JPH04329125A - Monolithic molding method of composite - Google Patents

Abstract

PURPOSE:To materialise monolithic molding method where the number of molding jigs to be used and working hours are a few and securing of accuracy is easy. CONSTITUTION:Other molding jig for exclusive use of one molding element 2 is made unnecessary and securing of accuracy of the molding element 2 is made easy, by laminating a prepreg material on the surface of a molding jig having a recessed part in the same form as an external form of the molding element 2. Then a foam 3 is filled into a space between the one and other molding elements 2, 4 and autoclave heating and pressurizing molding is performed, through which the title composite can be molded by an individual molding process and a monolithic molded product which is superior in molding quality can be made manufacturable at a low cost.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a composite material integral molding method applied to resin-based composite material products.

0002

2. Description of the Related Art There are various methods for integrally molding resin-based composite materials depending on the shape of the parts to be molded, but here we will discuss the case of integrally molding a reinforced outer panel consisting of a hat-shaped stringer and an outer panel.

A conventional method of molding a molded product having such a structure will be explained with reference to FIG. First, as shown in Fig. 4(a), one of the molded elements (stringer) is assembled in consideration of the ease of handling the molded parts and the shape retention of the parts during integral molding assembly.
02 is preformed in an autoclave (the matrix resin is semi-cured). Specifically, the molding jig 10 is set on the molding jig 01, and a prepreg material for molding the molding element 02 is laid up thereon in a predetermined laminated configuration. Next, in order to perform autoclave molding, Breather Cloth 05, Vacuum Sealant 06, and Vacuum Film 07 are applied, vacuum is drawn from the vacuum port 08 to create a vacuum inside the vacuum film 07, and heated and pressurized in the autoclave (as necessary). ) according to the shape. The other molded element (outer plate) 04 is also preformed in an autoclave in the same manner as in FIG. 4(a), as shown in FIG. 4(b).

The above-mentioned preformed molding element 02 and molding element 04 are integrally molded, and the process involves setting the preformed molding element 04 in a molding jig 01 as shown in FIG. 4(c). The molding jig 11 and the preformed molding element 02 assembled thereon are set at a predetermined position. After that, as in the case of FIG. 4(a), the breather cloth 05,
Vacuum sealant 06 and vacuum film 07 are applied, and the inside of vacuum film 07 is evacuated by drawing a vacuum through vacuum port 08, and then heating and pressure molding is performed in an autoclave. After the above molding, the molding jig 11 was removed from the integrally molded product to obtain the integrally molded product shown in FIG. 4(d).

[0005]

Problems to be Solved by the Invention The conventional method described above for integrally molding the stringer and the outer panel had the following problems. (1) When molding actual parts, especially in multi-curved structures, each stringer has a different curvature depending on its mounting position, so a molding jig that matches each curvature is required, and many molding jigs are required. Requires. (2) Conventional methods require two processes, roughly divided into preforming and integral molding, and preforming requires two separate processes of outer plate and stringer molding, etc.
Autoclave operation requires a large amount of time. (3) Because the outer panel and the stringer assembled to the molding jig are simply placed on one molding jig, slippage between the molding elements occurs due to the low viscosity of the matrix resin during autoclave curing. occurs, and in that state it is difficult to secure the positional dimensions after molding. If the positional dimensions were to be secured using an external restraint structure, the positioning jig would be quite complex and expensive.

An object of the present invention is to provide a molding method that solves the above-mentioned problems, makes it easy to ensure the positioning accuracy of a molded product, and allows a high-quality integral molded product to be obtained in a single molding process. do.

[0007]

[Means for Solving the Problems] The method for integrally molding a composite material of the present invention involves laminating a prepreg material on the surface of a molding jig having a concave portion having the same external shape as the external shape of one of the molding elements. forming a molded element, filling the recessed part of one molded element with a foam, laminating a prepreg material on the upper surface of the molded element and the foam to form the other molded element, and forming the other molded element. The molding element is wrapped in a cover and evacuated, and then heated and pressurized in an autoclave for molding.

[0008]

[Operation] In the above, one of the molding elements can be formed with high precision without requiring another molding jig by laminating the prepreg material on the surface of the molding jig having the recessed portion.

[0009] In addition, in heat and pressure molding using an autoclave, a predetermined autoclave pressure is applied to the outer surfaces of one molding element and the other molding element that come into contact with the molding jig, and the area surrounded by the molding elements of one and the other is Since the autoclave pressure is transmitted and pressurized through the foam that hardens together with the prepreg material, an integrally molded product of good quality is obtained.

[0010] According to the above, a single autoclave heating
Since it is possible to integrally mold a molded product using a pressure molding process, it is possible to produce a molded product of good quality at low cost.

