JP2954836B2 - Molding method of fiber-reinforced resin mold - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a T-type, J-type or channel-type fiber-reinforced resin-based material having a high strength per unit weight and high rigidity applied to an aircraft plate-like structural material. It relates to a method of forming well.

[0002]

2. Description of the Related Art As a plate-shaped structural material for aircraft having high strength per weight and high rigidity, a fiber-reinforced resin-based material having a predetermined width, in which a required number of prepregs are laminated in advance, is formed into reinforcing ribs. There is a method for forming a reinforcing material for a plate-like structural material described in JP-A-62-207637. The method of forming the reinforcing material for a plate-like structural material will be described with reference to FIG.
The bent ends 2 of the molding jig 20 which can be opened and closed as shown in FIG.
The first hole (not shown) is fitted into the engaging projection 25 of the jig support member 24 as shown in FIG.
4 is erected upward as shown in FIG. 9, and then the central part in the width direction of the flat fiber-reinforced resin material 30 is placed on the upper surface of the molding jig 20 as shown in FIG. 12, the Teflon cylindrical core 26 held on the lower surface of the core support member 27 is positioned above the center in the width direction of the fiber-reinforced resin-based material 30, and then the cylindrical core 26 is moved to the position shown in FIG.
As shown in FIG. 13, the jig support member 24 is tilted in the direction opposite to the above while keeping the fiber-reinforced resin-based material 30 in contact with the fiber-reinforced resin-based material 30, and then the core is left as shown in FIG. The support member 27 is pulled up and the jig support member 24 is folded down. Then, as shown in FIG. 14, both side bent ends 31 of the fiber-reinforced resin material 30 are bent by the bending pressing member 28 on both sides of the forming jig 20. 15 is bent and pressed, and then the core supporting member 27 and the bending pressing member 28 are lifted as shown in FIG.
As shown in FIG. 6, the jig support member 24 is disengaged from the engagement projection 25, and then filled in an autoclave, heated and pressurized for a required time, and then the columnar core 26 is removed from the hollow cylindrical portion 3.
By pulling it out from Step 2, an Ω-shaped reinforcing rib 33 is formed.

[0003] By the way, when the above-mentioned conventional molding method is used, it is possible to easily and efficiently form a fiber-reinforced resin-based mold material applicable to a plate-like structural material, but the cross-sectional shape is limited to Ω, and the structure of an aircraft structure is limited. T as a general reinforcement material
It was impossible to mold a fiber-reinforced resin-based material having a cross-sectional shape such as a mold, a J-shape or a channel shape.

When a molded Ω-shaped cross section fiber-reinforced resin material is used for a plate-like structural material, nondestructive inspection is required to guarantee internal quality. The inspection was very time-consuming and inefficient. Moreover, the Ω-shaped cross section of the fiber reinforced resin-based material has a drawback that as a reinforcing material of the plate-like structural material for aircraft, the hollow head is in the way and it is difficult to attach the stringer clip.

[0005]

SUMMARY OF THE INVENTION Accordingly, the present invention relates to a method for reinforcing a member having a cross section of a general T-type, J-type or channel-type as a reinforcing material for a plate-like structural material for an aircraft by using a normal prepreg. It is intended to provide a method of forming efficiently.

[0006]

According to one aspect of the present invention, there is provided a method of forming a fiber-reinforced resin mold material, comprising forming a predetermined number of prepregs on a plate-like fiber-reinforced resin material in advance. In the method of bending using a mold and a rod-shaped core, the fiber-reinforced resin-based material is divided into two parts with a gap in the center in the width direction and an upper horizontal plane of the left and right molding dies having a vertical plane and a horizontal plane at the top and bottom. Is set, and then a rod-shaped core having a cylindrical tip in the horizontal direction is pushed into the gap between the left and right molds from above to bend the fiber-reinforced resin-based material into a U-shape, and then the rod-shaped core is bent. After retreating upward, press the right and left molds with an air cylinder or the like to make the U-shaped fiber-reinforced resin-based material adhere to it, and then apply the width of the fiber-reinforced resin material to the upper horizontal plane of the left and right molds. Direction end by bending roller etc. It is characterized in that for molding a fiber-reinforced resin molding material of the T-shaped cross section by pressing.

