JP4664081B2 - Preform manufacturing method, fiber reinforced composite material manufacturing method, preform, and fiber reinforced composite material using the same - Google Patents

Description

  The present invention relates to a method for manufacturing a preform that is an intermediate product of a fiber-reinforced composite material, and more particularly to a method for manufacturing a three-dimensional shape preform.

A technique (see Patent Documents 1 to 3) for manufacturing a three-dimensional preform by shaping a two-dimensional base material such as a fabric into a three-dimensional shape is known.
However, when a two-dimensional substrate is shaped into the desired three-dimensional shape, the surface area of the convex portion of the three-dimensional shape increases, so that the two-dimensional substrate is opened and thinned, strengthening There was a problem that the fiber density (the amount of fibers per area) was partially reduced. Since the strength of the portion where the reinforcing fiber density is reduced partially decreases, there is an inconvenience of constituting the starting point of fracture.
Further, as in Patent Document 4, the method of spraying short fibers to form a desired three-dimensional shape preform takes only a short fiber as a reinforcing substrate, in addition to the problem that it takes a relatively long processing time. Therefore, there was a problem that sufficient strength could not be secured.
Japanese Patent Laid-Open No. 4-97828 JP 2001-269987 A Japanese Patent Laid-Open No. 2003-21447 JP 2004-114439 A

This invention is made | formed in view of the above subject, and it aims at providing the manufacturing method of preform with high processing efficiency, maintaining high intensity | strength.
According to the present invention, when forming a fiber substrate into a predetermined three-dimensional shape including a two-dimensional shape having a flat surface and a three-dimensional shape having irregularities on the surface, the first fiber substrate is formed into a two-dimensional shape. A preform manufacturing method is provided in which a second fiber base material is shaped into a three-dimensional shape, and these are joined to produce a desired three-dimensional shape preform.

  According to the preform manufacturing method of the present invention, a high-strength preform can be manufactured with high processing efficiency.

<First Embodiment>
Hereinafter, based on FIGS. 1-7, the preform manufacturing method of 1st Embodiment which concerns on this invention is demonstrated. The preform manufacturing method of this embodiment is a method of shaping a fiber base material into a predetermined three-dimensional shape including a two-dimensional shape with a flat surface and a three-dimensional shape with irregularities on the surface. The procedure of the manufacturing method of a fiber reinforced composite material including the preform manufacturing method of this embodiment was shown in FIG.

  First, a target three-dimensional shape is determined, and a mold for forming the three-dimensional shape is prepared (S101). With respect to the target three-dimensional shape, the unevenness of the surface of each region (part) is detected (S102), and it is determined whether the surface has an unevenness for each region. Although not particularly limited, in the present embodiment, it is determined that there is unevenness when the absolute value of the step between the reference plane set in advance in each region and the surface of each region is greater than or equal to a predetermined value. The region is preferably defined in advance by dividing the surface of the three-dimensional shape into predetermined sections that can be identified.

  If it is determined that the surface of each region is uneven (Y in S103), the process proceeds to S104, and a three-dimensional shape region is determined. When the three-dimensional shape region is determined, a mold for forming the uneven shape is prepared (S105). This mold has a pair of upper and lower molds that can be relatively approached, and the upper mold and the lower mold approach each other with the fiber substrate sandwiched therebetween, and the mold is clamped. The fiber substrate is formed into a desired shape. From the viewpoint of facilitating the release of the shaped fiber base material, a silicon mold release material may be applied to the shaping surface of the mold, or the shaping mold surface may be coated with a silicon film or a polyethylene film. May be.

  FIG. 2 shows the lower mold 10 of the mold. This shape is almost the same as the target three-dimensional shape. 2A is a perspective view of the lower die 10 of the molding die that forms the desired three-dimensional shape, FIG. 2B is a top view of the lower die 10 of the molding die shown in FIG. 2A, and FIG. ) Is a side view of the lower mold 10 of the mold shown in FIG. The lower mold 10 includes a planar mold 1 corresponding to a two-dimensional shape having a flat surface and a convex mold 2 corresponding to a three-dimensional shape having irregularities.

