 2 and the second plate 3 are uniform. Although the plates 2 and 3 have a certain degree of rigidity, they have the property of slightly bending when an external force exceeding a certain level is applied in the plate thickness direction. By bending the plates 2 and 3 into desired shapes, a plurality of types of structures 20 having different shapes can be manufactured. Therefore, when manufacturing a plurality of types of structures 20, the number of exchanges of the plates 2 and 3 according to the type of the structure 20 can be reduced. It is possible to reduce the work load on the operator involved in replacement.

The support member 4 supports the first plate 2 from the concave surface 2b side while maintaining the convex surface 2a in a predetermined shape, and is arranged so that the first plate 2 can be reversed in the plate thickness direction while supporting the first plate 2. ing.

In the present embodiment, the support member 4 is suspended in the vertical (z) direction by the wire W while supporting the first plate 2 from below. The plate 2 is turned over in the plate thickness direction.

Specifically, the support member 4 has a frame member 6 and a plurality of holding members 7 fixed to the frame member 6 . The frame member 6 has a body portion 6a and a plurality of arm portions 6b. The body portion 6a is composed of a combination of a plurality of long members. Suspension portions 6c for suspending the support member 4 with wires W are provided at a plurality of positions of the body portion 6a.

The arm portion 6b protrudes from one surface of the body portion 6a. The tip of the arm portion 6 b contacts the concave surface 2 b of the first plate 2 . Thereby, the first plate 2 is supported from the concave surface 2b side by the plurality of arm portions 6b.

The arm portion 6b has a plurality of connecting members 6d connected in its longitudinal direction. The connection angle θ between the adjacent connection members 6d when viewed from the side of the arm 6b and the maximum length dimension of the arm 6b can be adjusted within a certain range.

In this embodiment, when viewed from a specific direction (the X direction in FIG. 2), the arm portions 6b are arranged at positions corresponding to the central position and both sides of the main body portion 6a. Adjacent connecting members 6d in each arm portion 6b are connected so that the tip of the arm portion 6b is bent outward from the main body portion 6a.

The support member 4 supports the first plate 2 so that the specific direction and the one direction match. By adjusting at least one of the connection angle θ and the maximum length dimension of the arm portions 6b, the support member 4 supports the first plate 2 with the plurality of arm portions 6b while maintaining the convex surface 2a in a predetermined shape. .

Moreover, in this embodiment, the connecting member 6d has a bolt hole. Adjacent connecting members 6d in each arm portion 6b are connected by screwing bolts B into their respective bolt holes. The plurality of connecting members 6d in the arm portion 6b are connected by screwing the bolt hole and the bolt B in a state where the connecting angle θ between the adjacent connecting members 6d is set to a predetermined angle.

The holding member 7 is attached to the arm portion 6b of the frame member 6 and holds the first plate 2 from the concave surface 2b side. The holding member 7 is, for example, a vacuum chuck. The holding member 7 has a cylinder, an actuator having an operating shaft that can move back and forth from the cylinder, and a suction cup 7a attached to the tip of the operating shaft of the actuator. The holding member 7 holds the first plate 2 by causing the suction cups 7a to adhere to the concave surface 2b of the first plate 2 in a state in which the operating shaft is set to have a predetermined projecting length.

Here, the first plate 2 is held by the holding member 7 while the first plate 2 is supported by the plurality of arm portions 6b in which the connection angle θ between the adjacent connection members 6d is set to a predetermined angle. 1 plate 2 can be held by holding member 7 while maintaining convex surface 2a in a predetermined shape. Note that the holding member 7 is not limited to a vacuum chuck, and may be any member that can hold the first plate 2 .

The base 5 supports the stacking unit 16 from the second plate 3 side. The base 5 supports the stacking unit 16 while preventing deformation due to gravity. The base 5 has a support surface 5a. The support surface 5a supports the laminated unit 16 from the second plate 3 side while maintaining the convex surface 2a of the first plate 2 in a predetermined shape.

As shown in FIG. 2, the base 5 is, for example, a rectangular parallelepiped with the X direction as the width direction, the Y direction as the length direction, and the Z direction as the height direction. When viewed from the direction perpendicular to one side surface (here, the X direction), the upper surface of the base 5 is curved in a downwardly convex arc shape. The upper surface of the base table 5 corresponds to the support surface 5a.

