JPH1199529A - Integral molding method for composite material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a composite integral molding method, with which a composite material is integrally molded its production cost can be reduced and, in addition, the same production quality as that of the conventional integral molding can be realized without requiring the use of an upper side jig and a molding jig, in which a rubber sheet is used, in the conventional integral molding method. SOLUTION: By laminating a filmy composite material for forming a part member 5 onto the surface of a beam forming mold 10, the part member 5, which is bonded to a composite material base material 06 laminated onto the surface of a lower side jig 04 so as to reinforce the base material 10, is formed. Next, in order to arrange the part member 5 to the predetermined position, to which the base material 06 is bonded, the position of the beam forming mold 10, to which the part member 5 is laminated, is adjusted and arranged. Thus, the part member 5, which is arranged at the predetermined position of the base material 06, is bonded to the base material 06.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing an airframe, for example, by laminating a composite member on a base material on which a composite member is laminated on the surface of a lower jig, and molding the composite member into a single body. Reinforcement, when stacking and integrally forming partial members and manufacturing an airframe, etc., use the molding die of the partial member formed as a single body as it is, and integrally mold with the base material to form a structure The present invention relates to a method for integrally molding a composite material.

[0002]

2. Description of the Related Art An airframe structure including a main wing, a fuselage, a tail fin, etc. of an aircraft requiring light weight and high strength is provided with a base member formed by laminating a composite member on the surface of a lower jig. In recent years, a member formed by integrally joining partial members serving as a reinforcing material has been adopted in recent years. This integral molding is made of a rubber sheet, etc., after covering the base material and the partial members arranged in a state of being joined on the base material with a vacuum back, and then evacuating the inside of the vacuum back using a vacuum plug, After molding with a molding jig so that the base and the partial member are integrally molded, an autoclave (autoclave) is formed.
e), and the substrate and the partial member are integrated by heating and pressing.

FIG. 2 shows that the present applicant proposes a method of integrally forming a vacuum back structure and a composite material using the same in Japanese Patent Application Laid-Open No. Hei 8-2070065 in order to integrate such a base material and a partial member. FIG. 6 is a view showing a molding jig used in the composite material integral molding method described above.

[0004] As shown in the figure, a molding jig 08 employed in this composite material integral molding method comprises an upper jig 01, a lower jig 04 and a rubber sheet 02, and is formed on the surface of the lower jig 04. Composite outer plate 0 as a base material to be laminated and formed as an outer plate
6 and a composite girder member 05 as a partial member, which is provided orthogonal to the composite outer plate 06 and serves as a girder material and reinforces the composite outer plate 06, is completely wrapped in the rubber sheet 02, and Vacuum plug 03 opened inside
Then, the composite material outer plate 06 and the composite material girder member 05 are brought into a shape formed in the upper jig 01 and the lower jig 04 to be integrally formed by evacuating the rubber sheet 02.

[0005] Next, in a curing step in which the composite girder member 05 and the composite outer plate 06 integrated within the tolerance of the shape to be integrally molded by the molding jig 08 are carried into an autoclave (not shown), By applying a fluid pressure 07 from the outside of the rubber sheet 02, the composite outer plate 06 and the composite girder member 0
5 is uniformly pressurized at a pressure of several atmospheres or less.
By heating at 0 ° C. or lower, the composite outer plate 06 and the composite girder member 05 are integrated. The height of the composite girder member 05 after curing is assured by fixing the upper end of the composite girder member 05 and maintaining the height accuracy of the upper jig 01 forming the upper end shape. Like that.

However, the use of the upper jig 01 and the rubber sheet 02 constituting such a molding jig 08 causes a rise in the molding jig 08, and a molding for integrally molding a plurality of composite members. In order to reduce the cost of the jig, a product equivalent to that integrally formed using such a forming jig 08 without using such a forming jig 08 and integrally forming the same. The development of a method for integrally forming a composite material that can provide high quality has conventionally been an issue.