  In parallel with the preparation of the mold, a second fiber base material that is shaped into a three-dimensional shape is prepared (S105). The second fiber base material preferably uses short fibers as the reinforcing base material (reinforced fiber). As the reinforcing fibers, inorganic fibers such as glass fibers and carbon fibers, and organic fibers such as aramid fibers and polyethylene fibers can be used. In the present embodiment, short fibers such as milled fiber, chopped strand, and chopped strand mat are used. The length of the short fiber is 3 mm or more and 50 mm or less, preferably 3 mm or more and 25 mm or less. The second fiber base material is preferably mixed with a binder having a fiber focusing function including a thermosetting resin, a thermoplastic resin, or a polymer.

  When the three-dimensional shape mold 10 and the second fiber base material are ready, the second fiber base material is shaped into a three-dimensional shape (S106). Specifically, the second fiber base material may be arranged and molded on the lower mold 10 of the three-dimensional shape mold, or the mixture of the second fiber base material and the binder may be formed into a three-dimensional shape mold. It may be molded by pouring, coating or spraying on the lower mold 10. Furthermore, in order to stabilize the shape of the 2nd fiber base material shape | molded by the three-dimensional shape, it is preferable to apply | coat or spray an adhesive or a paste. The convex part preform 3 of the second fiber substrate shaped into a three-dimensional shape using the convex mold 2 of the lower mold 10 is shown in FIG.

  Returning to S103, the area determined to have no unevenness on the surface is determined as a two-dimensional shape area (S114). When the two-dimensional shape region is determined, a mold for forming the flat shape is prepared (S115). In this example, the lower mold 10 of the mold shown in FIG. 2 is prepared.

  In parallel with the preparation of the mold, a first fiber base material that is shaped into a two-dimensional shape is prepared (S115). The first fiber base material preferably uses continuous fibers as the reinforcing base material (reinforced fiber). As the reinforcing fibers, inorganic fibers such as glass fibers and carbon fibers, and organic fibers such as aramid fibers and polyethylene fibers can be used. In the present embodiment, fabric-like continuous fibers such as woven fabrics, knitted fabrics (woven fabrics), nonwoven fabrics, mats, and the like composed of plain weave and satin weave are used. From the viewpoint of preventing fluffing and improving the shape stability, it is preferable to add a binder having a fiber focusing function including a thermosetting resin, a thermoplastic resin, or a polymer to the first fiber base material.

  When the two-dimensional shape mold 10 and the first fiber base material are prepared, the first fiber base material is shaped into a two-dimensional shape (S116). Specifically, the first fiber base material is cut out along the two-dimensional shape region. In order to stabilize the shape of the second fiber base formed into a two-dimensional shape and make it easy to handle, it is preferable to apply or spray a fixing agent or a paste. The flat part preform 4 of the 1st fiber base material shape | molded in the two-dimensional shape using the flat type | mold 1 of the lower mold | type 10 was shown to FIG. 3 (B).

  The convex part preform 3 and the flat part preform 4 are prepared according to the number of laminations required in the subsequent lamination process (S120).

  When the shaped fiber base material is prepared for the necessary number of layers, the process proceeds to S121. In S121, the convex part preform 3 and the flat part preform 4 are joined. Specifically, first, the convex portion preform 3 is set on the convex die 2 of the mold 10. This state is shown in FIG. FIG. 4A is a top view in which the convex part preform 3 is set on the convex mold 2, and FIG. 4B is a side view thereof. Next, the flat part preform 4 cut out in the shape of the flat mold 1 is superimposed on the set convex part preform 3. This state is shown in FIG. FIG. 5A is a top view in which the flat portion preform 4 is superimposed on the convex portion preform 3, and FIG. 5B is a side view thereof. A predetermined number of convex part preforms 3 and a predetermined number of flat part preforms 4 are alternately overlapped to obtain a preform 5 shaped into a target three-dimensional shape using a mold. This is shown in FIG. In this example, the convex part preform 3 is set first, but the flat part preform 4 may be set first. By alternately stacking the convex part preform 3 and the flat part preform 4, the bonding force between the convex part preform 3 and the flat part preform 4 can be increased, and the strength of the entire preform is improved. Can be made.

