JP2023001602A - Manufacturing method of composite material component - Google Patents

Abstract

To provide a manufacturing method of a composite material component whose outer mold face is smoothly formed along an outer jig, that is capable of positioning a skin member and a reinforcement member.SOLUTION: The manufacturing method includes: a film installation step of closely attaching a bag film 50 to an IML jig 40 arranged on an inner mold face side of a skin 10; a member placement step of placing the skin 10 and reinforcement members 21, 22 onto the IML jig 40 in a state where the bag film 50 is interposed; an outer jig installation step of forming a sealed space with the bag film 50 in between, while arranging a cowl plate 60 on an outer mold face 12 side of the skin 10; a gap formation step of providing a gap between the IML jig 40 and the bag film 50 after the outer jig installation step; and a deaeration step of deaerating the sealed space after the gap formation step. The cowl plate 60 is made of a material exhibiting higher rigidity than that of the bag film 50.SELECTED DRAWING: Figure 12

Description

The present disclosure relates to methods of manufacturing composite parts.

When manufacturing aircraft wings and fuselage skins from composites containing thermosetting resins or composites containing thermoplastic resins, autoclave molding accompanied by heat and pressure and oven molding accompanied by heating are generally used. target.

In order to improve the strength of the outer panel made of a composite material, reinforcing members such as separately molded stringers are sometimes provided.
The jigs used at that time are roughly classified into OML (Outer Mold Line) jigs and IML (Inner Mold Line) jigs (for example, Patent Document 1).

Japanese Patent No. 6133968

However, when the OML jig is used, there is a possibility that the number of man-hours required for setting is increased, or that the reinforcing member is misaligned.
Moreover, when using an IML jig, unevenness may occur on the OML surface of the outer plate, and demolding may be difficult. The following are considered as examples of the causes of unevenness on the OML surface of the outer plate. That is, the amount of decrease in plate thickness due to heat shrinkage when the molten resin hardens differs from part to part.

The present disclosure has been made in view of such circumstances, and a composite material in which the skin member and the reinforcing member can be positioned and the outer mold surface is smoothly formed along the outer jig It aims at providing the manufacturing method of components.

In order to solve the above problems, the manufacturing method of the composite material part of the present disclosure employs the following means.
That is, a method of manufacturing a composite component according to one aspect of the present disclosure includes a skin member having an inner mold surface and an outer mold surface, and a reinforcing member provided on the inner mold surface of the skin member. A method for manufacturing a composite material part comprising: a film installation step of closely contacting a bag film to an inner jig disposed on the inner mold surface side of the skin member; a member placing step of placing the member and the reinforcing member on the inner jig; a jig installation step; after the outer jig installation step, a gap forming step of providing a gap between the inner jig and the bag film; and after the gap forming step, degassing the sealed space. and a cooling step, wherein the outer jig is made of a material having higher rigidity than the bag film.

According to the present disclosure, it is possible to manufacture a composite material part in which the skin member and the reinforcing member can be positioned and the outer mold surface is smoothly formed along the outer jig.

1 is a composite component manufactured by a manufacturing method according to one aspect of the present disclosure (front view); FIG. 3 is a diagram of an IML fixture; It is a figure when preparing a bag film. FIG. 10 is a view when the bag film is placed on the IML jig; It is a figure when a bag film sticks to an IML jig. 6 is an enlarged view of a portion A shown in FIG. 5; FIG. It is a figure when a stringer etc. are prepared. It is a figure when a stringer etc. are arrange|positioned to the IML jig|tool with which the bag film adhere|attached. It is a figure when preparing a cowl plate. It is a figure when forming a sealed space between the cowl plate and the bag film. It is a figure when cutting|disconnecting the vicinity of the edge part of a bag film. It is a figure when providing a gap between the bag film and the IML jig. FIG. 10 is a view when taking out the composite material part; FIG. 10 is a view when a stringer or the like is arranged on the IML jig to which the bag film is in close contact in modification 1; 15 is an enlarged view of a B portion shown in FIG. 14; FIG. It is a figure when an auxiliary plate is arranged. 17 is an enlarged view of the C section shown in FIG. 16; FIG. FIG. 11 is a diagram of an auxiliary plate according to Modification 2;

Hereinafter, a method for manufacturing a composite material part according to an embodiment of the present disclosure will be described with reference to the drawings.

