JP2815665B2 - Integral molding method and integral molding apparatus for composite multi-girder structure - Google Patents

Abstract

PURPOSE:To mold a composite material multi-cross beam structure of stabilized quality by disposing the composite material multi-cross beam structure on a composite material outer board, placing a top force and a press frame of a molding tool on the upper face of an upper frame of the composite material multi-cross beam structure, coating the whole of said structure with a film, pressing the left and right inner sides of ribs and the lower face of the upper flange by a rigid locator, heating, pressurizing and hardening. CONSTITUTION:A composite material outer board 2 is placed on the upper face of a molding tool base 6 of an integral molding device 5 of a composite material multi-cross beam structure 1, and the composite material multi-cross beam structure, provided with a frame for the ribs with a flange and with ribs disposed lengthwise and crosswise in the frame, is disposed of said composite material outer board 2. Sheets 10 are disposed from both ends of a lower flange of the composite material multi-cross beam structure all over the composite material outer board, and pads 9 of given plate thickness are covered all over inner sides, left and right, of the kinds of composite material multi-cross beam structure. An upper face jig 7 is placed on the upper face of an upper section flange of the composite material multi-cross beam structure, and a press frame is placed on the upper face jig 7, and the whole is coated with a film 11 for vacuum packaging. Also, the inner faces, left and right, of the rib and the lower face of the upper flange are pressed by a rigid locator 12 and heated, pressurized and hardened by an autoclave to form the composite material multi-cross beam structure.

Description

Description: TECHNICAL FIELD The present invention relates to an integral molding method and an integral molding apparatus for a composite multi-girder structure applied to a primary structural material such as an aircraft.

(Prior art) Conventionally, metal materials such as aluminum and titanium, and fiber-reinforced plastic-based composite materials have been used as structural members for aircraft and the like, but from the viewpoint of weight reduction of aircraft structures and the like, specific strength, The application of fiber-reinforced plastic-based composite materials with high specific rigidity to primary structural materials such as wing structures has been progressing, and recently, there have been many cases where the outer plate and a number of girders and small bones are bonded and assembled at once without using an adhesive. A girder integrated structure is being put into practical use.

As a method of integrally molding a composite multi-girder structure, an autoclave pressure is applied to the web surface of a girder or a small bone through a silicone bladder mold using a fiber-reinforced plastic stiffening diaphragm, a jig that maintains the smoothness of the part. The technical means to load the AIAA report
80-0744 (Integral wing and fuselage connection).

Apply vacuum film or bladder mold (pressurized bag) directly to the skin, girder, small bone assembly,
A method of integrally molding a composite material product under an autoclave pressure is described in Japanese Patent Application Laid-Open No. 58-205730.

The composite material is molded and assembled with a molding jig using an elastomeric material, the elastomeric jig is packed without gaps, heated via a vacuum bag film, and a composite material utilizing the thermal expansion pressure of the elastomeric material A method for integrally forming a structural component is described in Japanese Patent Application Laid-Open No. 55-41210.

Further, there is known a technique for cutting a seal groove on a joint surface (a girder flange surface) between components and filling the seal groove with a sealant. A molding method for integrally molding is disclosed, for example, in Proc Instn Mech Engrs Vo1200 (1986).

Also, AIAA Report 80-0744 (Integrated wing and fuselage)
The integrated molding apparatus of the composite multi-girder structure described in
A steel base having a multi-curved surface to form the outer surface shape of the outer plate, a sabo having a multi-curved surface to form a flange surface of a spar and a small bone that matches the outer plate, and a vacuum manifold that retains the shape of the sabo An upper part ring plate having a functioning double curved surface is provided, and a surface in contact with the flange of the sabo and a surface in contact with the upper part ring plate are double curved surfaces.

(Technical Problem to be Solved by the Invention) In a technical means in which a stiffening diaphragm is provided on a web surface of a girder or a small bone and an autoclave pressure is applied through a silicone bladder mold, an autoclave is formed on an outer peripheral portion of the stiffening diaphragm. Non-uniform pressure causes deformation of the web surface of the girders and small bones or quality deterioration such as meandering of reinforcing fibers inside the laminated molded product.If the outer plate has a complicated curved surface, the girders and small bones Are not arranged at right angles to the surface of the skin, making it unstable during curing, and at the juncture between the spar and the small bone, there is no stiffening diaphragm, so even if the pressure is uneven, a large deformation will occur in the molded product .