  FIG. 7 shows a cross-sectional view of the preform 5. The preform 5 shown in FIG. 7 is an example in which the flat part preform 4 is set first, the convex part preform 3 is set thereon, and the flat part preform 4 is set thereon. As shown in FIG. 7, the flat portion preform 41 is set in the lowermost layer, the convex portion preform 3 is set in the upper layer, and the flat portion preform 42 is set in the upper layer. The convex part preform 3 and the flat part preform 4 are formed such that the joint regions (X1, X2) in the vicinity of these boundaries overlap each other. In this example, the convex part preform 3 is formed so as to cover the periphery of the convex mold 2 so that the convex part preform 3 and the flat part preform 4 overlap in the joining region (X1, X2). I made it. The width of the bonding region (X1, X2) is preferably 5 mm or more and less than 100 mm, and more preferably 10 mm or more and less than 100 mm. There is a difference between the elastic modulus of continuous fibers and the elastic modulus of short fibers, and since the stress state changes suddenly at the overlapping part, if this joining area is small (less than 5 mm), the boundary area tends to break. It is. On the other hand, if the joining area is too large (100 mm or more), the weight of the preform 5 increases, so the width of the joining area is preferably less than 100 mm.

  Thus, by providing the joining area | region of predetermined width, the convex part preform 3 and the flat part preform 4 which were prepared separately are joined firmly, and do not fall apart. Thereby, the shape of the produced preform is stabilized, handling becomes easy, and production efficiency can be improved. Moreover, even when this preform is used for a fiber-reinforced composite material, it can be prevented from becoming a starting point of destruction.

  Although not particularly limited, in the present embodiment, three or more odd-numbered layers in the bonding region between the laminated convex portion preform 3 (second fiber base material) and the flat portion preform 4 (first fiber base material). It is preferable to laminate so that. For example, when the first fiber base material of continuous fibers and the second fiber base material of short fibers 2 are laminated one layer at a time, a partial difference occurs in the thickness of the preform 5, and the in-plane When stress is generated, a deformation moment that rises in the thickness direction is generated, and there is a possibility that fracture occurs at a low load below the design load. On the other hand, in this embodiment shown in FIG. 7, the convex part preform 3 and the flat part preform 4 are laminated so as to be an odd number layer of three or more layers, so the thicknesses of the preforms 5 are compared. Uniform. Further, by arranging the flat portion preform 4 in the lowermost layer and the uppermost layer, it is possible to suppress the occurrence of a step with another member in the preform joining region and to suppress the generation of a deformation moment.

  In this embodiment, in the lamination process of the convex part preform 3 and the flat part preform 4, the laminated convex part preform 3 (second fiber substrate) or the flat part preform 4 (first fiber base) are laminated. A binder is applied to each surface of the material (S122). When a binder is contained in the first fiber base and / or the second fiber base, this step may be omitted. The binder only needs to be able to stabilize the form / shape of the preform, and it is preferable to use a thermosetting resin, a thermoplastic resin, rubber, starch, or the like. Specifically, examples of the thermosetting resin include an epoxy resin, a polyester resin, a vinyl ester resin, a phenol resin, and a urethane resin. Examples of the thermoplastic resin include polyethylene resin, polyamide resin, polyester resin, ABS resin, and polycarbonate resin. A binder containing a thermosetting resin and a thermoplastic resin can also be used. Although not particularly limited, it is preferable to use the same resin as that used in the manufacture of the fiber-reinforced composite material. When applying and spreading the binder, the binder is diluted with a solvent such as acetone or MEK (methyl ethyl ketone). By dilution, the viscosity, spraying amount, and spraying state of the resin can be adjusted. By applying the binder, the shape of the prepared preform is stabilized, the handling becomes easy, and the production efficiency can be improved.

  The stacking of the convex part preform 3 (second fiber base material) and the flat part preform 4 (first fiber base material) and the dispersion of the binder are repeated until the predetermined number of layers is reached (S123). When the predetermined number of layers is reached, a preform mold is clamped and heated to obtain a predetermined three-dimensional preform (S124).

  By such a manufacturing method, a hybrid in which a first fiber base formed into a two-dimensional shape with a flat surface and a second fiber base formed into a three-dimensional shape having irregularities on the surface are joined. A preform can be obtained.

  In the present embodiment, continuous fibers such as woven fabrics are cut out (shaped) in accordance with a two-dimensional shape to form the flat portion preform 4, so that one-dimensional (not two-dimensional) short fibers are formed in a two-dimensional region. The production efficiency can be improved as compared with the method of obtaining a preform by lining up or spraying short fibers on a two-dimensional region. In addition, since the continuous fiber can cover the two-dimensional region without any spots, it is less wasteful than the arrangement and spraying of the short fiber, and the weight of the preform can be reduced.

