JP6667055B2 - 複合材料成形物製造用成形型および複合材料成形物の製造方法 - Google Patents
複合材料成形物製造用成形型および複合材料成形物の製造方法 Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Description
[複合材料成形物の構成例]
まず、本開示に係る複合材料成形物の一例について、図1A〜図1Cを参照して具体的に説明する。本開示に係る複合材料成形物は、熱硬化性樹脂組成物および繊維材料により少なくとも構成される複合材料製であって、繊維材料に熱硬化性樹脂組成物を含浸させて半硬化させたプリプレグの積層体を熱硬化することにより製造されるものであればよい。ただし、本開示に係る複合材料成形物は、その横断面に中空、折曲部および湾曲部の少なくともいずれかを含む断面形状を有している。
次に、このようなC型材20Aを製造するために用いられる、本実施の形態1に係る成形型の代表的な一例について、図2〜図4を参照して具体的に説明する。図2および図3に示すように、本実施の形態1に係る成形型10Aは、雌型部11、側面蓋型部12、加圧体13A,および端面蓋型部14等を備えており、図2に示すように、雌型部11および加圧体13Aとの間に成形空間15が形成される。成形空間15内には、硬化によってC型材20Aとなる積層体40が保持されている。
次に、本開示に係る複合材料成形物の製造方法について、前記構成の成形型10Aを用いた場合を例に挙げて、図5A,図5Bおよび図6A,図6Bを参照して具体的に説明する。
本実施の形態1では、加圧体13Aは、複合材料成形物の加圧面の形状に対応する外表面形状(加圧成形表面)を有し、熱膨張するものであれば特に限定されない。前述した図2〜図4に示す構成では、加圧体13Aは、熱膨張率の異なる複数の部材で構成されており、熱膨張の主体となる膨張核部31に対して圧力分散部32は熱膨張率が小さくなっているが、本開示はこれに限定されない。例えば、図8に示す成形型10Bは、基本的には図2〜図4に示す成形型10Aと同じ構成であるが、加圧体13Bは、単一の熱膨張部材として構成されている。
前記実施の形態1に係る成形型10A〜10Dは、成形型本体を組み立てた後に、例えばオーブン等の外部加熱装置を利用して積層体40を熱硬化していた。これに対して、本実施の形態2では、成形型本体が、当該成形型本体を加熱する加熱部を備えている構成を有している。このような成形型について図11を参照して具体的に説明する。
前記実施の形態1または2で説明した成形型10A〜10Eは、いずれも複合材料成形物としてC型材20Aを製造する構成であったが、本実施の形態3では、他の複合材料成形物として例えばJ型材20B(図7B参照)を挙げ、このJ型材20Bを製造する構成の成形型について、図12および図13を参照して具体的に説明する。
前記実施の形態1〜3で説明した成形型10A〜10Fまたは成形型50は、いずれも複合材料成形物の横断面において、中空側もしくは折曲部または湾曲部の内側となる表面を加圧面としたが、本開示はこれに限定されず、折曲部または湾曲部の外側となる表面を加圧面とすることができる。本実施の形態4では、このような成形型について図14〜図16を参照して具体的に説明する。
11,51:雌型部(成形型本体)
11a,12a,14a,51a,52a,62a,64a:締結孔
11b,51b,62b:キャビティ
12:側面蓋型部(蓋型部、成形型本体)
13A〜13D,53,63A,63B:加圧体
14,54:側面蓋型部(蓋型部、成形型本体)
15,55,65:成形空間
16,56,66:締結部材
17:加熱部
20A:C型材(複合材料成形物)
20B:J型材(複合材料成形物)
20C:L型材(複合材料成形物)
20D:H型材(複合材料成形物)
20E,20F:中空材
21:本体部(ウェブ)
22:フランジ部
23:リバースカット部
24:先端面
25:中空部
31,33,71,73:膨張核部
32,72,74:圧力分散部
34:複数の凸部(凹凸構造)
35:中空箱部
40:積層体
41:基材
42:マトリクス材
54:カールプレート
51c:加圧体領域(キャビティの一部)
51d:第一成形空間領域(キャビティの一部)
51e:第二成形空間領域(キャビティの一部)
61:第一型部(成形型本体)
62:第二型部(成形型本体)
64:ベースプレート(側面蓋部)
67:加圧孔部
Claims (11)
- 外型と内型とを有し、前記外型および前記内型との間のキャビティにプリプレグ積層体が収容される成形型本体と、
前記キャビティ内に設けられ、それ自身が膨張する膨張核部と、
前記キャビティ内に設けられ、前記膨張核部の膨張前に前記プリプレグ積層体の表面に接しており、前記膨張核部の膨張による加圧力を分散させて伝達する圧力分散部と、
を備えることを特徴とする、
複合材料成形物製造用成形型。 - 外側から順に、前記外型、前記膨張核部、前記圧力分散部、前記プリプレグ積層体、および前記内型が配置され、
前記圧力分散部は、前記プリプレグ積層体の一方側表面に接し、
前記内型は、前記プリプレグ積層体の他方側表面に接する、
請求項1に記載の複合材料成形物製造用成形型。 - 外側から順に、前記外型、前記プリプレグ積層体、前記圧力分散部、前記膨張核部、および前記内型が配置され、
前記圧力分散部は、前記プリプレグ積層体の他方側表面に接し、
前記外型は、前記プリプレグ積層体の一方側表面に接する、
請求項1に記載の複合材料成形物製造用成形型。 - 前記膨張核部は、加熱により熱膨張する、請求項1から3のいずれか1項に記載の複合材料成形物製造用成形型。
- 前記膨張核部は、熱膨張による加圧力を調整する凹凸構造を有する、請求項4に記載の複合材料成形物製造用成形型。
- 前記膨張核部の熱膨張率は、前記圧力分散部の熱膨張率よりも大きい、請求項4または5に記載の複合材料成形物製造用成形型。
- 前記膨張核部の熱膨張に伴って内側に変形可能な中空箱部をさらに備える、請求項4から6のいずれか1項に記載の複合材料成形物製造用成形型。
- 前記成形型本体は、当該成形型本体を加熱する加熱部を備えている、請求項1から7のいずれか1項に記載の複合材料成形物製造用成形型。
- 前記膨張核部はさらに、
前記成形型本体の外部と連通し、前記膨張核部の内部空間に圧縮空気を吹き込むための加圧孔部を有する、
請求項1から3のいずれか1項に記載の複合材料成形物製造用成形型。 - 外型と内型との間のキャビティに、プリプレグ積層体を配置し、