[0011]

Embodiment A first embodiment of the present invention will be described with reference to FIGS. 1(a) and 1(b). The present embodiment shown in FIGS. 1(a) and 1(b) shows an example of integral molding of a hat-shaped stringer (molding element) 2 and an outer plate (molding element) 4. The prepreg material for forming the molding element 2 is laid up in a predetermined layered configuration. Next, forming element 2
A predetermined amount of the foam 3 is filled into the concave portion, and a prepreg material forming the molded element 4 is laid up thereon in a predetermined laminated configuration. Next, a cover consisting of a breather cloth 5, a vacuum sealant 6, and a vacuum film 7 necessary for autoclave molding is applied, and a vacuum is drawn from the vacuum opening 8 to evacuate the inside of the vacuum film 7, which is then heated and pressure molded in an autoclave. I do.

In the above, since the forming jig 1 is provided with a groove having the same external shape as the stringer 2, it is possible to lay up the stringer 2 directly on the forming jig 1. This eliminates the need for a dedicated molding jig, and also ensures the positioning accuracy of the stringer 2 after molding.

After the stringer 2 is laid up, the concave portion of the stringer 2 is filled with the foam 3, and the outer panel 4 is laid up on top of it, and the outer panel 4 is coated with breather cloth 5 and vacuum sealant 6. , wrapped in a vacuum film 7, and evacuated.

During the autoclave heating and pressure forming performed after the vacuum evacuation, a predetermined autoclave pressure is applied to the stringer 2 and outer plate 4 portions that contact the forming jig 1 on the projection surface, and the stringer 2 and outer plate In the area surrounded by 4, autoclave pressure is transmitted and pressurized through the foam 3 that hardens together with the prepreg material.
) An integrally molded product of good quality can be obtained.

[0015] According to the above, a single autoclave heating
Since the molded product can be molded in one piece during the pressure molding process, it has become possible to produce molded products of good quality at low cost.

[0016] The foam used in this example has almost no weight increase compared to conventional foams by selecting an appropriate density depending on the pressure conditions required for molding, the weight required for the molded product, etc. A lightweight and low-cost integrally molded product can be obtained.

A second embodiment of the present invention is shown in FIGS. 2(a) and 2(b).
This will be explained with reference to. The present embodiment shown in FIGS. 2(a) and 2(b) is applied when higher pressure molding is required than in the first embodiment, or when high surface pressure strength is required for the stringer portion. The foam 3 in the first embodiment is molded using a honeycomb core 9 such as an aramid fiber-reinforced plastic honeycomb core, a glass fiber-reinforced plastic honeycomb core, or an aluminum honeycomb core. The molding method is the same as in the first example, and a molded product with higher strength than in the first example is obtained.

A third embodiment of the present invention is shown in FIGS. 3(a) and 3(b).
This will be explained with reference to. The present embodiment shown in FIGS. 3(a) and 3(b) shows the case of a semicircular stringer, and uses a forming jig 1a having the same outer shape as the stringer (molding element) 2a to be formed. A molded article having the shape shown in FIG. 3(b) is obtained by the same molding process as in the first example. This shows that there is a large degree of freedom in selecting the shape of the stringer.

[0019]

Effects of the Invention The method for integrally molding a composite material of the present invention has a method for integrally molding a composite material by laminating a prepreg material on the surface of a molding jig having a concave portion having the same external shape as that of one molding element. In addition to eliminating the need for other molding jigs,
It is easy to ensure the accuracy of one molding element, and it can be molded in a single autoclave molding process by filling a foam between one molding element and the other molding element and performing autoclave heating and pressure molding. , it is possible to manufacture integrally molded products with excellent molding quality at low cost.

[Brief explanation of drawings]

FIG. 1 is an explanatory diagram of a first embodiment of the present invention, in which (a) is an explanatory diagram of a molding method, and (b) is an explanatory diagram of a molded product.

FIG. 2 is an explanatory diagram of a second embodiment of the present invention, in which (a) is an explanatory diagram of a molding method, and (b) is an explanatory diagram of a molded product.

FIG. 3 is an explanatory diagram of a third embodiment of the present invention, in which (a) is an explanatory diagram of a molding method, and (b) is an explanatory diagram of a molded product.

FIG. 4 is an explanatory diagram of a conventional molding method.

[Explanation of symbols]

1 Molding jig 2, 2a Molding element 3 Foam 4 Molding elements 5 Breather Cross 6 Vacuum sealant 7 Vacuum film 8 Vacuum port 9 Honeycomb core

Claims (1)

[Claims] Claim 1: One molding element is formed by laminating a prepreg material on the surface of a molding jig having a concave portion having the same external shape as the outer shape of the one molding element, and Fill the recess with foam, layer the prepreg material on top of the molded element and the foam to form the other molded element, wrap the other molded element with a cover, evacuate it, and then autoclave. A composite material integral molding method characterized by molding by heating and pressurizing.