  High-strength, high-rigidity reinforcing fibers such as glass fibers, carbon fibers, and polyester fibers exhibit the best mechanical properties when used as continuous fibers. In this embodiment, since the fiber base material containing continuous fibers is used for the two-dimensional region, the strength of the entire preform including the two-dimensional region can be improved. In addition, an appropriate fiber orientation can be imparted in the two-dimensional region.

  In addition, when continuous fibers are shaped into uneven parts (three-dimensional shape), there is a tendency to cause openings or wrinkles, but the uneven parts are separated from flat parts (two-dimensional shape). Separately, a preform can be produced without generating openings or wrinkles by creating a convex-shaped preform 3 having a concavo-convex portion using a second fiber base material containing short fibers. According to this method, since a continuous fiber (woven fabric or the like) can be used for the flat portion, the fiber loss can be reduced as compared with the case where the short fiber is sprayed on the whole.

  Thus, by using the first fiber base material for the two-dimensional shape and using the second fiber base material for the three-dimensional shape, the weight can be reduced while maintaining the strength, and the production efficiency can be improved. . In addition, in order to manufacture the convex part preform 3 in a separate process from the flat part preform 4, a preliminary inspection is performed on the convex part preform 3 formed into a three-dimensional shape with a relatively high probability of occurrence of defective products. Since this can be performed, the probability of occurrence of defective defective preforms can be reduced.

  Next, a fiber-reinforced composite material is manufactured using the obtained preform. In the present embodiment, a fiber reinforced composite material is obtained using an RTM (Resin Transfer Molding) molding method. A preform obtained in a pair of male and female airtight molds and necessary insert parts are set. After setting, airtight mold clamping is performed, and a matrix containing resin is press-fitted and filled. Thereby, the preform is impregnated with the matrix (S125). The matrix of the fiber reinforced composite material is not particularly limited, and thermosetting resins such as phenol resin, unsaturated polyester resin, epoxy resin, vinyl ester resin, acrylic resin, and urethane resin can be used. As the thermoplastic resin, general-purpose plastics and engineering plastics can be used, but it is preferable to mainly use the latter. Examples of the engineering plastic include polyamide, polyacetal, polybutylene terephthalate, polycarbonate, polyphenylene sulfide, polyethersulfone, polyetheretherketone, nylon, polyimide, polyetherimide, and polyamideimide.

  Subsequently, after the matrix impregnation, the resin is cured by heating or the like (S126). After the temperature is lowered, the mold is released to obtain a fiber reinforced composite material shaped into the desired three-dimensional shape (S127).

  By improving the production efficiency of the preform, the production efficiency of the fiber-reinforced composite material can also be improved. By reducing the weight of the preform, the weight of the fiber-reinforced composite material can be reduced. Further, since the three-dimensional convex part preform 3 and the two-dimensional flat part preform 4 are joined with high strength, the handling property is high and the production efficiency of the fiber-reinforced composite material can be improved. it can. Moreover, since the preliminary | backup inspection of the convex part preform 3 which a defect tends to generate | occur | produce in the preform stage can be performed, the defective product incidence rate of a fiber reinforced composite material can be suppressed.

<Example 1>
A T300 short fiber (25 mm in length) manufactured by Toray Industries, Inc. is shaped into a three-dimensional shape using the convex mold 2 of the lower mold 10 shown in FIGS. 2 (A) to 2 (C). The convex part preform 3 shown was obtained. A CO6343 cross base material manufactured by Toray Industries, Inc. is cut and shaped into a two-dimensional shape using the flat mold 1 of the lower mold 10 shown in FIGS. 2 (A) to (C), and the flat shown in FIG. Part preform 4 was obtained. The flat part preform 4 has a portion corresponding to the convex mold 2 cut out. A short fiber base material was arranged on the surface of the convex mold 2, and then the flat part preform 4 was set on the lower mold 10 of FIG. 2. An upper mold (not shown) opposed to the lower mold 10 was brought close to the lower mold 10 to perform mold clamping, and the desired three-dimensional preform shown in FIGS. 6 and 7 was obtained. This preform was evaluated for ease of handling in the molding process, handling property evaluation, and appearance evaluation. There were no obstacles in the molding process. The handling property was good. No appearance of wrinkles or wrinkles was observed on the appearance.