[0007]

SUMMARY OF THE INVENTION According to the present invention, it is necessary to use an upper jig and a molding jig using a rubber sheet, which have caused a rise in manufacturing cost in the conventional method of integrally molding a composite material. In addition, the composite material can be integrally molded, the production cost can be reduced, and the product quality of the integral molding can be equal to the product integrally molded using the conventional molding jig. The task is to provide

[0008]

Therefore, the method of integrally molding a composite material according to the present invention employs the following means.

(1) A girder forming die in which a composite material formed by weaving a composite material made of carbon fiber or the like containing an epoxy resin and forming a partial member to form a film is formed on the surface of the partial member. A partial member that is laminated on the surface, formed into a single-piece molded material having a certain thickness of strength, and joined on a composite base material laminated on the lower jig surface to reinforce the base material Forming a. The composite base material laminated on the lower jig surface is formed of the same kind of composite material as the partial member, and the honeycomb core is sandwiched between the laminated film-like composite materials, and the strength, A structure having a high rigidity can also be used.

(2) In order to dispose the partial member at a predetermined position to be joined to the base material, the partial member formed into a laminated single-piece molding material is arranged at a predetermined position on the base material to be joined. A step of moving the girder mold on which the partial members are laminated, adjusting the position, and disposing the same. In addition, the position adjustment of the girder mold
A locator erected above the base material, and a sliding locator that is suspended from the locator and allows a girder forming die to be placed at a predetermined position where the partial member is joined to the base material, and the girder forming die It is preferable that the position can be adjusted three-dimensionally on the base material.

(3) The partial member arranged at a predetermined position on the base material is carried into an autoclave or the like together with the girder mold,
A step of joining to a substrate by heating and pressing. In addition,
In order to uniformly press the base member and the partial members laminated on the girder mold in order to join the partial members arranged in the step of arranging the girder mold to the shape to be integrally molded to the base material, they are coated. In the method of the present invention, a pressure of 1 atm or less is sufficient for the coating material, and a nylon film is sufficient. It is preferable to use the nylon film.

(A) According to the method of integrally molding a composite material of the present invention, the partial member and the base material are integrally molded by directly using the girder mold that is laminated to form the partial member. The need to apply the upper jig, which has caused the rise in the cost of the molding jig, is eliminated, and furthermore, during integral molding of the partial member and the base material, vacuum is applied while preventing air leakage, and pressure is applied from the outside. The application of the conventional rubber sheet, which has been made as described above, is not always necessary because the pressing force can be reduced, and the application can be made with a nylon film. As a result, instead of the rubber sheet, it is possible to apply vacuum from the outside by coating with a nylon film and applying low pressure from the outside. Can be reduced.

Further, the girder mold in which the partial members are disposed at predetermined positions on the base material on which the partial members are integrally formed requires a conventional upper jig because the partial members are disposed while holding the partial members in a laminated state. Without this, the arrangement of the partial members at the predetermined position of the base material becomes accurate.

Further, if the girder mold is positioned via a sliding locator suspended from a locator erected on the base material, the height of the integrally formed partial member is also within a predetermined height within a tolerance. Can be. As a result, it is possible to ensure the same height accuracy of the cured partial member as that of a member integrally formed using the conventional upper jig.

Further, the method for integrally molding a composite member according to the present invention comprises:
In addition to the above-described means (1), (2), and (3), the following means were employed.

(4) The step of arranging a girder forming die for arranging the partial member at a predetermined position of the base material is performed at a predetermined position where the partial member is to be joined to the base material within a range of molding tolerance for arranging the partial member.
The girder forming die is moved by fixing a predetermined position of a long hole of a bolt which can move a long hole provided in a sliding locator. The slot provided in the sliding locator to move the girder mold is horizontal,
Alternatively, it is preferable that the bolt is moved in the vertical direction and a predetermined position of the long hole is fixed with the bolt so that the position of the beam forming die can be precisely adjusted. Further, it is preferable that the elongated hole for adjusting the position in the vertical direction is provided on a sliding locator that is suspended from a locator provided above the base material and fixed integrally with the girder mold.

