JPH0767704B2 - Method for manufacturing hollow composite member - Google Patents

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The invention of this application relates to the invention of a method for producing a hollow composite member. More specifically, the present invention relates to a method of manufacturing a composite member using a heat-shrinkable material as a core material for forming a hollow portion.

[0002]

2. Description of the Related Art In a conventional method for manufacturing a hollow composite member, metal core materials (metal mandrels) 21a and 21b having a taper as shown in FIG. 11 are used. This core material is used, for example, as a two-part taper key type,
After winding a composite material around the periphery and heat-molding the composite material, a core material is pulled out by utilizing a taper to manufacture a hollow composite member. As a conventional technique disclosing such a manufacturing method,
For example, there is JP-A-62-207633.

[0003]

The above-mentioned prior art has a drawback that it is not easy to release the core material after molding. That is, a considerable load is required to pull out the core material, and there is even a risk of damaging the composite member that has been molded by the load. Therefore, there is a problem that a considerable amount of labor is required for the mold release work.

In particular, as the product becomes longer, it becomes more difficult to pull out the core material. Further, when the hollow portion is formed into a special shape such as an ellipse or a diaphragm, it is not easy to design and select the core material, and the releasing work becomes extremely difficult.

The object of the invention of this application is to provide a method for manufacturing a hollow member, which is suitable for manufacturing a long product and a product having a special hollow shape, and which can be easily released from the mold, in order to solve the above-mentioned problems. It is provided.

[0006]

In order to solve the above-mentioned problems, the invention of the present application provides a method for manufacturing a hollow composite member in which composite material prepregs 4 and 5 are wound around a core material 1 to form a heat-shrinkable material. Inner bag material to the core material 1 made of flexible material
2 and wrap the composite material prepregs 4 and 5 around the inner bag material, and cover the outer bag material 14 on the outer circumferences of the composite material prepregs 4 and 5 to form the composite material prepreg.
Hollow composite characterized in that the heat-shrinkable core material 1 is taken out by press-molding 4 and 5 from the inside through the inner bag material 2 and heat-pressing from the outside through the outer bag material 14. It is a manufacturing method of a member.

In the method for manufacturing the hollow composite member, the composite material prepregs 4 and 5 are wound around the inner bag material 2 while the core material 1 is supported by the rigid shaft 16.

[0008]

[Function] The core material 1 made of a heat-shrinkable material is heat-shrinked by being heated at the time of molding. Core material of heat-shrinkable material 1
Acts so as to form the shape of the hollow portion of the hollow composite member when the composite material prepregs 4 and 5 are wound, and so that it can be easily removed / released at the time of release after heat molding.

Further, the core material 1 of the heat-shrinkable material generally lacks rigidity and is easily bent by the tension when the composite material prepregs 4 and 5 are wound. This tendency is remarkable especially in the case of a long and thin core material. When the composite material prepregs 4 and 5 are wound, the rigid shaft 9 supports the core material 1 of the heat-shrinkable material and functions to prevent this bending.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the invention of this application will be described with reference to FIGS. FIGS. 1 to 8 are views for explaining a basic embodiment of the present invention, and FIGS. 1 to 6 are views showing steps for forming preparation when a rectangular core material is used, as an example. 7 and 8 are configuration diagrams of the bag for which molding preparation has been completed. Hereinafter, the manufacturing procedure of the present embodiment will be described based on these.

First, the foamed core 1 as a core material is machined into a required size and shape as shown in FIG. The core material is preferably a heat-shrinkable material such as expanded polystyrene, which is easy to process and inexpensive.

In particular, the cells in the foam core are preferably open cells. If the bubbles are not continuous, when applying the internal pressure in the heating step described below, the internal pressure is applied through a narrow gap between the foam core and the bag material, which may result in non-uniformity. This is because the internal pressure is also applied from the open air bubbles in the foam core when the pressure is present, so that the pressure is evenly applied.