<Comparative Example 1>
A CO6343 cross base material manufactured by Toray Industries, Inc. was prepared, and this cross base material (continuous fiber) was set on the lower mold 10 shown in FIGS. The cloth substrate was set so as to cover the entire lower mold 10, that is, the flat portion 1 and the convex mold 2. An upper mold (not shown) opposed to the lower mold 10 was brought close to the lower mold 10 and clamped to obtain a three-dimensional preform. This preform was evaluated for ease of handling in the molding process, handling property evaluation, and appearance evaluation. In the molding process, the mold was not closed, and there was a problem that the mold could not be clamped. The cause was that wrinkles occurred in the convex mold 2 and the wrinkles were caught in the mold. For this reason, the handleability of the preform obtained by releasing was poor. The appearance was distorted with wrinkles and wrinkles. In particular, a twist or wrinkle occurred at a position corresponding to the convex mold 2.

  Thus, it was not possible to create a three-dimensional preform including a three-dimensional shape having irregularities with continuous fibers. There were obstacles that reduced production efficiency, such as the inability to operate the mold. On the other hand, in the Example which concerns on this invention, the obstruction | occlusion does not generate | occur | produce at all in a shaping | molding process, The obtained preform obtained high evaluation in handling evaluation and external appearance evaluation.

<Second Embodiment>
Next, based on FIGS. 8-13, the manufacturing method of the preform of 2nd Embodiment which concerns on this invention is demonstrated. As in the first embodiment, the present embodiment is a method of shaping a fiber base material into a predetermined three-dimensional shape including a two-dimensional shape with a flat surface and a three-dimensional shape with irregularities on the surface. FIG. 8 shows a procedure of a method for manufacturing a fiber-reinforced composite material including the preform manufacturing method of the present embodiment. Since the basic part is the same as that of the first embodiment, different parts will be mainly described here. S201 to 204 shown in FIG. 8 are common to S101 to S104 shown in FIG. In the present embodiment, when the three-dimensional shape region is determined (S204), a mold for forming the uneven shape is prepared (S205). This mold has a lower mold capable of spraying a mixed material of short fibers and a binder from above. After the mixed material is sprayed, the upper mold relatively accessible to the lower mold is brought into pressure contact with the lower mold, and the sprayed fiber base material can be formed into a desired shape. From the viewpoint of facilitating the release of the shaped fiber base material, a silicon mold release material may be applied to the shaping surface of the mold, or the shaping mold surface may be covered with a silicon film or a polyethylene film. May be.

  FIG. 9 shows the lower mold 10 of the mold. This shape is almost the same as the target three-dimensional shape. In this example, the substantially conical shape is divided along the rotation axis, and the cross section thereof is shaped to be a plane. FIG. 9A is a top view of the lower mold 10 of the molding die that forms the desired three-dimensional shape, and FIG. 9B is a side view of the lower mold 10 of the molding die shown in FIG. The lower mold 10 includes a planar mold 11 corresponding to a two-dimensional shape having a flat surface and a convex mold 22 corresponding to a three-dimensional shape having irregularities.

  In parallel with the preparation of the mold, a fiber substrate is prepared by mixing a binder with the second fiber substrate shaped into a three-dimensional shape (S206). As the second fiber base material, the second fiber base material described in the first embodiment can be used. It is preferable to mix the 2nd fiber base material of this embodiment with the binder which has a fiber focusing function containing a thermosetting resin, a thermoplastic resin, or a polymer | macromolecule. The binder only needs to be able to stabilize the form / shape of the preform, and it is preferable to use a thermosetting resin, a thermoplastic resin, rubber, starch, or the like. Specifically, examples of the thermosetting resin include an epoxy resin, a polyester resin, a vinyl ester resin, a phenol resin, and a urethane resin. Examples of the thermoplastic resin include polyethylene resin, polyamide resin, polyester resin, ABS resin, and polycarbonate resin. In addition, a binder including both a thermosetting resin and a thermoplastic resin can be used. Although not particularly limited, it is preferable to use the same resin as that used in the manufacture of the fiber-reinforced composite material.

  Returning to S203, the area determined to have no irregularities on the surface is determined as a two-dimensional shape area (S214). When the two-dimensional shape region is determined, a mold for forming the flat shape is prepared (S215). In this example, the lower mold 11 of the mold shown in FIG. 9 is prepared. In parallel with the preparation of the mold, a first fiber base material that is shaped into a two-dimensional shape is prepared (S215). As the first fiber base material, continuous fibers can be used as reinforcing fibers, and the same fibers as in the first embodiment can be used.