In addition, a vacuum film or a bladder mold is directly applied to the assembled product of the outer plate, the girder, and the small bone to apply an autoclave pressure. Because the jigs are not placed, large deformations occur in the molded product, and the vacuum film or bladder mold directly contacts the outer plate, girder, and small bone, so that fiber meandering and wrinkling may occur in the laminated product is there.

In addition, using a molding jig in which the composite member is formed of an elastomeric material, further filling the elastomeric jig without gaps, heating through a vacuum bag film, and using the thermal expansion pressure of the elastomeric material In the integral molding method for structural parts, the curing pressure due to the thermal expansion of the elastomeric material causes the pressure to vary depending on the temperature difference during curing, which causes deformation and internal quality defects.In addition, the elastomeric jig has a large heat capacity In addition, the heating efficiency is poor, the temperature becomes uneven, and the energy consumption of the autoclave and the curing furnace increases.

In addition, in order to secure the accuracy of the flange surface, in order to ensure the accuracy of the flange surface, in order to ensure the accuracy of the flange surface, a curved upper part ring is formed so that there is no gap between the sabo and the upper part ring plate in AIAA Report 80-0744. After the sabo is laminated on the plate or the sabo is made into a flat shape, a process of cutting the curved surface to match the curved shape of the upper part ring plate is required, and a long manufacturing time is required. Since the upper part ring plate is made of steel while the composite material is used to eliminate the difference in thermal expansion, the contact surface shifts due to the difference in thermal expansion between the sabo and the upper part ring plate during autoclave curing, This causes sabo deformation or poor precision of the flange surface. Moreover, since the upper part plate has a hollow cross section, forming a double curved surface requires welding a plate formed into a curved surface or cutting the plate after welding the plate, which requires a long manufacturing time. When using a Prada mold to decompress the composite multi-girder structure under vacuum, it is necessary to seal the upper part of the upper ring plate to maintain airtightness, but the upper part ring plate has a double curved surface Therefore, even if an adhesive tape or a mechanical clamping device is used, it is difficult to ensure perfect airtightness, which affects the quality of the product.

Also, in the technical means of cutting the seal groove on the joint surface of the parts and filling the seal groove with the sealing material, a special jig and N / C programming are required to cut the seal groove, The cost will be high. In addition, in the molding method in which a seal groove is integrally formed on a joint surface of a single component, when the members are connected to each other, if the groove position is shifted due to a variation in the shape of the member, the seal groove must be corrected. It is difficult to stabilize the quality of the entire product.

The present invention has been made in view of the above points, and aims to maintain the shape and pressure uniformity of the girder and small bone during curing and to equalize the pressure of the joint between the girder and small bone, and to provide a composite multi-girder structure with stable quality. It is an object of the present invention to provide an integrated molding method and an integrated molding apparatus for a composite multi-girder structure for integrally molding a composite material.

[Configuration of the invention]

(Means for Solving the Problems) A method of integrally forming a composite multi-girder structure according to the present invention comprises a plurality of girders having webs and flanges arranged in substantially the same direction, and having webs and flanges and connecting girders. Of a composite multi-girder structure in which a composite multi-girder structure having small bones arranged in a direction crossing the girder and a skin following the flanges of the girder and the small bones is subjected to pressure heat treatment and joined. In the molding method,
Place the girder and small bone on the skin placed on the mold base, place a backing sheet between the girder and the lower flange of the girder to transmit uniform pressure to the skin, and apply it to the girder and small bone. A pad for transmitting uniform pressure is placed inside the spar and small bone, and a sabot with a lower surface shape and a flat upper surface shape that follows the shape of the upper flange of the spar and small bone is placed on the upper flange of the spar and small bone. Placed, place an upper jig having a flat lower surface and a flat upper surface on the sabo, cover the whole with an airtight bag, and hold the spar and small bone with a deformation prevention plate from the outside of the airtight bag, It is configured by placing a change prevention tool at the intersection of a spar and a small bone and subjecting it to a heat and pressure treatment.