The manufacturing method according to this embodiment is a method for manufacturing a composite material component 1 as shown in FIG.
The composite material part 1 is a member in which a reinforcing member is provided integrally with a skin (skin member) 10, and is used, for example, as an outer panel of an aircraft wing or fuselage. Examples of reinforcing members include hat stringers 21 and T stringers 22 shown in FIG.
However, the shape and number of reinforcing members are not limited to this, and can be changed as appropriate according to the specifications of the outer panel of the aircraft.

The skin 10 is a member whose cross-sectional shape is arc-shaped and has a predetermined thickness.
The inner peripheral surface of the skin 10 is defined as an internal mold surface 11 and the outer peripheral surface of the skin 10 is defined as an external mold surface 12 .
The outer mold surface 12 is the surface that comes into contact with the atmosphere in the aircraft. Therefore, it is important to form a smooth surface without irregularities.

The hat stringer 21 is a hat-shaped member in cross section and is connected to the inner mold surface 11 of the skin 10 .

The T-stringer 22 is a T-shaped member in cross-section and is connected to the inner mold surface 11 of the skin 10 .

The skin 10, hat stringer 21 and T stringer 22 are all composite materials containing resin. Examples of resins include thermosetting resins and thermoplastic resins.

In the composite material part 1 as described above, the skin 10, the hat stringer 21, and the T stringer 22, which are separated before molding, are integrated by autoclave molding with heating and pressure or oven molding with heating. Manufactured in

The manufacturing method thereof will be described below.
First, as shown in FIG. 2, an IML jig (inner jig) 40 is prepared (IML: Inner Mold Line).
The IML jig 40 is a jig arranged on the inner mold surface 11 side of the skin 10 (see FIG. 7).
The surface (mounting surface 41 ) of the IML jig 40 is a smooth surface following the shape of the internal mold surface 11 of the skin 10 . Further, slots 42 for positioning the hat stringers 21 and the T stringers 22 are formed in the mounting surface 41 of the IML jig 40 .
Invar is exemplified as the material of the IML jig 40 .

Next, as shown in FIG. 3, a bag film 50 is prepared.
The bag film 50 is a thin film-like flexible member arranged on the mounting surface 41 of the IML jig 40 .
The surface area of the surface of the bag film 50 facing the IML jig 40 is larger than the surface area of the surface of the IML jig 40 facing the bag film 50 (preferably about two to three times).
Examples of materials for the bag film 50 include nylon, polyester, and polyvinyl chloride.

The bag film 50 is provided with a first degassing nozzle 52 .
The first degassing nozzle 52 is a nozzle that communicates the front surface and the back surface of the bag film 50 .

Next, as shown in FIG. 4 , the edges of the bag film 50 are adhered to the mounting surface 41 of the IML jig 40 using the first sealing material 81 . As a result, an airtight closed space is formed between the IML jig 40 and the bag film 50 . However, gas can be supplied and exhausted through the first degassing nozzle 52 .

Next, as shown in FIG. 5, the sealed space between the IML jig 40 and the bag film 50 is evacuated. As a result, the flexible bag film 50 is brought into close contact with the IML jig 40 (specifically, the mounting surface 41 and the slot 42) (film installation step).
Degassing is performed, for example, by a vacuum pump (not shown) connected to one end of the first degassing nozzle 52 .

At this time, as described above, the surface area of the surface of the bag film 50 facing the IML jig 40 is larger than the surface area of the surface of the IML jig 40 facing the bag film 50 . That is, the surface area of the surface of the bag film 50 in close contact with the IML jig 40 is larger than the surface area of the surface of the IML jig 40 in close contact with the bag film 50 . As a result, wrinkles 51 can be generated in the bag film 50 in close contact with the IML jig 40, as shown in FIG.