The support surface 5 a has a shape corresponding to the shape of the convex surface 20 a of the structure 20 . Although the support surface 5a is formed smooth as an example, it may be formed with minute unevenness, for example. The base 5 and the plates 2 and 3 are combined so that the vertical direction and one direction are aligned.

A plurality of suspending portions 5b are provided on the side surface of the base table 5 for suspending the base table 5 when the base table 5 is arranged in an autoclave. The base 5 is made of aluminum, for example. In this embodiment, the laminate 15 is formed mainly by the first plate 2 and the second plate 3 and does not come into contact with the base 5, so the support surface 5a of the base 5 is not formed with such high accuracy. may Therefore, as the material of the base table 5, a relatively inexpensive material having appropriate rigidity can be used. Also, the production cost of the base table 5 is kept relatively low.

Note that the base 5 may have a structure including, for example, a plate member having a support surface 5a and a support frame that supports the plate member from a surface opposite to the support surface 5a. Also, the shape and size of the plates 2 and 3 and the base 5 are appropriately set according to the shape and size of the structure 20 . In FIG. 2, the X-direction dimensions of the plates 2 and 3 and the base table 5 are set to values smaller than the Y-direction dimensions. may

[Manufacturing method of composite material structure]
FIG. 3 is a flow diagram of a method for manufacturing the structure 20 according to the embodiment. 4A to 4D are diagrams for explaining each step in FIG. As shown in FIG. 3, the manufacturing method has a first step S1 and a second step S2.

In the first step S1, the laminate 15 is placed on the convex surface 2a of the first plate 2, and the second plate 3 is placed on the surface of the laminate 15 opposite to the first plate 2 side. A laminated unit 16 is formed by stacking the plate 2 and the convex surfaces 2a and 3a while aligning the directions thereof. The first step S1 comprises a first sub-step SS1, a second sub-step SS2, a third sub-step SS3 and a fourth sub-step SS4.

In the second step S2, after the first step S1, the laminated body 15 is formed into a predetermined shape and cured while the laminated unit 16 is supported by the base 5 from the second plate 3 side. Each step S1 and S2 will be described below with reference to FIG.

First, the operator disposes the first plate 2 so that the upper surface is the convex surface 2a and the lower surface is the concave surface 2b, and while the convex surface 2a of the first plate 2 is kept in a predetermined shape, the operator moves the first plate 2 from the lower surface side to the supporting member. 4 (first substep SS1 in FIG. 3). Also, after the first sub-step SS1, the operator places the layered body 15 over the upper surface of the first plate 2 (second sub-step SS2 in FIG. 3).

Specifically, the operator places the support member 4 so that the tip side of the arm 6b faces upward. A connection angle θ between adjacent connection members 6 d in the arm portion 6 b is set according to the shape of the structure 20 . After setting, the operator causes the arms 6b of the support member 4 to support the first plate 2 from the concave surface 2b side. Thereby, the first sub-step SS1 is performed (FIG. 4(A)).
Also, the operator places the stack 15 on the convex surface 2 a of the first plate 2 . An operator constructs the laminate 15 by laminating (laying up) a plurality of sheet-like prepregs. As an example, the laminate 15 includes a stringer ply 12 , a sheet-like filler 13 , and a sheet-like skin ply 14 . The stringer ply 12, filler 13, and skin ply 14 are made of prepreg.

The operator places the stringer plies 12 at positions corresponding to the recessed portions 2 c of the first plate 2 and places the filler 13 between the adjacent stringer plies 12 . At a position corresponding to the recess 2c of the stringer ply 12, an elongated jig (bladder) 17 for forming the stringer 20c is placed on the stringer ply 12 so as to overlap. Then, the skin ply 14 is laid on the stringer ply 12, the filler 13, and the jig 17 (FIG. 4(A)). Each time these members are placed on the first plate 2, they are covered with a bag film and subjected to vacuum suction for compaction and close contact, thereby performing the second sub-step SS2.

After the second sub-step SS2, the operator inverts the first plate 2 and the stack 15 together with the supporting member 4 while supporting the first plate 2 by the supporting member 4 (the third sub-step SS3 in FIG. 3). ).