According to the method of integrally molding a composite material of the present invention, the bolt moves in the elongated hole and the predetermined position of the elongated hole is fixed.
The partial member can be installed within a molding tolerance range on a substrate on which the partial member is integrally molded. Also, to move the bolts in the elongated holes provided in the vertical direction, more preferably in the elongated holes provided in the vertical direction on the sliding locator suspended from the locator, so that the girder mold can be freely slid up and down. During the hardening step in which an external pressure is applied to the upper surface of the girder, fluid pressure is transmitted to the lower surface of the girder via the girder. In addition, since the vertical slot is provided in the range of the molding tolerance, the vertical sliding amount of the girder mold is within the tolerance of the girder height after curing,
Girder height accuracy can be secured precisely.

[0018]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the method for integrally forming a composite material according to the present invention will be described below with reference to the drawings. FIG.
BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a view showing an entire structure of a molding jig used in the present embodiment to show one embodiment of a method of integrally forming a composite material of the present invention. In the drawings, the same members as those shown in FIG. 1 are denoted by the same reference numerals, and description thereof will be omitted as much as possible.

In the figure, a composite girder member 9 as a partial member is formed in a state of being laminated on a girder mold 10. The composite girder member 9 includes a locator 12 erected between columns 10 erected on both ends of a composite outer panel 6 as a base material.
Is positioned by a sliding locator 13 which can be moved up and down by a sliding locator 13 which is connected to a vertical locator (not shown) vertically suspended downward and which can be moved up and down, and is positioned on the composite material outer plate 6. Is set to a predetermined position.

The mounting portion of the vertical locator and the sliding locator 13 vertically provided from the locator 12 is provided with an elongated hole 14 for keeping the height of the cured composite girder member 5 within the tolerance of accuracy. Bolt that can move inside 14
4, the sliding locator 13 is moved up and down so that the girder forming die 10 can slide up and down freely, and the composite girder member 5 is integrally formed on the composite outer plate 6. Position (height).

Further, the locator 12 into which the bolt for fixing the sliding locator 13 by moving the elongated hole 14 is screwed.
A long hole in the horizontal direction is also provided between the vertical locator and the locator 12 which are vertically suspended from the vertical direction. By fixing a bolt which can move in the long hole, the sliding locator 13 can be moved in the horizontal direction, and the girder forming die is formed. 10 can be freely slid horizontally, and the composite girder member 5 can be three-dimensionally adjusted and arranged at a predetermined position on the composite outer plate 6 where integral molding is performed.

Further, the fastening portion for fastening the fixing bolt 15 for fixing the sliding locator 13 and the girder forming mold 10 has an air leakage prevention structure using a double O-ring 16,
Only the composite outer panel 6 and the girder mold 10 are made of nylon film 1
Vacuuming is performed in the state of being wrapped in 7.

When the composite material is integrally molded using the molding jig 20 of the present embodiment, a carbon fiber woven fabric impregnated with a film-like epoxy resin constituting the composite girder member 9 is laminated. Thus, since the girder forming die 10 for forming the composite girder member 9 is used as it is and integrally formed, the conventional application of the upper jig 01 becomes unnecessary. In addition, since the girder mold 10 can be freely slid up and down particularly through the sliding locator 13, the fluid pressure 07 of the curing process applied to the upper surface of the girder mold 10 is applied to the lower surface side via the girder mold 10. Propagated. The vertical sliding amount of the girder forming die 10 is within the tolerance of the accuracy of the length of the elongated hole 14, so that the girder height accuracy of the composite girder member 9 after curing can be ensured.