Next, as shown in FIGS. 7 and 8, the skin 10, the hat stringers 21 and the T stringers 22 are placed on the IML jig 40 with the bag film 50 in close contact (member placement step).
Specifically, first, the hat stringers 21 and the T stringers 22 are accommodated in the respective slots 42 . In installing the T stringer 22 , the core 32 may be used to stably support the T stringer 22 .
Next, the skin 10 is placed on the placement surface 41 over the hat stringers 21 and the T stringers 22 . At this time, the bladder bag 31 may be placed in the space defined by the inner mold surface 11 of the skin 10 and the hat stringer 21 .

The hat stringers 21 and T stringers 22 are positioned against the skin 10 by the slots 42 during the component placement process.

Next, as shown in FIG. 9, a cowl plate (outer jig) 60 is prepared.
The cowl plate 60 is a jig arranged on the outer mold surface 12 side of the skin 10 .
The inner surface 61 of the cowl plate 60 is a smooth surface that conforms to the desired shape of the outer mold surface 12 of the skin 10 .
The cowl plate 60 is made of a material having higher rigidity than the bag film 50 . Examples of materials for the cowl plate 60 include metals and composite materials.

A second degassing nozzle 62 is provided on the cowl plate 60 .
The second degassing nozzle 62 is a nozzle that communicates the inner surface 61 and the outer surface of the cowl plate 60 .

Next, as shown in FIG. 10, the edge of the cowl plate 60 is adhered to the bag film 50 using the second sealing material 82 . As a result, a sealed space is formed between the bag film 50 and the cowl plate 60, in which the skin 10, the hat stringers 21 and the T stringers 22 are accommodated and airtightness is maintained (external jig installation process). However, gas can be supplied and exhausted through the second degassing nozzle 62 .

Next, as shown in FIG. 11, the bag film 50 between the first sealing member 81 and the second sealing member 82 is cut in the vicinity of the edge of the bag film 50 . As a result, the airtightness of the closed space between the IML jig 40 and the bag film 50 is released.

Next, as shown in FIG. 12, a gas such as air is supplied between the IML jig 40 and the bag film 50 to form a gap between the IML jig 40 and the bag film 50 (gap forming step). ). Then, a wedge 83 is driven between the IML jig 40 and the bag film 50 to maintain the gap. As a result, the skin 10 , hat stringers 21 and T stringers 22 are separated from the IML jig 40 .
The gas is blown into the gap through, for example, a plurality of air supply channels 43 provided in the IML jig 40 . Gas is supplied to the air supply channel 43 by a blower (not shown).

After that, the sealed space between the bag film 50 and the cowl plate 60 is deaerated (deaeration step).
Degassing is performed, for example, by a vacuum pump (not shown) connected to one end of the second degassing nozzle 62 .
This causes the flexible bag film 50 to adhere to the skin 10 , hat stringers 21 , T stringers 22 and cowl plate 60 .

At the same time, pressure from the bag film 50 forces the outer mold surface 12 of the skin 10 against the inner surface 61 of the cowl plate 60 . At this time, since the cowl plate 60 has higher rigidity than the bag film 50 , the outer mold surface 12 is in closer contact with the inner surface 61 of the cowl plate 60 than the bag film 50 . As a result, the outer mold surface 12 can be formed into a smooth surface that conforms to the shape of the cowl plate 60 in the integration process to be described later.

Further, as described above, since the bag film 50 has the wrinkles 51, excessive tension (tension) is generated in the bag film 50 when the bag film 50 is brought into close contact with the skin 10 or the like in the degassing process. can be suppressed. This is because the wrinkles 51 generated in the bag film 50 become the margin/margin. This reduces the possibility that the bag film 50 will be damaged.

Next, the skin 10, the hat stringer 21 and the T stringer 22 are heated and integrated by autoclave molding or oven molding (integration step). The IML jig 40, the bag film 50, the cowl plate 60, etc. are also heated at the same time.