The multi-girder constant molding apparatus of the present invention has a web and a flange, and a plurality of girders arranged in substantially the same direction, and a web and a flange having a web and a flange, and intersecting the girder so as to connect the girders. In the integrated molding device of the composite multi-girder structure that joins the composite multi-girder structure with the small bone arranged in the A base sheet, a backing sheet disposed between the lower flanges of the spar and the small bone for transmitting uniform pressure to the skin, a pad disposed in contact with the inner surface of the spar and the small bone, and an upper flange of the spar and the small bone. A sabo mounted on a composite member having a lower surface shape and a planar upper surface shape following the shape of the above and having a concave groove laminated on the upper flange or the flange of the girder and the small bone; With a bottom surface and a flat top surface A jig placed on the top, an airtight bag covering the whole of them, a deformation prevention plate arranged outside the airtight bag and holding the spar and small bones, and arranged at the intersection of the spar and small bone outside the airtight bag. And a deformation preventing tool.

(Operation) In the integral molding method of the composite multi-girder structure of the present invention,
When joining the composite multi-girder structure, the seat was placed on the part other than the girder of the outer plate placed on the mold base and the flange of the small bone, and the pad was placed inside the girder and the small bone. The pressure unevenness that occurs during curing is corrected, uniform pressure is applied to the small bones and girders of the composite multi-girder structure, the direct contact of the vacuum film is prevented, and the lower surface on the upper flange side of the composite multi-girder structure Following the flange shape, a sabo with a flat top surface and an upper jig with a flat bottom surface and a top surface are placed on top of it.The entire jig is covered with an airtight bag, and a deformation prevention plate is used to remove the spar and small bone from the outside of the airtight bag. By placing it so as to hold it, and by placing the deformation prevention device at the intersection of the spar and small bone, the joint to be deformed due to uneven pressure is held in the proper shape, and a lightweight and improved quality complex curved surface Composite girder with It can be molded to the body.

In the integrated molding device of the composite multi-girder structure of the present invention,
By making the surface in contact with the molded product a multi-curved surface and making the other surfaces flat, the manufacturing time of the device is greatly reduced, the manufacturing cost of the device is reduced, and the sealing surface is made flat so that the airtight bag is used. Airtightness can be ensured, and a multi-girder structure of a complex material having a complicated curved surface with improved quality and light weight can be formed.

Embodiment An embodiment of the present invention will be described below with reference to the drawings.

FIG. 1 shows an example of a composite multi-girder structure made by the method of integrally forming a composite multi-girder structure according to the present invention. A plurality of girders 3 arranged on the plate 2 in substantially the same direction, and a plurality of small bones 4 arranged on the outer plate 2 in a direction crossing the girders 3 so as to connect the girders 3 to each other. ing. The beam 3 has a web and flanges at both ends of the web in a T-shape and following the outer plate 2. The small bone 4 also has a web and a flange erected around the web, and has a shape following the spar 3 and the outer plate 2, and the spar 3 and the outer plate 2 abut on the flange surface. However, the webs of the spar 3 and the small bone 4 are arranged at an angle that is not perpendicular to the skin 2.

As shown in FIGS. 2 to 4, the integral molding apparatus 5 includes a molding die base 6 having a surface following the shape of the composite material outer plate and holding the shape of the outer plate 2, and a vacuum. An upper surface jig 7 that also functions as a manifold, a sabo 8 that maintains the curved surface shape on the upper surface side of the spar 3 and the small bones 4, and a uniform autoclave pressure is transmitted to the flange surface and the web both surfaces of the spar 3 and the small bones 4 and is being cured. The pad 9 made of an elastomer having a constant thickness to hold the shape of the spar 3 and the small bone 4 and the flange 3 of the spar 3 and the small bone 4 are placed on the outer plate 2 in contact with each other, and a uniform pressure is applied to the outer plate 2. A contact sheet 10 for transmitting and preventing wrinkles such as auxiliary materials at the time of evacuation from being transferred to the outer plate 2;
It has an elastomer bladder mold or a vacuum bag film 11 that forms an airtight bag during evacuation.