Further, as the heat-shrinkable material of the core material, it is desirable that the shrinkage start temperature is slightly higher than the curing / molding temperature of the composite material. When the shrinkage starting temperature is lower than the molding temperature, there is no one that restrains the shape of the stringer in the heating and molding process, and there is a risk of deformation due to a slight pressure imbalance. On the other hand, when the shrinkage start temperature of the core material is higher than the molding temperature, the temperature is raised to and held at the molding temperature to cure the stringer, and then the core material is further heated to and held at the shrinking temperature. By shrinking the material, the dimensional accuracy of molding is improved.

Next, as shown in FIG. 2, after covering the foam core 1 with the inner bag material 2, the roving prepreg material 3 is wound to bring the inner bag material 2 into close contact with the foam core 1. This inner bag material 2 pressurizes the composite material prepregs 4 and 5.
This is for holding the prepreg side in a vacuum and applying pressure from the inside during molding, and also for releasing the core material at the same time. Nylon bag film or the like is used as the inner bag material 2. The surface of the inner bag material is subjected to a mold release treatment so that the mold release after molding can be performed easily. In addition, the roving prepreg material 3 is for making the inner bag material 2 in close contact with the foam core 1 to form a predetermined hollow shape. When the bag material is covered, it is preferable that the wrinkles of the inner bag material 2 be provided on the stringer side as shown in FIG.

Furthermore, as shown in FIG. 4, a unidirectional material tape 4 and a roving material 5 are appropriately wound as a composite material prepreg. As the unidirectional material tape 4, for example, a tape-shaped prepreg in which a large number of reinforcing fibers are arranged in a strip shape with a predetermined width and impregnated with resin is used. As the reinforcing fiber, glass fiber, carbon fiber or the like is used. As the roving material 5, for example, a roving prepreg impregnated with a resin is used by bundling dozens of long fibers of reinforcing fibers into a thread shape. The winding operation is preferably automated by, for example, a winding machine as disclosed in JP-A-62-97834.

As shown in FIG. 5, for example, three wound composite prepregs 4 and 5 are arranged to form a box structure. That is, a filler 6 such as a roving prepreg material is laminated in the gap between the three corners,
As the upper surface skin 7a and the lower surface skin 7b, a composite material such as a unidirectional prepreg or a cross prepreg is appropriately laminated as necessary.

Further, in order to prevent bending and falling of the stringer, as shown in FIG. 6, an already cured composite material pre-cure plate 8 and the like and an adhesive sheet 9 may be set.

Next, as shown in FIGS. 7 and 8, the composite material of which the lamination is completed as shown in FIG. 5 is set on the base plate 10 subjected to the mold release treatment, and the outer mold 11 is made of aluminum or stainless steel. The side block 11a and the curl plate 11b, which have been subjected to release treatment such as the above, are set, and the release film 12 is set on the outer surface of the outer mold 11 for the purpose of suppressing release and resin outflow.

Further, as shown in the figure, a breather 13 for removing the gas released from the resin is covered, and the outer surface of the breather 13 is held in vacuum during pressure molding, and the composite material is applied from the outside. It is covered with an outer bag material 14 made of nylon or the like for pressing. Sealing material between the outer bag material 14 and the base plate 10
Inner bag material 2 sealed with 15 and covered with core material 2
The seal material completely seals between both ends of the outer bag material 14 and the base plate, and the inside is evacuated to complete the preparation for molding.

After completion of the molding preparation, molding is performed while heating and pressurizing with an autoclave or the like. That is, the composite material prepregs 4 and 5 are heated and molded through the inner bag material 2 and the outer bag material 14 by the internal pressure of the autoclave while being pressurized. After the molding is completed, the foam core 1 contracted by heating is removed together with the bag materials 2 and 14 and the molding process is completed. At this time, the foam core 1 has already undergone volumetric heat contraction from about 1/5 to 1/30 before heating.

In the case of a heating / pressurizing device such as an autoclave, which has a pressurization line separate from the pressurization inside the can,
It is also possible to individually pressurize the inside of the bag of the inner bag material and form while maintaining balance with the pressure applied from the outside.
In this case, by bending the inner pressure of the inner bag material slightly higher than the outer pressure from the outer side to increase the pressure, it is possible to prevent the stringer of the product from bending, falling, and the like.