Further, since the vacuum can be evacuated with the nylon film 17 while ensuring the prevention of air leakage, it is not necessary to apply the conventional rubber sheet. As described above, the forming jig of the present embodiment does not require the application of the upper jig 01 and the rubber sheet 02 of the conventional forming jig, and can realize the forming jig at low cost. In addition, the same accuracy of the girder height after curing as in the conventional case can be secured.

[0025]

As described above, according to the method for integrally molding a composite material of the present invention, a composite material formed into a film forming a partial member is laminated on the surface of a girder mold, and a lower jig is formed. A step of forming a partial member joined to a composite base material laminated on the surface to reinforce the base material, and to arrange the partial member at a predetermined position to be joined to the base material, Is arranged and adjusted by adjusting the position of the girder forming die on which the partial members are stacked so that the partial members are arranged at the predetermined positions, and the partial members arranged at the predetermined positions of the base material are heated and externally pressurized. It consisted of the step of joining to the material.

As a result, since the girder mold formed by laminating the partial members is used as it is to integrally mold the partial members and the base material, conventionally, the cost of the molding jig has risen. In addition, the upper jig becomes unnecessary,
It is not always necessary to apply a rubber sheet for performing vacuum evacuation while ensuring the prevention of air leakage in the integral molding of the partial member and the base material, and the cost of the molding jig, which has been a drawback in the past, is greatly reduced. be able to. In addition, the girder mold for arranging the partial members at predetermined positions on the base material for integrally molding,
Since the partial members are held and arranged in a stacked state, the arrangement of the partial members at the predetermined position of the base material becomes accurate without the need for a conventional upper jig.

In the method for integrally molding a composite material according to the present invention, the step of arranging the girder mold includes moving an elongated hole formed within a molding tolerance within which a partial member is arranged at a predetermined position to be joined to the base material. This is performed by moving a bolt fixed to a girder forming die.

Thus, by moving the bolt in the elongated hole and fixing the predetermined position of the elongated hole, the partial member can be set within a molding tolerance range on the base material on which the integral member is integrally molded. In addition, in the elongated hole provided in the vertical direction, more preferably in the elongated hole provided in the sliding locator suspended from the locator in the vertical direction, the bolt can be moved and the girder mold can be slid up and down freely. During the curing process on the upper surface, the fluid pressure is transmitted to the lower surface of the girder via the girder, and the slot in the vertical direction is provided within the range of the molding tolerance. The amount of vertical sliding of the mold is such that the girder height of the composite girder member, which is a partial member after curing, is within the tolerance of accuracy, and the girder height accuracy can be secured.

[Brief description of the drawings]

FIG. 1 is a view showing an entire structure of a forming jig used in the present embodiment to show one embodiment of a method of integrally forming a composite material according to the present invention, and FIG. FIG. 1B is a detailed sectional view of a portion A shown in FIG.

FIG. 2 is an overall sectional view of a molding jig used in a conventional method of integrally molding a composite material.

[Explanation of symbols]

 01 Upper jig 02 Rubber sheet 03 Vacuum plug 4,04 Lower jig 05 Composite girder member as partial member 6,06 Composite outer plate as base material 07 Fluid pressure 08 Molding jig 9 Composite as partial member Material girder member 10 girder forming die 11 support 12 locator 13 sliding locator 14 long hole 15 fixing bolt 16 O-ring 17 nylon film 20 forming jig

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁶ Identification code FI B29L 9:00 31:30

Claims (2)

[Claims] 1. A composite material integral molding method in which a composite material partial member molded as a single body is joined to a composite material base material laminated on a lower jig surface and integrally molded. A step of laminating and forming the partial member on a girder forming die, a step of disposing the girder forming die to arrange the partial member at a predetermined position to be joined to the base material, and a predetermined position of the base material Joining the partial member arranged on the base material to the base material. 2. The method according to claim 1, wherein the step of disposing the girder forming die is performed by fixing a bolt that can move in an elongated hole formed in a range of molding tolerance in which the partial member is disposed at a predetermined position to be joined to the base material. 2. The method according to claim 1, wherein the beam forming die is moved and arranged.