  When the two-dimensional shape mold 10 and the first fiber base material are ready, the first fiber base material is shaped into a two-dimensional shape (S216). Specifically, the first fiber base material is cut out along the two-dimensional shape region. In order to stabilize the shape of the second fiber base formed into a two-dimensional shape and make it easy to handle, it is preferable to apply or spray a fixing agent or a paste. The flat part preform 41 of the 1st fiber base material shape | molded by the two-dimensional shape using the flat type | mold 11 of the lower mold | type 10 was shown in FIG. The flat part preform 41 which shape | molded the 1st fiber base material in the two-dimensional shape is prepared according to the number of lamination | stacking (S220).

  When the shaped fiber base material has been prepared for the required number of layers, the process proceeds to S221. In S221, the fiber base material layer corresponding to the three-dimensional shape is formed. First, the flat part preform 41 shown in FIG. 10 is set on the lower mold 10 shown in FIG. 9 (S221). At this time, the fiber base layer is not formed in the portion corresponding to the three-dimensional shape, and the convex mold 22 of the lower mold 10 is exposed. A second fiber base material containing a binder is sprayed onto a portion corresponding to the three-dimensional shape and a boundary portion between the three-dimensional shape and the two-dimensional shape (S222). This state is shown in FIG. The fiber supply device 7 is a device that sprays a mixture of cut fibers and a binder. The second fiber base material sprayed by the fiber supply device 7 forms a fiber base material layer and is shaped into the shape of the convex mold 22 (S222). Thereby, unlike the flat part preform 41, the convex part preform 31 whose reinforcing base material (reinforced fiber) is a short fiber is formed in a part corresponding to the three-dimensional shape.

  Moreover, as shown in FIG. 12, you may spray the fiber base material of a short fiber, after applying a continuous fiber to the part corresponding to a three-dimensional shape. A continuous fiber such as a woven fabric is excellent in strength, but if it is shaped into a three-dimensional shape including a concavo-convex shape or the like, the fiber in the concavo-convex shape portion will have openings (the density of warp and / or weft becomes coarse). Since the amount of fibers per unit area is different between the portion where the openings are formed (β region in FIG. 12) and the portion where the openings are not formed (α region in FIG. 12), there is a partial strength imbalance. Can be a trigger for destruction. In the present embodiment, the fibers are sprayed only on the portions where the openings are generated. By using continuous fibers, the strength is increased, and by partially spraying the short fibers, the strength imbalance caused by shaping the continuous fibers into a three-dimensional shape can be corrected.

  Since the short fiber is sprayed on the part corresponding to the three-dimensional shape and the boundary part between the three-dimensional shape and the two-dimensional shape, the first fiber base material and the second fiber base material are laminated in this part. It becomes a state. When the number of layers of the first fiber base material and the second fiber base material reaches a predetermined number (Y in S223), molding is performed using a molding die to obtain a preform 5 shaped into a target three-dimensional shape (S224). ). Thus, by laminating the convex part preform 31 and the flat part preform 41 in the joining region, the joining force between the convex part preform 31 and the flat part preform 41 can be strengthened, The strength of the entire reform can be improved. FIG. 13 shows a cross section of a preform 51 in which the convex part preform 31 and the flat part preform 41 are joined. The mode of lamination can be the same as that of the first embodiment.

  Subsequently, a fiber-reinforced composite material is manufactured using the preform 5. S225 to S227 related to this manufacturing step are the same as S125 to S127 of the first embodiment.

  According to this embodiment, while producing the same effect as in the first embodiment, by improving the work efficiency of the step of shaping the second fiber substrate into a three-dimensional shape by partially blowing short fibers. Can do.

<Third Embodiment>
Next, based on FIG.14 and FIG.15, the manufacturing method of the preform of 3rd Embodiment which concerns on this invention is demonstrated. This embodiment is a method of shaping a fiber base material into a target three-dimensional shape as in the first embodiment. The present embodiment is characterized in a method of determining a first part having a flat surface and a second part having unevenness as compared with the first part, among the target three-dimensional shape.

  FIG. 14 shows a procedure of a method for manufacturing a fiber-reinforced composite material including the preform manufacturing method of the present embodiment. Since the basic part is the same as that of the first embodiment, different parts will be mainly described here. First, a target three-dimensional shape is determined, and a mold for forming the three-dimensional shape is prepared (S301). For this target solid shape, the specific surface area with respect to the projection surface of the solid shape is calculated for each region (part).