Another method of forming a fiber-reinforced resin mold according to the present invention is a method of bending a flat fiber-reinforced resin material in which a required number of prepregs are laminated in advance by using a forming die and a rod-shaped core. , With a gap at the center in the width direction
Divided, set the fiber reinforced resin-based material on the upper horizontal surface of the left and right molds having a vertical surface and a horizontal surface up and down,
Next, a rod-shaped core having a cylindrical end in the horizontal direction was pushed into the gap between the left and right molds from above to bend the fiber-reinforced material into a U-shape, and then the rod-shaped core was retracted upward. Then, press the left and right molds with an air cylinder etc.
At the same time, the U-shaped bent portion is formed by forming a space in the U-shaped bent portion, and then a bending roller extending in the longitudinal direction of the fiber-reinforced resin material is attached to the lower horizontal surface of one of the molding dies. From the other mold while pressing against the lower horizontal surface of the other mold, crushing the space of the fiber-reinforced resin material to form a J-shaped fiber-reinforced resin mold material, and at the same time, the fiber-reinforced resin It is characterized in that the width direction end of the system material is pressed and bent by a bending roller or the like.

In still another method of forming a fiber-reinforced resin mold according to the present invention, a plate-shaped fiber-reinforced resin material in which a required number of prepregs are laminated in advance is bent using a molding die and a rod-shaped core. In the method, the fiber-reinforced resin-based material is set on an upper horizontal surface of a left and right mold having a vertical surface and a horizontal surface on the upper and lower sides with a gap in a center portion in a width direction, and then the tip is horizontally oriented. The rod-shaped core formed into a column shape is pushed into the gap between the left and right molding dies from above to bend the fiber-reinforced resin material into a U-shape, and then the rod-shaped core is retracted upward, and then the left and right molding dies are formed. Is pressed by air-scilling or the like to make the U-shaped fiber-reinforced resin-based material adhere, and at the same time, a space is formed in the U-shaped bent portion, and then formed, a folding roller extending in the longitudinal direction of the fiber-reinforced resin-based material is formed. , Under one mold At the same time as pressing and moving from the horizontal plane to the lower horizontal plane of the other molding die to crush the space of the fiber-reinforced fiber material, the width direction end of the fiber-reinforced resin-based material is And press to form a fiber-reinforced resin mold having a channel-shaped cross section.

In the above two other methods for molding a fiber-reinforced resin mold according to the present invention, when the rod-shaped core is pushed into the gap between the left and right molding dies from above, the rod-shaped core is moved downward at an arbitrary position. It is preferable to provide a stopper so as to stop and adjust the length of the bent head of the fiber-reinforced resin material.

[0010]

According to the method of molding a fiber-reinforced resin mold of the present invention, a fiber-reinforced resin mold having a cross section such as a T-type, a J-type or a channel-type can be efficiently molded.
In addition, it can cope with cross-sectional changes such as changes in the thickness and height of the fiber-reinforced resin mold to be molded. Since the fiber-reinforced resin mold remains flexible after molding, the fiber-reinforced resin mold in a straight state By setting and curing the mold in a predetermined contour or twisted mold, it is possible to obtain a fiber-reinforced resin-based mold having a gentle bend or twist.

Further, the method of molding a fiber-reinforced resin mold according to the present invention can be automated with a simple device without the need for a complicated device, and can be carried out by using a general fiber without using a special material. A reinforced resin-based material can be used, and the degree of freedom of the laminated structure is increased.

Further, according to the method of molding a fiber-reinforced resin-based mold material of the present invention, the fiber is molded without being cut at the end face of the flange head of the molded fiber-reinforced resin-based mold material, which is advantageous in strength. It is.

[0013]

EXAMPLE An example of the method for molding a fiber-reinforced resin mold according to the present invention will be described. A prepreg is preliminarily laminated in a planar development shape with a fiber-reinforced resin-based material in a predetermined layer configuration in advance. The fiber-reinforced resin material used is carbon fiber,
A reinforced fiber such as aramid fiber or glass fiber is impregnated with a thermosetting resin such as epoxy fiber, bismaleidic resin, polyimide resin or phenol resin to form a sheet. May be used, or a one-way material arranged in one direction may be used. When a change in the thickness of the molded material is required, it is preferable to adjust the number of layers so as to obtain a predetermined change in the thickness in the preliminary lamination stage.