Next, another embodiment of the method of winding the core material will be described. 9 and 10 are sectional views of the core material used in this embodiment. The prepreg is wound around the core material while applying tension, but since the heat-shrinkable material such as styrofoam does not have rigidity, the core material may bend during winding. There is even a risk of the core material breaking if the bending is severe.

The configuration of this embodiment is as shown in FIG.
Foam cores 1a and 1b divided into two are used. This foam core 1
Each is processed so that a hollow cylindrical portion is formed in the center when a and 1b are combined, and the support shaft 16 made of aluminum is inserted into the hollow cylindrical portion. The support shaft 16 and the foam cores 1a and 1b
As shown in FIG.
Secure with 17a and 17b. After the winding is completed, the fixtures 17a and 17b and the support shaft 16 are removed, and the bag is molded and processed in the same manner as in the above manufacturing method.

[0024]

EFFECTS OF THE INVENTION Since a heat-shrinkable material is used as the core material, even if it is used for hollow composite members of various shapes and sizes,
Release work becomes easy. In particular, the effect of facilitating the manufacture of a long or specially shaped structural member is exhibited.

Furthermore, by supporting the core material of this heat-shrinkable material with a rigid shaft, the core material is not bent during the winding operation, and the winding operation is facilitated. The core material does not break in the middle. In particular, it is effective in manufacturing a long or special structural member.

[Brief description of drawings]

FIG. 1 is a view showing a manufacturing process according to an embodiment of the present invention, which is an outline view of a foamed core after machining.

FIG. 2 is a cross-sectional view of a foam core in which a bag material is closely attached to the core, which is a diagram showing a manufacturing process of one embodiment of the present invention.

3 is a cross-sectional view taken along the line AA of FIG.

FIG. 4 is a diagram showing a manufacturing process of an embodiment of the present invention, which is a diagram showing a winding state of a unidirectional material tape and a roving material.

FIG. 5 is a diagram showing a manufacturing process according to an embodiment of the present invention, and is a diagram showing a state in which a composite material is wrapped with a prepreg and covered with a vacuum bag, and the periphery is surrounded by an outer mold.

FIG. 6 is a diagram showing a manufacturing process of an embodiment of the present invention, which is a diagram after completion of stacking in which measures are taken to prevent bending, falling, and the like of the stringer portion.

FIG. 7 is a cross-sectional view of a bag structure that has been prepared for molding.

8 is a cross-sectional view taken along the line AA of FIG.

FIG. 9 is a cross-sectional view showing a state in which a fixture and a shaft are provided on a core material.

10 is a cross-sectional view taken along the line AA of FIG.

FIG. 11 is an external view of a conventional metal core material.

[Explanation of symbols]

 1 Foam Core 2 Inner Bag Material 4 Unidirectional Material Tape 5 Roving Material 14 Outer Bag Material 16 Support Shaft

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification number Reference number within the agency FI Technical indication location // B29K 105: 08 B29L 23:00 (72) Inventor Shunichi Bando 1 Kawasaki-cho, Kakamigahara-shi, Gifu Prefecture Address Kawasaki Heavy Industries Ltd. Gifu factory inside

Claims (2)

[Claims] 1. A method of manufacturing a hollow composite member, comprising winding a composite material prepreg around a core material to form the core material, which is made of a heat-shrinkable material, with an inner bag material, and the composite material is provided on the outer periphery of the inner bag material. Wrap the material prepreg, cover the outer periphery of the composite material prepreg with an outer bag material, press the composite material prepreg from the inner side through the inner bag material, and heat-mold while applying pressure from the outer side through the outer bag material. A method for manufacturing a hollow composite member, comprising: 2. The method for producing a hollow composite member according to claim 1, wherein the composite material prepreg is wound around the outer periphery of the inner bag material while supporting the core material with a rigid shaft.