  An example of a specific surface area detection method will be described with reference to FIG. FIG. 15 shows a vehicle floor panel model 8 having a desired three-dimensional shape. An example of calculating the specific surface area of the vehicle floor panel model 8 will be described. X1, X2, X3, and X4 in FIG. 15 are placement surfaces X of the model 8 of the vehicle floor panel. A projection plane Y (Y1, Y2, Y3, Y4) parallel to the placement surface X (X1, X2, X3, X4) is set. A point obtained by projecting a point on the model 8 of the vehicle floor panel onto the projection plane Y is plotted, and the two points are associated with each other. A region is determined by three or more points on the model 8 of the vehicle floor panel. When the region is defined, the surface area of the model 8 included in the determined region is detected, and the area of the projection plane of this region is calculated. Then, the surface area of the model 8 with respect to the projection plane (area) is calculated as a specific surface area.

  In S303, it is determined whether or not the calculated specific surface area is a predetermined value or more (S303). If the surface area (specific surface area) of the model 8 with respect to the projected area is greater than or equal to a predetermined value, it can be determined that the second portion corresponding to the region is a three-dimensional shape having an uneven shape. On the other hand, if the surface area (specific surface area) of the model 8 with respect to the projected area is less than a predetermined value, it can be determined that the first portion corresponding to the region has a relatively small uneven shape or a two-dimensional shape with no uneven shape. .

  From this point of view, when the specific surface area is equal to or larger than the predetermined value in S303, it can be determined that the second portion corresponding to the region is a three-dimensional shape including an uneven shape (S304).

  In the example shown in FIG. 15, “surface area A” of A1 to A4 of model 8 relative to “projection area B” of B1 to B4 obtained by projecting the areas A1 to A4 of model 8 onto projection plane Y, that is, specific surface area A / B. Is calculated. On the other hand, the surface area C of C1 to C12 of the model 8, that is, the specific surface area C / D is calculated with respect to the area D of D1 to D12 obtained by projecting the regions C1 to C12 of the model 8 onto the projection plane Y. In this example, since the specific surface area A / B is less than the predetermined value, it is determined that the areas A1 to A4 of the model 8 are the first part (two-dimensional area). On the other hand, since the specific surface area C / D is equal to or greater than a predetermined value, it is determined that the regions C1 to C12 of the model 8 are the second portion (three-dimensional region). In this example, the area is set in advance based on the shape of the model 8, but the area may be defined by a predetermined mesh.

  Incidentally, the 2nd part of this embodiment can be handled similarly to the three-dimensional shape containing the unevenness | corrugation in 1st Embodiment and 2nd Embodiment. Subsequent S305 and S306 are common to S105 and S106 in FIG. On the other hand, when the specific surface area is less than the predetermined value in S303, the portion is determined as the first portion (S314). The first part of the present embodiment can be handled in the same manner as the two-dimensional shape having a flat surface in the first and second embodiments. Subsequent S315 and S316 are common to S115 and S116 of FIG. S320 to S327 following S306 and S316 are common to S120 to S127 in FIG. Although not shown, steps S205 and S215 to S227 may be executed instead of steps S305 to S306, S315 to S316, and S320 to S327.

  According to this embodiment, there exists an effect similar to 1st Embodiment and 2nd Embodiment. In the present embodiment, the three-dimensional shape is divided into a first portion having a relatively flat surface and a second portion having irregularities on the surface based on the specific surface area. Thereby, it is possible to quantitatively determine a three-dimensional region having a three-dimensional unevenness and a flat two-dimensional region. In other words, not only the presence / absence of unevenness but also the degree of unevenness (depth of unevenness, number of unevenness per area, etc.) can be taken into consideration to determine a two-dimensional shape and a three-dimensional shape. For example, by determining based on the specific surface area, it is possible to determine the region that can be shaped with continuous fibers, although there are some irregularities, as the first portion.

  By appropriately determining the two-dimensional shape and the three-dimensional shape in this way, it is possible to obtain a hybrid foam in which continuous fibers and short fibers are properly used for each region, thereby improving strength maintenance and production efficiency. Can be achieved.

  The embodiment described above is described for facilitating the understanding of the present invention, and is not described for limiting the present invention. Therefore, each element disclosed in the above embodiment is intended to include all design changes and equivalents belonging to the technical scope of the present invention.