The sabo 8 has a lower surface shape following the shape of the upper film of the spar 3 and the small bones 4 and a flat upper surface shape that makes a flat contact with the upper surface jig 7.
Rests on the top flange. The sabo 8 eliminates deformation of the sabo 8 due to a gap formed between the sabo 8 and the upper surface jig 7 due to a difference in thermal expansion during curing.
The upper surface of the upper surface jig 7 is flat, so that the sealing property with the vacuum bag film 11 is ensured.

On the other hand, at the part where the spar 3 and the small bone 4
As shown in the figure, a deformation preventing plate 12 is arranged outside a vacuum bag film 11. The deformation preventing plate 12 is made of steel or carbon fiber reinforced plastic.
The deformation preventing plate 12 is fixed to the mold base 6 or the upper jig 7 and is disposed at a portion where the difference between the degree of vacuum reduction and the autoclave pressure is large, and prevents the deformation of the beam 3 during evacuation or autoclave hardening. Act like.

Further, in the portion where the spar 3 and the small bone 4 are cross-jointed rather than orthogonal to each other, it becomes more difficult to equalize the thickness, and such a portion is also reinforced with steel or carbon fiber as shown in FIG. The deformation preventing plate 13 made of plastic is squeezed from the outside of the film 11 for a vacuum bag.
It is set so as to sandwich the joint of the small bone 4 and the small bone 4 to prevent deformation of the spar 3 and the small bone 4 due to uneven pressure during evacuation or hardening of the autoclave. This deformation prevention plate
13 is fixed to the upper surface jig 7 by bolts or the like so as not to move during curing of the autoclave.

 Next, the operation will be described.

First, the composite outer plate 2 is placed on the upper surface of a molding die base 6 of an integrated molding apparatus having a composite multi-girder structure, and a web 3 and a composite girder 3 having flanges at both ends thereof are placed on the composite outer plate 2.
Are arranged in substantially the same direction, and the small ribs 4 of the composite material having the web and the flanges at both ends thereof are arranged in a direction intersecting the spar so as to connect the spar 3 to each other.

Next, a contact sheet 10 is arranged over the entire composite outer plate 2 from both ends of the lower flange of the spar 3 and the small bone 4, and a pad 9 having a constant thickness is put on both surfaces of the spar 3 and the small bone web and the entire inner surface of the flange.

Then, a sabo 8 for maintaining the surface shape is placed on the upper surface of the upper flange of the assembled spar 3 and small bone 4, and further, an upper surface jig 7 as an upper mold is placed thereon. After that, the part where the spar 3 and the small bone 4 intersect and the other part of the spar 3 and the small bone 4 are deformed and fixed to the upper jig 7 or the mold base 6 to prevent deformation. By pressing with plate 12, heating, pressurizing and curing in an autoclave. A composite multi-girder structure 1 is formed.

5 and 6 show a modified example of the present invention. In the modified example shown in FIG. 5, in order to prevent deformation of the molding die base 6, the same curvature surface as the lower surface of the molding die base 6 is used. By attaching the reinforcing assembly other body 17 to the mold base 6 and providing the adhesive tape 18 between the upper surface jig 7 and the vacuum bag film 11, the space between the upper surface jig 7 and the vacuum bag film 11 is provided. I try to seal.

The modification shown in FIG. 6 is a case in which a sealing groove is provided on the joint surface between the parts, and a member 14 having a concave groove 15 is laminated on the upper surface of the flange portion of the spar 3 and the small bone 4, and the sabo 8 is A convex portion 16 corresponding to the concave groove 15 is provided on the lower surface, so that the step of cutting the groove is unnecessary, and there is no seam shift of the groove generated when assembling a single member with a groove, and The molding pressure acts uniformly on the groove to stabilize the product quality.

〔The invention's effect〕

As described above, according to the present invention, even in a structure having a complicated curve, it is possible to prevent deformation of each member and to form a composite multi-girder structure with stable quality, and to assemble a composite multi-girder structure. Sometimes the elimination of fasteners and adhesives can significantly reduce structural weight and cost of the assembly process, and minimize the use of high heat capacity elastomeric materials and make heavy use of fiber reinforced plastics. Thereby, the quality of the molded article can be stabilized and the energy consumption of the autoclave can be reduced.