Specifically, the operator connects the wire W to the hanging portion 6 c of the support member 4 and holds the first plate 2 by the holding member 7 . In this state, the support member 4 is turned upside down from the state of FIG. 4A by the wire W, so that the first plate 2 and the laminate 15 are turned upside down together with the support member 4 (FIG. 4B). Thereby, the third sub-step SS3 is performed.

Also, the operator places the second plate 3 on the support surface 5 a of the base table 5 . After the third sub-step SS3, the operator places the first plate 2 and stack 15 on top of the second plate 3 (fourth sub-step SS4 in FIG. 3).

Specifically, the operator places the second plate 3 on the support surface 5a of the base 5 so that the concave surface 3b faces upward. In addition, the operator adjusts the relative positions of the support member 4 and the base 5 in the horizontal direction so that the first plate 2, the laminate 15, and the second plate 3 are stacked at appropriate positions. After this adjustment, the operator moves the support member 4 downward to place the first plate 2 and the laminate 15 over the second plate 3 on the base 5 . Thereby, a fourth sub-step SS4 is performed. 1st step S1 is completed above.

Subsequently, as a second step S2, the operator molds and hardens the laminate 15 into a predetermined shape while supporting the laminate unit 16 from the second plate 3 side by the base 5 after the first step S1.

In the second step S2 of the present embodiment, the operator airtightly covers the lamination unit 16 with the bag film 18 independently of the base table 5, and then, with the lamination unit 16 supported by the base table 5, the lamination unit 16 is heated and pressed from both sides in the thickness direction, the laminate 15 is cured.

Specifically, after the fourth sub-step SS4, the operator seals the internal space V1 between the first plate 2 and the second plate 3 with the bag film 18 and evacuates (bags) the internal space V1. Also, the supporting member 4 is removed from the first plate 2 and the laminated unit 16 is supported by the base 5 .

In this state, the operator connects the wire W to the suspending portion 5b of the base table 5, lifts the base table 5 by the wire W, and places the lamination unit 16 together with the base table 5 in the autoclave. After that, the operator molds and hardens the laminate 15 into a predetermined shape by subjecting the laminate 15 to high temperature and high pressure treatment in the autoclave (FIG. 4(C)).

Here, in this embodiment, vacuuming using the bag film 18 is performed between the first plate 2 and the second plate 3, but not between the plates 2, 3 and the support surface 5a. In other words, the space between the convex surface 3a of the second plate 3 and the supporting surface 5a of the base 5 is not airtight. Therefore, between the convex surface 3a of the second plate 3 and the supporting surface 5a of the base 5, the high-temperature and high-pressure gas in the autoclave enters.

As a result, as shown in FIG. 4C, the laminate 15 is pressed from both sides in the thickness direction while being sandwiched between the first plate 2 and the second plate 3 . The laminated body 15 is pressed against the convex surface 2a of the first plate 2 having high rigidity, thereby forming a body skin with an accurate inner surface shape. When the thickness of the laminated body 15 varies peculiar to the composite material after curing, the thickness of the laminated body 15 is caused to occur on the side of the second plate 3 having a low rigidity, and the laminate 15 is thermally cured.

By performing the above second step S2, the laminate 15 is molded and cured to obtain the structure 20 (FIG. 4(D)). The first plate 2, the second plate 3, and the base 5 used to manufacture the structure 20 can be used repeatedly. It should be noted that the structure 20 may be subjected to trimming such as drilling for inserting a rivet, while being supported from the side of the concave surface 20b by a dedicated support member, for example.

Here, FIG. 5 is a diagram for explaining the curing step by the conventional scalpel construction method. When performing the curing step, for example, the operator stacks a sheet-like laminate 115 including a plurality of laminated prepregs on the support surface 105a of the base 105, which is a female type in advance. In addition, the plate 103 is stacked on the layered body 115 so as to cover the upper surface of the layered body 115 with a plurality of plates (curl plates) 103 .

Next, the operator seals the internal space V2 between the plate 103 and the support surface 105a with the bag film 118 and evacuates. A curing step is then performed by subjecting the laminate 115 to a high temperature and pressure treatment in an autoclave.

In this curing step, the surface of the laminate 115 opposite to the plate 103 side (hereinafter referred to as convex surface 115a) is in close contact with the support surface 105a of the highly rigid female-type base 105. FIG. Therefore, the convex surface 115a is formed with high precision by the support surface 105a.