The flat fiber reinforced resin material 1 on which the prepregs are pre-laminated is divided into two parts with a gap 2 at the center in the width direction as shown in FIG. It is set on the upper horizontal surface 3b of the mandrels 3 and 3, which are left and right molding dies having 3c. At this time, if the flexibility of the fiber-reinforced resin-based material 1 is insufficient at room temperature, the fiber-reinforced resin-based material 1 is heated by an infrared heater or a heater (not shown) built in the mandrels 3 and 3 (resin). (Approximately 50 ° C. is appropriate when the material is epoxy). If the material 1 to be molded is thick and the number of prepregs laminated is large, wrinkles are likely to occur at the time of bending and molding after the next step. It is better to divide it into layers and pre-laminate. Next, as shown in FIG. 2, the push rod 4, which is a rod-shaped core having a cylindrical end in the horizontal direction, is pushed into the gap 2 between the mandrels 3 and 3 until it stops against the stopper 5 together with the fiber-reinforced resin material 1. After bending the fiber-reinforced resin material 1 into a U-shape, the push rod 4
To the upper mandrel 3, as shown in FIG.
3 is pressed by air cylinders 6, 6 or the like, and the opposing surfaces of the fiber-reinforced resin-based material 1 bent in a U-shape are brought into close contact with each other, and at the same time, a space 7 is formed in the U-shaped bent portion and molded. Next, as shown in FIG. 4, the bending roller 8 extending in the longitudinal direction of the fiber-reinforced resin material 1 is moved while being pressed from the lower horizontal surface 3c of the left mandrel 3 to the lower horizontal surface 3c of the right mandrel 3. Space 7 of reinforced resin material 1
To form a fiber reinforced resin material having a J-shaped cross section, and simultaneously press and bend the widthwise end of the fiber reinforced resin material 1 on the upper horizontal surface 3b of the left and right mandrels 3, 3 by means of a bending roller 9. I do.

In FIG. 2, by adjusting the position of the stopper 5, the length of the flange portion of the fiber-reinforced resin mold to be formed can be adjusted. Further, by eliminating the flange portion, a fiber-reinforced resin-based mold having a T-shaped cross section can be formed. Further, as shown in FIG. 5, by using the bending roller 8 not only on the lower horizontal surface 3c side of the mandrel 3, 3 but also on the upper horizontal surface 3b side of the mandrel 3, 3, the fiber reinforcement having the channel type cross section is obtained. A resin-based material can be molded.

The fiber-reinforced resin mold 10 shown in FIG. 4 formed by the molding method of the above embodiment is set on a separately laminated fiber-reinforced resin plate 11 as shown in FIG. The reinforcing panel can be integrally molded by applying a vacuum bag and hardening by autoclaving. Of course, after the molded fiber-reinforced resin-based mold member 10 is cured alone, the fiber-reinforced resin-based plate member 11 may be subjected to secondary bonding or fastener bonding. In FIG. 6, 12 is a mold core, 13
Is a cowl plate, and 14 is a molding die face plate.

The mold core 12 for autoclaving the molded fiber-reinforced resin mold 10 may be used as the mandrels 3 and 3 at the time of bending and molding, but the fiber-reinforced resin mold of the same shape is mass-produced. In this case, the time required for setting up the mandrels 3 and 3 can be saved by removing the molded fiber-reinforced resin mold material 10 from the mandrels 3 and 3 and setting it in another molding die core 12 and autoclaving. It is advantageous. In this case, when the fiber-reinforced resin-based material 1 in which the prepreg shown in FIG. 1 is pre-laminated is set on the mandrel 3, 3 in order to easily remove the molded fiber-reinforced resin-based mold material 10 from the mandrel 3, 3. It is preferable to place a release film between the mandrels 3 and 3 and the fiber-reinforced resin material 1 in which the prepregs are pre-laminated.

[0018]

According to the method of molding a fiber-reinforced resin mold of the present invention described above, a fiber-reinforced resin mold having a cross section such as a T-type, a J-type or a channel-type can be efficiently molded. . In addition, it can cope with cross-sectional changes such as changes in the thickness and height of the fiber-reinforced resin mold material to be molded. Since the molded fiber-reinforced resin mold material remains flexible, it has a straight fiber reinforcement. By setting and curing the resin-based mold in a predetermined contour or a twisted mold, a fiber-reinforced resin-based mold having a gentle bend or twist can be obtained.

Further, the method of molding a fiber-reinforced resin mold according to the present invention does not require a complicated device, can be automated with a simple device, and can use a general fiber without using a special material. A reinforced resin-based material can be used, and the degree of freedom of the laminated structure is increased.

Further, according to the method of molding a fiber-reinforced resin-based mold of the present invention, the fiber is molded without being cut at the end face of the top of the flange of the molded fiber-reinforced resin-based mold. is there.

[Brief description of the drawings]

FIG. 1 is a view showing a state in which a fiber-reinforced resin material preliminarily laminated with a prepreg is set on a mandrel as a molding die in one embodiment of a method of molding a fiber-reinforced resin mold material of the present invention. .

FIG. 2 is a diagram showing a state in which the fiber-reinforced resin-based material is bent into a U-shape from the state of FIG. 1 by a push rod as a rod-shaped core.