At the time of heating, since gas exists in the gap provided between the IML jig 40 and the bag film 50, the gas acts like a heat insulating layer to heat the skin 10 and the hat stringer 21, which are objects to be heated. And heat transfer from the T stringer 22 (which will become the composite material part 1) to the IML jig 40 becomes difficult. Thereby, the skin 10, the hat stringers 21 and the T stringers 22 can be efficiently heated.

Further, if the gas supplied from the air supply passage 43 is heated in advance, the skin 10, the hat stringers 21 and the T stringers 22 can be heated more efficiently.

Finally, as shown in FIG. 13, the airtightness of the closed space between the bag film 50 and the cowl plate 60 is released, and the composite material part 1 in which the skin 10, the hat stringers 21 and the T stringers 22 are integrated is assembled. take out.

[Modification 1]
As shown in FIGS. 14 and 15, wrinkles 51 are generated in the bag film 50 after the film setting process.

If the skin 10, the hat stringer 21 and the T stringer 22 are heated in this state, the resin will flow into the wrinkles 51 as shown in FIG. . However, since the inner mold surface 11 is not exposed to the outside air in an aircraft, the swelling 11a is usually negligible.

However, even on the inner mold surface 11, there is a portion where the occurrence of the bulge 11a is not allowed. In such a case, as shown in FIGS. 16 and 17, an auxiliary plate (auxiliary jig) 70 may be provided between the inner mold surface 11 and the bag film 50 (auxiliary jig installation step).

The auxiliary plate 70 is made of a material having higher rigidity than the bag film 50 and lower rigidity than the cowl plate 60 . As a result, it is possible to prevent the resin from flowing into the wrinkles 51 while maintaining the adhesion of the skin 10 and the like to the cowl plate 60 .

In addition, the auxiliary plate 70 may be provided at a portion corresponding to the hat stringer 21 and the T stringer 22 . Also, the auxiliary plate 70 may be provided, which is made of a material having higher rigidity in order from the portion requiring smoothness.

[Modification 2]
As shown in FIG. 18, a channel groove 71 may be provided in the auxiliary plate 70 . This allows the resin to flow smoothly along the channel groove 71 when molding by RTM (Resin Transfer Molding) or the like.

According to this embodiment, the following effects are obtained.
A film installation step of closely contacting the bag film 50 to the IML jig 40 arranged on the inner mold surface 11 side of the skin 10, and the skin 10, the hat stringer 21 and the T stringer 22 are subjected to the IML jig with the bag film 50 interposed. and a step of placing members on the tool 40, the skin 10, the hat stringer 21 and the T stringer 22 can be positioned by the IML jig 40 to which the bag film 50 is in close contact.

In addition, after the outer jig installation step of installing the cowl plate 60 on the outer mold surface 12 side of the skin 10 and forming a sealed space with the bag film 50, and the outer jig installation step, the IML jig 40 is installed. The cowl plate 60 includes a gap forming step of forming a gap with the bag film 50 and a degassing step of degassing the closed space after the gap forming step. Therefore, after separating the skin 10, hat stringers 21 and T stringers 22 from the IML jig 40, the cowl plate 60 having higher rigidity than the bag film 50 is brought into surface contact with the outer mold surface 12 of the skin 10. can be made As a result, the outer mold surface 12 is brought into close contact with the cowl plate 60 , so that the outer mold surface 12 is smoothly formed along the cowl plate 60 .

In addition, since a gap is provided between the skin 10, the hat stringers 21 and the T stringers 22, and the IML jig 40, for example, when the skin 10, the hat stringers 21 and the T stringers 22 are integrated by heating, The gap acts like a heat insulating layer. Therefore, it becomes difficult for heat to be transferred from the skin 10, the hat stringers 21 and the T stringers 22 to the IML jig 40, and the skins 10, the hat stringers 21 and the T stringers 22 can be efficiently heated.