In addition, the surface of the sabot placed between the molded product and the upper surface jig, which comes into contact with the molded product, is made into a multi-curved surface according to the shape of the molded product, and the contact surface with the upper surface jig is made flat. By making the upper surface flat, the manufacturing time of the device is greatly shortened, the manufacturing cost of the device is reduced, and by making the sealing surface flat, it is possible to secure airtightness by using an airtight bag, which is lightweight and improves quality. A composite multi-girder structure having a complicated curved surface can be formed.

[Brief description of the drawings]

FIG. 1 is a perspective view of a composite material multi-girder structure formed by an integral molding method of a composite material multi-girder structure according to the present invention, and FIG. 2 is a line AA of FIG. 1 held in a forming jig. FIG. 3 is a cross-sectional view taken along a line B- in FIG.
FIG. 4 is a sectional view taken along the line B, FIG. 4 is an enlarged view of a portion C in FIG. 1 held by a molding jig, and FIGS. 5 and 6 are views showing another modified example of the present invention. is there. 1 ... multi-girder structure of composite material 2 ... outer plate 2, 3 ... girder, 4 ...
... Small bone, 5 ... Integral molding device, 6 ... Base for molding die,
7: Upper surface jig, 8: Sabo, 9: Elastomer pad, 10: Backing sheet, 11: Vacuum bag film, 12: Deformation prevention plate.

──────────────────────────────────────────────────続 き Continuation of the front page (51) Int.Cl. ⁶ identification code FI B29L 31:30 (58) Field surveyed (Int.Cl. ⁶ , DB name) B29C 65/02-65 / 46,65 / 70 B29C 67/14 B29C 43/10-43/12 B64C 1/00

Claims (3)

(57) [Claims] A plurality of girders having a web and a flange and arranged in substantially the same direction; small ribs having a web and a flange and arranged in a direction intersecting the girders so as to connect the girders; In a method of integrally forming a composite multi-girder structure in which a multi-girder structure with an outer plate imitating a flange of a small bone is joined by pressurizing, heating and hardening, the outer plate placed on a mold base is formed. Place the girder and small bone on top, place a backing sheet between the girder and the lower flange of the girder to transmit uniform pressure to the skin, and place the pad for transmitting even pressure to the girder and small bone. The sabo having a lower surface shape and a planar upper surface shape following the shape of the upper flange of the girder and the small bone is placed on the upper flange of the girder and the small bone, and the flat lower surface and the flat Place an upper surface jig with an upper surface on the Cover the entire structure with an airtight bag, hold the girder and small bones with a deformation prevention plate from the outside of the airtight bag, place a deformation prevention tool at the intersection of the girder and small bones, and perform pressure heat curing treatment. An integrated molding method for composite multi-digit structures. 2. A composite member having a groove on a spar and a flange of a small bone is laminated, and a sabo having a convex portion corresponding to the groove is disposed on the member. Item 1. An integrated molding method for a composite multi-girder structure according to Item 1. 3. A plurality of girders having a web and a flange and arranged in substantially the same direction; small ribs having a web and a flange and arranged in a direction intersecting the girders so as to connect the girders; An integrated molding apparatus for a composite multi-girder structure that joins a composite multi-girder structure having an outer plate imitating a flange of a small bone by applying heat, heat, and heat to a molding die base, and a lower flange of a girder and a small bone. Between the spar and the inside surface of the ossicles and the pad, and the lower surface and the plane following the shape of the upper flange of the spar and the ossicles A sabo mounted on a composite member having an upper surface shape of a girder and having a concave groove laminated on an upper flange or a flange of a spar and a small bone; a planar lower surface and a planar upper surface. Upper surface jig placed on sabbo An airtight bag covering the entirety, a deformation prevention plate arranged outside the airtight bag to hold the spar and the small bone, and a deformation prevention device arranged outside the airtight bag at the intersection of the spar and the small bone. An integrated molding apparatus for a composite multi-girder structure.