FIG. 3 is a view showing a state in which a fiber-reinforced resin-based material is brought into close contact with a mandrel from the state of FIG. 2;

FIG. 4 is a diagram showing a state in which a fiber-reinforced resin-based mold having a J-shaped cross section is formed by a bending roller from the state of FIG. 3;

FIG. 5 is a view showing a state in which a fiber-reinforced resin-based mold having a channel-shaped cross section is molded by another embodiment of the method of molding a fiber-reinforced resin-based mold of the present invention.

6 is a diagram showing a state in which a fiber-reinforced resin-based mold having a J-shaped cross section and a fiber-reinforced resin-based plate shown in FIG. 4 are integrally formed as a reinforcing panel by autoclave curing.

7 to 16 are views showing steps of a conventional method for forming a reinforcing material for a plate-like structural material.

[Explanation of symbols]

 Reference Signs List 1 fiber-reinforced resin material pre-laminated with prepreg 2 gap 3 molding die (mandrel) 3a vertical surface 3b upper horizontal surface 3c lower horizontal surface 4 rod-shaped core (push rod) 5 stopper 6 air cylinder 7 space 8,9 bending roller 10 fiber Reinforced resin type material

Claims (4)

(57) [Claims] 1. A method for bending a flat fiber reinforced resin material in which a required number of prepregs are laminated in advance by using a molding die and a rod-shaped core. A rod-shaped core having the fiber-reinforced resin-based material set on the upper horizontal surface of the left and right molding dies having horizontal surfaces on the top and bottom, and then having a cylindrical end in the horizontal direction,
The fiber-reinforced resin-based material is bent into a U-shape by pushing it into the gap between the left and right molds from above, and then the bar-shaped core is retracted upward. Then, the right and left molds are pressed with an air cylinder or the like to form a U-shape. The fiber-reinforced resin-based material having a T-shaped cross section is pressed against the upper horizontal surface of the left and right molds with a bending roller, etc. A method for molding a fiber-reinforced resin-based mold material, characterized in that: 2. A method of bending a plate-like fiber-reinforced resin material in which a required number of prepregs are laminated in advance using a molding die and a rod-shaped core. A rod-shaped core having the fiber-reinforced resin-based material set on the upper horizontal surface of the left and right molding dies having horizontal surfaces on the top and bottom, and then having a cylindrical end in the horizontal direction,
The fiber-reinforced resin material is bent into a U-shape by pushing it into the gap between the left and right molds from above, then the bar-shaped core is retracted upward, and then the left and right molds are pressed with an air cylinder or the like to form a U-shape. At the same time, a space is formed in the U-shaped bent portion and molded, and then a bending roller extending in the longitudinal direction of the fiber-reinforced resin material is moved from the lower horizontal surface of one molding die to the other. While pressing and moving against the lower horizontal surface of the mold, the space of the fiber-reinforced resin material is crushed to form a J-shaped cross-section fiber-reinforced resin material, and at the same time, the fiber-reinforced resin material is placed on the upper horizontal surface of the left and right molds. Forming an end portion in the width direction by pressing and bending with a bending roller or the like. 3. A method of bending a flat fiber-reinforced resin material in which a required number of prepregs are laminated in advance by using a molding die and a rod-shaped core, wherein the material is divided into two parts with a gap at the center in the width direction, and A rod-shaped core having the fiber-reinforced resin-based material set on the upper horizontal surface of the left and right molding dies having horizontal surfaces on the top and bottom, and then having a cylindrical end in the horizontal direction,
The fiber-reinforced resin material is bent into a U-shape by pushing it into the gap between the left and right molds from above, then the bar-shaped core is retracted upward, and then the left and right molds are pressed with an air cylinder or the like to form a U-shape. At the same time, a space is formed in the U-shaped bent portion and molded, and then a bending roller extending in the longitudinal direction of the fiber-reinforced resin material is moved from the lower horizontal surface of one molding die to the other. While pressing it against the lower horizontal surface of the molding die, it crushes the space of the fiber-reinforced resin material, and at the same time, overlaps the width direction end of the fiber-reinforced resin material with the bending roller on the upper horizontal surface of the other molding die A method of forming a fiber-reinforced resin-based material, wherein the fiber-reinforced resin-based material having a channel-shaped cross section is formed by pressing while molding. 4. The method of molding a fiber-reinforced resin mold according to claim 2, wherein the rod-shaped core is moved downward at an arbitrary position when the rod-shaped core is pushed into the gap between the left and right molding dies from above. A method of forming a fiber-reinforced resin-based mold material, wherein a stopper is provided so as to stop, and the length of the bent head of the fiber-reinforced resin-based material is adjusted.