JPH01275107A - Preparation of mold made of composite material - Google Patents

Abstract

PURPOSE:To ensure the improvement of handleability, using a light weight matrix with low processing cost and short lead time, by processing a high- density foaming material having heat resistance and pressure resistance in accordance with the shape of a mold to be made to form said matrix, sticking and laminating a composite material onto the surface of said matrix, hardening it for forming and releasing said matrix. CONSTITUTION:A high-density foamed material 1 having heat resistance and pressure resistance as matrix is processed to form a matrix 5. This matrix 5 is placed on the upper surface of a metal fixing plate 6 and fixed thereon, and a mold release film 7 such as FEP film is applied on the surface of the matrix 5. Then, a composite material 8 is laminated thereon, a bagging material 9 is applied thereon, a sealing material 10 is placed between the surrounding of the bagging material 9 and the fixing plate 6 and the composite material 8 laminated by means of vacuum suction is closely contacted onto the surface of the matrix 5 via the mold release film 7. Then, the composite material 8 is heated and pressed to be hardened and formed, and after a mold 11 is formed, the matrix 5 is released together with the mold release film 7 to obtain a final product.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention is suitable for use in a method for manufacturing a mold made of composite material, particularly as a mold for molding a composite molded product for an aircraft, and is a leading tool in processing. This invention relates to a method for manufacturing composite molded products that reduces time and processing costs.

(Prior art) Conventionally, the method for manufacturing the above-mentioned molds generally involves using metal or plaster as a matrix material, processing it to match the mold to be manufactured to form a matrix, and making the surface of the matrix Add mold release material and surface coating material as necessary/2! After applying a release film or the like, a composite material such as a prepreg material is laminated in close contact with each other, and the laminated composite material is cured and molded by heating and pressurizing. The mold was released and, if necessary, the mold surface of the mold was subjected to finishing processing to produce a mold having a good mold surface.

(Civil report to be solved by the invention) However, in the above conventional example, when metal is used as the matrix material and the matrix is made of metal, the matrix is made by processing the metal to match the shape of the mold. It is quite difficult to form, which not only leads to an increase in processing costs, but also because this processing is difficult, the lead time for tooling and tool processing becomes longer, resulting in a shorter lead time for mold production. It becomes long. Furthermore, for example, for aircraft use, etc.
When the mold becomes larger, the mother mold also becomes larger, which causes a problem in that ff1ffi increases and handling performance deteriorates.

In addition, when plaster is used as the matrix material and the matrix is made of plaster, it is necessary to apply lacquer to the surface of the plaster to condition the surface, and to remove internal moisture, which takes a considerable amount of lead time. There was a problem with it being too long.

In view of the above, it is an object of the present invention to provide a mold made of composite material that can be manufactured reliably and with improved handling properties using a lightweight mother mold with low processing cost and short lead time. purpose.

(Means for Solving the Problems) In order to achieve the above object, the method for manufacturing a mold according to the present invention involves processing a high-density foam material having heat resistance and pressure resistance in accordance with the shape of the mold to be manufactured. The composite material is laminated in close contact with the surface of the matrix, and after the laminated composite material is cured and molded, the matrix is released.

(Function) According to the present invention configured as described above, high-density foam materials are generally very easy to process and lightweight, so it is possible to manufacture a matrix at low cost and in a relatively short time. In addition, it is possible to reliably manufacture a composite mold by improving the handling properties during mold manufacturing.

(Example) Examples will be described below with reference to the drawings.

First, as shown in FIG. 1(a), a heat-resistant and pressure-resistant high-density foam material 1 is used as a matrix material, and this is machined by a cutter 2 such as a milling machine, or by a cutter knife 3 and a burr 4. Processed by hand using
A mother mold 5 is formed to match the shape of the mold as shown in FIG.

This mother mold 5 is formed into a smaller shape by the thickness of the composite material 8 to be laminated on its surface as described below, so that the final mold 11 is uniformly larger by the thickness of the composite material 8. Prevent this from happening.

By forming the matrix 5 from the high-density foam material 1 in this way, the high-density foam material 1 is generally very easy to process.
Since it is lightweight and lightweight, the mother die 5 can be produced at low cost and in a relatively short time, and the handling properties for the following operations can be improved.

Then, as shown in FIG. 2, the processed mother mold 5 is placed and fixed on the upper surface of a metal surface plate 6, thereby ensuring airtightness.

Next, as shown in FIG. 3, the resin in the composite material 8 described below is prevented from flowing into the interior of the matrix 5 on the surface of the matrix 5, and the matrix of the composite material 8 is FE is used to prevent digging into the mold 5 and to improve the mold releasability of the mother mold 5.
A release film 7 such as P film is attached.

Thereafter, as shown in FIG. 4, a composite material 8 such as a prepreg material, which will be the material for the molding die, is laminated thereon, and a bagging material 9 is placed thereon, and the surroundings of this bagging material 9 and the above-mentioned surface plate 6 are laminated. The laminated composite material 8 is brought into close contact with the surface of the mother mold 5 via the release film 7 by interposing the sealing material 10 therebetween and applying vacuum suction.

Then, in this state, the composite material 8 is heated and pressurized using an autoclave or the like to harden and mold it.
After forming the mold 11 with the composite material 8,
As shown in FIG. 5, the mother mold 5 and the release film 7 are released from the mold 11 to form a finished product.

As shown in FIG. 6, the mold surface 11a of the mold 11 after the above-mentioned molding is subjected to a surface finishing process such as grinding using the cutter 12 to obtain the final mold surface as a mold made of composite material. 11a.

(Effects of the Invention) Since the present invention has the above-described configuration, the matrix is generally made of high-density foam +4 which is extremely easy to process and lightweight. Therefore, this mother mold can be manufactured at low cost and in a relatively short time, which reduces processing costs and lead times for molds, and also improves handling when manufacturing molds. This has the effect of allowing improvements to be made.

[Brief explanation of the drawing]

The drawings show an embodiment of the present invention in the order of steps. Figures 1 (a) and 2 (b) are perspective views showing the state in which a mother mold, which is a hole, is manufactured, respectively, and Figure 2 is a perspective view showing the state in which the mother mold is placed on a surface plate. Fig. 3 is a perspective view showing a state in which a release film is attached on top of the mold, Fig. 4 is a perspective view showing a state in which a composite material is laminated on top and a bagging material is covered. 5 is a cross-sectional view showing the main parts when the mother mold is released, and FIG. 6 is a partially cutaway perspective view showing the state in which surface finishing is being applied. DESCRIPTION OF SYMBOLS 1... High-density foam material, 5... Matrix, 7... Release film, 8... Composite key, 9... Bagging) A, 1
1... Molding mold, 11a... The same mold surface. Applicant's agent Mr. Yu Sato 1 Prisoner 2nd fan Art 3 Vice Secular 4 Figure Jin 5 Figure Sheep 6 Figure

Claims (1)

[Claims] Heat-resistant and pressure-resistant high-density foam material is processed to match the shape of the mold to be manufactured to form a matrix, and the composite material is laminated in close contact with the surface of this matrix. A method for manufacturing a mold made of a composite material, which comprises curing and molding the composite material, and then releasing the mother mold.