However, the surface of the laminate 115 on the plate 103 side (hereinafter referred to as a concave surface 115 b ) contacts the plate 103 having a lower rigidity than the base 105 . Also, in this method, the high-temperature, high-pressure gas in the autoclave cannot enter between the supporting surface 105a of the base 105 and the convex surface 115a of the laminate 115. FIG. For this reason, in the laminated body 115, the plate thickness after curing is uneven on the surface side of the concave surface 115b, and the accuracy is lower than that of the convex surface 115a.

Since the shape accuracy of the concave surface 115b is lowered in this way, when using the structure obtained by curing the laminate 115 as a skin panel for an aircraft fuselage, parts can be accurately attached to the inner peripheral surface of the skin panel. Therefore, a huge amount of shim adjustment is required, which greatly increases the work load.

On the other hand, according to the present embodiment, as described above, in the second step S2, the convex surface 2a of the first plate 2 having higher rigidity than that of the second plate 3 forms the highly accurate concave surface 15b. Laminate 15 can be cured. Further, in the second step S2, the laminate unit 16 is supported by the base stand 5 from the laminate 15 side of the second plate 3, so that the laminate 15 can be supported while sandwiched between the first plate 2 and the base stand 5. Therefore, the accuracy of the inner surface shape of the laminate 15 can be improved, and the laminate 15 can be stably cured. Therefore, it is possible to manufacture the panel-like structure 20 in which the concave surface 20b is formed with high precision.

As a result, for example, when the structure 20 is used as a skin panel for an aircraft fuselage, the structure 20 is manufactured so that the concave surface 20b is the inner peripheral surface of the skin panel. No need to adjust shims during installation. Therefore, the structure 20 can be favorably used as a skin panel while preventing an increase in work load.

Further, for example, by bending at least one of the first plate 2 and the second plate 3, the shapes of the first plate 2 and the second plate 3 can be adjusted. Therefore, a plurality of types of structures 20 can be manufactured using a pair of the first plate 2 and the second plate 3 .

In addition, since the laminate 15 is cured while being molded by the first plate 2 and the second plate 3, a dedicated base 5 and plates 2 and 3 are individually prepared each time a different type of structure 20 is manufactured. you don't have to.

In addition, since the structure 20 can be manufactured using relatively light plates 2 and 3, handling by the operator can be improved. Therefore, it is possible to reduce the production cost and the work load when manufacturing the structure 20 .

The base 5 also has a support surface 5a that supports the stacked unit 16 by contacting the stacked unit 16 from the second plate 3 side while maintaining the convex surface 2a of the first plate 2 in a predetermined shape. Therefore, since the laminated unit 16 can be well supported by the supporting surface 5a of the base 5, the structure 20 having the concave surface 20b formed with high precision can be manufactured.

In the second step S2, after the lamination unit 16 is air-tightly covered with the bag film 18 independently of the base 5, the lamination unit 16 is supported by the base 5 and laminated using a high-temperature and high-pressure gas. The laminate 15 is cured while the unit 16 is heated and pressed from both sides in the thickness direction. For this reason, the laminate 15 is brought into close contact with the first plate 2 and the second plate 3 using the bag film 18 and the high-temperature and high-pressure gas while reducing the production cost and the work load. is pressed from both sides in the thickness direction to harden the structure 20 in which the concave surface 20b is formed with high precision.

Also, since the maximum plate thickness dimension of the first plate 2 is thicker than the maximum plate thickness dimension of the second plate 3 , the rigidity of the first plate 2 can be made easier than the rigidity of the second plate 3 .

The first step S1 also comprises a first sub-step SS1, a second sub-step SS2 and a third sub-step SS3. Therefore, in the first sub-step SS1, the convex surface 2a of the first plate 2 is maintained in a predetermined shape by the supporting member 4, and in the second sub-step SS2, the laminate 15 is formed on the upper surface of the first plate 2 in an appropriate shape. can be stacked with . In the third sub-step SS3, while the first plate 2 is supported by the supporting member 4, the first plate 2 and the laminated body 15 are turned upside down together with the supporting member 4, so that the first plate 2 and the laminated body While maintaining the shape of 15, it is possible to smoothly transition from the third sub-step to the second step.