それ自身が膨張する膨張核部と、当該膨張核部の膨張による加圧力を分散させる圧力分散部と、を前記キャビティ内に配置するとともに、前記圧力分散部を前記プリプレグ積層体に接するように配置し、
前記キャビティを封止し、
前記外型と前記内型とを含む成形型本体を加圧せずに加熱して前記膨張核部を膨張させて、前記膨張核部の膨張による加圧力を前記圧力分散部で分散させながら前記プリプレグ積層体を硬化させることを特徴とする、
複合材料成形物の製造方法。 - 外型と内型との間のキャビティに、プリプレグ積層体を配置し、
それ自身が膨張する膨張核部と、当該膨張核部の膨張による加圧力を分散させる圧力分散部と、を前記キャビティ内に配置するとともに、前記圧力分散部を前記プリプレグ積層体に接するように配置し、
前記キャビティを封止し、
前記膨張核部に圧縮空気を吹き込んで膨張させて、前記膨張核部の膨張による加圧力を前記圧力分散部で分散させながら前記プリプレグ積層体を硬化させることを特徴とする、
複合材料成形物の製造方法。
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US11988237B2 (en) * | 2020-07-31 | 2024-05-21 | Spirit Aerosystems, Inc. | System including breakaway fasteners for fabrication of composite parts |
IT202000025525A1 (it) * | 2020-10-28 | 2022-04-28 | Leonardo Spa | Procedimento di fabbricazione di pannello rinforzato con correntini a sezione aperta per applicazione aeronautica |
CN112643934A (zh) * | 2020-12-26 | 2021-04-13 | 上海晋飞碳纤科技股份有限公司 | 一种深腔超壁厚u型结构复合材料产品的模具 |
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JPS57125020A (en) * | 1981-01-28 | 1982-08-04 | Mitsubishi Electric Corp | Molding of reinforced plastics |
IL87589A0 (en) * | 1987-10-15 | 1989-01-31 | Lockheed Corp | Integrally stiffened composite structure |
US5190773A (en) * | 1991-11-18 | 1993-03-02 | United Technologies Corporation | Mold for fabricating composite articles having integrally bonded stiffening members |
WO1996009159A1 (en) * | 1994-09-20 | 1996-03-28 | Viatech, Inc. | Method of making internally reinforced composite tubes |
JP4243802B2 (ja) * | 2003-10-07 | 2009-03-25 | 東邦テナックス株式会社 | ロボットアームの一体成形方法 |
JP2005288756A (ja) * | 2004-03-31 | 2005-10-20 | Toho Tenax Co Ltd | 繊維強化樹脂成形体の製造方法 |
US7824171B2 (en) * | 2005-10-31 | 2010-11-02 | The Boeing Company | Corner-consolidating inflatable apparatus and method for manufacturing composite structures |
JP2008018623A (ja) * | 2006-07-13 | 2008-01-31 | Toray Ind Inc | ラバー成形方法 |
DE102009036584A1 (de) * | 2009-08-07 | 2011-02-17 | Gummiwerk Kraiburg Gmbh & Co. Kg | Verbundbauteil aus Silikon und Verfahren zu dessen Herstellung |
KR101219397B1 (ko) * | 2010-08-31 | 2013-01-11 | 연세대학교 산학협력단 | 튜브없이 공기팽창식으로 몰딩하는 복합재 중공구조물 제조방법 |
JP5763206B2 (ja) * | 2010-11-11 | 2015-08-12 | スピリット アエロシステムズ,アイエヌシー. | 剛性/展性のあるsmp装置を使用して複合部品を相互結合または相互硬化する方法およびシステム |
FR2971195B1 (fr) * | 2011-02-04 | 2013-04-26 | Latecoere | Outillage de moulage pour la realisation d'une piece en materiau composite au moyen d'une preforme souple composee d'une peau et de preformes profilees solidarisees sur la dite peau. |
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US9993946B2 (en) * | 2015-08-05 | 2018-06-12 | The Boeing Company | Method and apparatus for forming tooling and associated materials therefrom |
US11040502B2 (en) * | 2016-08-09 | 2021-06-22 | Mitsubishi Heavy Industries, Ltd. | Method for producing fiber-reinforced resin molded articles |
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