Further, in the gap forming step, the gap is provided by supplying gas between the IML jig 40 and the bag film 50 , so that the bag film 50 in close contact with the IML jig 40 can be separated from the IML jig 40 by a simple means. can be released.

Further, by supplying heated gas, the skin 10, the hat stringers 21 and the T stringers 22 can be efficiently heated when the skins 10, the hat stringers 21 and the T stringers 22 are integrated by heating, for example. can.

In addition, after the degassing step, the skin 10, the hat stringers 21 and the T stringers 22 are integrated, so that the skin 10, the hat stringers 21 and the T stringers 22 are separated from the IML jig 40, and The skin 10, the hat stringers 21 and the T stringers 22 can be integrated with the outer mold surface 12 in surface contact with the cowl plate 60. This makes it possible to provide a composite component 1 with a smooth outer mold surface 12 .

In addition, it includes an auxiliary jig installation step of installing an auxiliary plate 70 between the bag film 50 and the skin 10 and/or the reinforcing member (hat stringer 21 or T stringer 22). Since the cowl plate 60 has a high rigidity and a rigidity lower than that of the cowl plate 60, a smooth surface can be formed even in a portion such as the skin 10 facing the bag film 50. - 特許庁

In addition, since the surface area of the surface of the bag film 50 in close contact with the IML jig 40 is larger than the surface area of the surface of the IML jig 40 in close contact with the bag film 50, the step of bringing the bag film 50 into close contact with the IML jig 40; It is possible to suppress the occurrence of excessive tension in the bag film 50 in the degassing process or the like. This reduces the possibility that the bag film 50 will be damaged.

The manufacturing method of the composite material part according to the embodiment described above can be grasped, for example, as follows.
That is, a method of manufacturing a composite component (1) according to one aspect of the present disclosure comprises: a skin member (10) having an inner mold surface (11) and an outer mold surface (12); reinforcement members (21, 22) provided on the surface of the composite material part, the method comprising: enclosing a bag in an inner jig (40) located on the inner mold surface side of the skin member; A film setting step of closely contacting the film (50), a member placing step of placing the skin member and the reinforcing member on the inner jig with the bag film interposed therebetween, and the outer mold of the skin member. An outer jig installation step of installing an outer jig (60) on the surface side and forming a sealed space with the bag film, and after the outer jig installation step, the inner jig and the bag film are installed. a gap forming step of forming a gap between the It is

According to the manufacturing method according to this aspect, the film installation step of closely contacting the bag film to the inner jig arranged on the inner mold surface side of the skin member, and the skin member and the reinforcing member are placed inside with the bag film interposed. and a step of placing the member on the jig, so that the skin member and the reinforcing member can be positioned by the inner jig to which the bag film is in close contact.
In addition, an outer jig installation step of installing an outer jig on the outer mold surface side of the skin member and forming a sealed space with the bag film, and an inner jig and the bag film after the outer jig installation step. Since the outer jig is made of a material having higher rigidity than the bag film, it includes a gap forming step of providing a gap between them, and a degassing step of degassing the sealed space after the gap forming step. After separating the skin member and the reinforcing member from the inner jig, the outer jig having higher rigidity than the bag film can be brought into surface contact with the outer mold surface of the skin member. As a result, the outer mold surface is brought into close contact with the outer jig, so that the outer mold surface is smoothly formed along the outer jig.
In addition, since a gap is provided between the skin member and the reinforcing member and the inner jig, the gap acts like a heat insulating layer when the skin member and the reinforcing member are integrated by heating, for example. . Therefore, it becomes difficult for heat to be transferred from the skin member and the reinforcing member to the inner jig, and the skin member and the reinforcing member can be efficiently heated.

Further, in the method for manufacturing a composite material part according to an aspect of the present disclosure, the gap is provided by supplying gas between the inner jig and the bag film in the gap forming step.

According to the manufacturing method of this aspect, in the gap forming step, the gap is formed by supplying gas between the inner jig and the bag film. It can be separated from the jig.
Further, by supplying heated gas, the skin member and the reinforcing member can be efficiently heated, for example, when the skin member and the reinforcing member are integrated by heating.