The base 5 also has a support surface 5a that supports the stacked unit 16 by contacting the stacked unit 16 from the second plate 3 side while maintaining the convex surface 2a of the first plate 2 in a predetermined shape. Therefore, by supporting the laminated unit 16 from the second plate 3 side by the support surface 5a of the base 5 while maintaining the convex surface 2a of the first plate 2 in a predetermined shape, the production cost and the work load can be reduced. , the structure 20 in which the concave surface 20b is formed with high precision can be manufactured.

Moreover, since the manufacturing jig 1 includes the support member 4, the support member 4 can maintain the convex surface 2a of the first plate 2 in a predetermined shape. For this reason, while maintaining the predetermined shape of the layered body 15 placed on the first plate 2, the layered body 15 is reversed in the thickness direction of the first plate 2 together with the first plate 2 by the support member 4, and the layered body 15 is stacked. The body 15 can be arranged with good overlap on the second plate 3 .

Further, in this embodiment, a plurality of structures 20 are combined to manufacture an aircraft fuselage. Therefore, compared to the case where the aircraft fuselage is manufactured in one piece in the circumferential direction, transportation of manufacturing facilities and parts for manufacturing the aircraft can be facilitated. In addition, since manufacturing equipment such as an autoclave can be downsized, manufacturing equipment costs can be reduced. Therefore, an aircraft can be manufactured efficiently using the structure 20 .

In the above-described embodiment, after the first plate 2 and the laminate 15 are turned upside down, the second plate 3 is placed on top of the laminate 15 to support the laminate unit 16 by the base 5. However, after setting the first plate 2 , the laminate 15 , and the second plate 3 to configure the laminate unit 16 , the laminate unit 16 may be turned upside down and supported by the base 5 .

The present invention is not limited to the above-described embodiments, and its configuration and method can be changed, added, or deleted without departing from the scope of the present invention.

INDUSTRIAL APPLICABILITY In the case of manufacturing a panel-shaped composite material structure having a concave surface, the present invention can reduce the cost of jigs and work load, and can form the surface shape of the composite material structure with high precision. It can be widely and suitably used in various fields using material structures.

S1 first step S2 second step SS1 first sub-step SS2 second sub-step SS3 third sub-step 1 manufacturing jig 2 first plate 2a convex surface 2b concave surface 3 second plate 4 supporting member 5 base 5a supporting surface 15 Laminate 15a convex surface (upper surface of laminate)
16 laminated unit 18 bag film 20 composite structure

Claims (5)

A sheet-like laminate including a plurality of laminated prepregs is stacked on the convex surface of a first plate that curves in an arc when viewed from one direction perpendicular to the plate thickness direction, and the first plate of the laminate is arranged. A second plate, which is curved in an arc when viewed from the one direction and has lower rigidity than the first plate, is stacked on the surface opposite to the plate side while aligning the direction of the convex surface with that of the first plate. a first step of forming a laminate unit having a laminate structure including the first plate, the laminate, and the second plate, by
After the first step, a second step of molding and curing the laminate into a predetermined shape while the laminate unit is supported by a base from the second plate side. . 2. The base according to claim 1, wherein the base has a supporting surface that supports the stacked unit by contacting the stacked unit from the second plate side while maintaining the convex surface of the first plate in a predetermined shape. Production method. In the second step, after the lamination unit is airtightly covered with a bag film independently of the base, a high-temperature and high-pressure gas is used to press the lamination unit while the lamination unit is supported by the base. 3. The manufacturing method according to claim 2, wherein the laminate is cured while heating and applying pressure from both sides in the thickness direction. The manufacturing method according to any one of claims 1 to 3, wherein the maximum thickness dimension of the first plate is thicker than the maximum thickness dimension of the second plate. The first step is
The first plate is arranged so that the upper surface is the convex surface and the lower surface is the concave surface, and the first plate is supported by a supporting member from the lower surface side while the convex surface of the first plate is maintained in a predetermined shape. 1 substep;
After the first substep, a second substep of overlapping the laminate on the upper surface of the first plate;
2. After the second sub-step, a third sub-step of vertically inverting the first plate and the stack together with the supporting member while the first plate is supported by the supporting member. 5. The production method according to any one of 4.

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