It is a flowchart figure which shows the manufacture procedure of the preform of 1st Embodiment. (A) is a perspective view which shows an example of the shaping | molding die of 1st Embodiment, (B) is a top view of the shaping | molding die, (C) is a side view of the shaping | molding die. (A) is a figure which shows a convex part preform, (B) is a figure which shows a flat part preform. (A) is a top view which shows the state which set the convex-shaped part preform to the lower mold | type, (B) is the side view. (A) is a top view which shows the state which set the flat part preform to the lower mold | type, (B) is the side view. It is a perspective view which shows the preform of 1st Embodiment. It is sectional drawing of the preform of 1st Embodiment. It is a flowchart figure which shows the manufacture procedure of the preform of 2nd Embodiment. (A) is a top view which shows an example of the shaping | molding die of 2nd Embodiment, (B) is a side view of the shaping | molding die.

It is an example of correspondence information between reliability and control content.
It is a figure which shows the flat part preform of 2nd Embodiment. It is a figure for demonstrating the process of spraying a 2nd fiber base material. It is a figure for demonstrating the other process of spraying a 2nd fiber base material. It is sectional drawing of the preform of 2nd Embodiment. It is a flowchart figure which shows the manufacture procedure of the preform of 3rd Embodiment. It is a figure for demonstrating the calculation method of a specific surface area.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 ... Mold for preform 1,11 ... Convex mold 2,22 ... Flat mold 3,31 ... Convex part preform 4,41 ... Flat part preform 5,51 ... Preform

Claims (13)

A preform manufacturing method for shaping a fiber substrate into a predetermined three-dimensional shape including a two-dimensional shape having a flat surface and a three-dimensional shape having irregularities on the surface,
Shaping a first fiber substrate containing continuous fibers as a reinforcing substrate into the two-dimensional shape;
Concurrently with the step, a step of shaping a second fiber base material containing short fibers as a reinforcing base material into the three-dimensional shape;
The step of joining the first fibrous base material shaped into the two-dimensional shape and the second fibrous base material shaped into the three-dimensional shape to obtain a preform shaped into the predetermined three-dimensional shape A preform manufacturing method comprising: Wherein the second fiber substrate that is shaped into the three-dimensional shape as the first fiber substrate that is shaped into a two-dimensional shape, according to claim 1 for bonding to a predetermined area thereof near the boundary overlap Preform manufacturing method. The preform manufacturing method according to claim 2 , wherein a width of the predetermined region is 5 mm or more and less than 100 mm. A preform manufacturing method for shaping a fiber substrate into a predetermined three-dimensional shape including a two-dimensional shape having a flat surface and a three-dimensional shape having irregularities on the surface,
Shaping a first fiber substrate containing continuous fibers as a reinforcing substrate into the two-dimensional shape;
The first fiber base shaped into the two-dimensional shape is set in a mold corresponding to the predetermined three-dimensional shape, and the second fiber base containing short fibers and a binder as a reinforcing base is Spraying a portion corresponding to a three-dimensional shape and a boundary portion between the two-dimensional shape to obtain a preform shaped into the predetermined three-dimensional shape. The preform manufacturing method in any one of Claims 1-4 joined so that these may become the state laminated | stacked alternately in the boundary vicinity of a said 1st fiber base material and a said 2nd fiber base material. The preform manufacturing method according to claim 5 , wherein the first fiber base material and the second fiber base material are joined so as to be laminated in an odd number of three or more odd layers. The preform manufacturing method according to claim 6 , wherein an uppermost layer and / or a lowermost layer of the laminated first fiber base material and the second fiber base material is a first fiber base material. The preform manufacturing method in any one of Claims 1-7 which further has the step of apply | coating a binder to the said 1st fiber base material and / or 2nd fiber base material which are laminated | stacked. Wherein the step of impregnating the matrix containing the resin into the preform obtained by the production method described in claim 1, method for producing a fiber-reinforced composite material further comprising the step of curing the resin. A preform obtained by the production method according to any one of claims 1 to 8 . A fiber-reinforced composite material obtained by the production method according to claim 9 . A first fiber base shaped into a two-dimensional shape and a second fiber base shaped into a three-dimensional shape are joined, and a preform shaped into a predetermined three-dimensional shape,
The preform, wherein the first fiber base material includes continuous fibers as a reinforcing base material, and the second fiber base material includes short fibers as a reinforcing base material. In the joining region of the first fiber base shaped in the two-dimensional shape and the second fiber base shaped in the three-dimensional shape, the first fiber base and the second fiber base are alternately laminated. The preform according to claim 12 .