Further, the method of manufacturing a composite material component according to an aspect of the present disclosure includes an integration step of integrating the skin member and the reinforcing member after the degassing step.

According to the manufacturing method of this aspect, after the degassing step, the integration step of integrating the skin member and the reinforcing member is included. The skin member and the reinforcing member can be integrated while the mold surface is in close contact with the outer jig. This can provide a composite component with a smooth outer mold surface.
The integration of the skin member and the reinforcing member is performed, for example, by de-autoclave molding such as autoclave molding accompanied by heat and pressure or oven molding accompanied by heating.

Further, a method for manufacturing a composite material part according to an aspect of the present disclosure includes an auxiliary jig installation step of installing an auxiliary jig (70) between the bag film and the skin member and/or the reinforcing member. , the auxiliary jig has a rigidity higher than that of the bag film and a rigidity lower than that of the outer jig.

According to the manufacturing method according to this aspect, the step of installing an auxiliary jig between the bag film and the skin member and/or the reinforcing member is included. In addition, since it has lower rigidity than the outer jig, it is possible to form a smooth surface even in the portion of the skin member and/or the reinforcing member facing the bag film.

Further, in the method for manufacturing a composite material part according to an aspect of the present disclosure, the surface area of the surface of the bag film that is in close contact with the inner jig is larger than the surface area of the surface of the inner jig that is in close contact with the bag film. .

According to the manufacturing method according to this aspect, the surface area of the surface of the bag film in close contact with the inner jig is larger than the surface area of the surface of the inner jig with which the bag film is in close contact, so the bag film is brought into close contact with the inner jig. It is possible to suppress the occurrence of excessive tension in the bag film in the process, the degassing process, and the like. This reduces the possibility of damage to the bag film.
For example, the surface area of the bag film is preferably about two to three times the surface area of the inner jig.

1 Composite Part 10 Skin 11 Inner Mold Surface 11a Blister 12 Outer Mold Surface 21 Hat Stringer (Reinforcing Member)
22 T stringer (reinforcing member)
31 bladder bag 32 core 40 IML jig (inner jig)
41 mounting surface 42 slot 43 air supply channel 50 bag film 51 wrinkles 52 first degassing nozzle 60 cowl plate (outer jig)
61 inner surface 62 second degassing nozzle 70 auxiliary plate (auxiliary jig)
71 channel groove 81 first sealing material 82 second sealing material 83 wedge

Claims (5)

1. A method of manufacturing a composite component comprising a skin member having an inner mold surface and an outer mold surface and a reinforcing member disposed on the inner mold surface of the skin member, the method comprising:
a film installation step of bringing the bag film into close contact with an inner jig arranged on the inner mold surface side of the skin member;
a member placing step of placing the skin member and the reinforcing member on the inner jig with the bag film interposed therebetween;
an external jig installation step of installing an external jig on the side of the external mold surface of the skin member and forming a sealed space with the bag film;
After the outer jig installation step, a gap forming step of providing a gap between the inner jig and the bag film;
After the gap forming step, a degassing step of degassing the sealed space;
including
The manufacturing method, wherein the outer jig is made of a material having higher rigidity than the bag film. 2. The manufacturing method according to claim 1, wherein in the gap forming step, the gap is provided by supplying gas between the inner jig and the bag film. 3. The manufacturing method according to claim 2, further comprising an integration step of integrating the skin member and the reinforcing member after the degassing step. An auxiliary jig installation step of installing an auxiliary jig between the bag film and the skin member and/or the reinforcing member;
4. The manufacturing method according to any one of claims 1 to 3, wherein the auxiliary jig has a rigidity higher than that of the bag film and a rigidity lower than that of the outer jig. 5. The manufacturing method according to any one of claims 1 to 4, wherein the surface area of the surface of the bag film in close contact with the inner jig is larger than the surface area of the surface of the inner jig with which the bag film is in close contact.

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