JPWO2012090468A1 - 成形治具および成形方法 - Google Patents
成形治具および成形方法 Download PDFInfo
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract
Description
(第1実施形態)
はじめに、図1乃至図7を参照して、本発明の第1実施形態について説明する。
まず、図1を参照しながら、本実施形態に係る成形治具100の構成について説明する。なお、本実施形態に係る成形治具100は、大型航空機の胴体部分のスキンパネルを成形するものとする。また、このスキンパネルは、直径が約6mで軸方向長さが約7mの円筒形状を有するものとする。図1は、本実施形態に係る成形治具100の使用状態を示した斜視図である。図1に示すように、本実施形態に係る成形治具100は、成形型10と、軸方向保持ベルト20と、軸方向スペーサ30と、周方向保持ベルト40と、周方向スペーサ50とを備えている。以下、これらの各構成要素について順に説明する。
次に、図2から図7を参照しながら、本実施形態に係る成形方法について説明する。本実施形態に係る成形方法によって成形されるのは、上述した大型航空機の胴体部分のスキンパネルである。本実施形態に係る成形方法には、積層工程と、被覆工程と、バギング工程と、硬化工程と、脱型工程と、が含まれる。以下、各工程について、順に説明する。なお、図2から図4は被覆工程を示す図であり、図5から図7はバギング工程を示す図である。また、図2及び図3は、後述するマンドレル61の軸方向から見た図(正面図)である。図4乃至図7は、マンドレル61の側面側から見た図(側面図)であり、巻上げ部22、42等の図示を省略した概略図である。
(i)まず、図4に示す成形型10が積層体60に取り付けられた状態から、図5に示すように、周方向に隣接する成形型10同士の境界部分に帯状のバッグフィルム68を貼って、各成形型10間の全ての隙間を覆う。
(ii)次に、図6に示すように、成形型10の周方向に周方向保持ベルト40を掛けて締め付ける。このとき、周方向保持ベルト40と成形型10との間には周方向スペーサ50を挿入する。なお、周方向に掛ける周方向保持ベルト40は、軸方向に張られている軸方向保持ベルト20よりも内周側に位置させる。
(iii)次に、図7に示すように、軸方向に張った軸方向保持ベルト20を取り外す。軸方向保持ベルト20を取り外しても、周方向保持ベルト40が成形型を押えているため、成形型10が積層体60に密着する状態は保持される。
(iv)次に、同じく図7に示すように、成形型10の軸方向両端部分を覆うように周方向に帯状のバッグフィルム68を貼り、成形型10の軸方向両端部分とマンドレル61の間の隙間を覆う。以上により、積層体60は成形型10およびバッグフィルム68により全体が覆われて密閉されることになる。
(v)次に、成形型10およびバッグフィルム68により密閉された空間を真空引きして成形型10を積層体60にさらに密着させる。これにより、内側のバギング(インナーバギング)が完了する。
(vi)次に、周方向に張った周方向保持ベルト40を外す。成形型10およびバッグフィルム68により密閉された空間は真空引きされているため、周方向保持ベルト40を外しても成形型10が積層体60に密着する状態は保持される。
(vii)最後に、成形型10およびマンドレル61をさらに全体バッグフィルム(図示せず)で覆い、その全体バッグフィルムとマンドレル61の間の空間を真空引きする。これにより外側のバギング(アウターバギング)が完了する。以上がバギング工程である。
(第2実施形態)
次に、図8乃至図11を参照しながら、本発明の第2実施形態に係る成形治具200の構成について説明する。ここで、図8乃至図11は、マンドレル61の側面側から見た図(側面図)である。このうち、図8及び図9は、本実施形態に係る成形方法の被覆工程の一部を示した図である。また、図10及び図11は、本実施形態に係る成型方法のバギング工程の一部を示した図である。上述のように、第1実施形態では軸方向保持ベルト20等を用いて成形型10を保持していたのに対し、本実施形態では保持磁石70を用いて成形型10を保持する。つまり、本実施形態に係る成形治具200は、成形型10と、保持磁石70とによって主に構成されている。以下、保持磁石70の構成、及び本実施形態の成型方法について説明する。
(i)まず、図9に示す成形型10が積層体60に取り付けられた状態から、図10に示すように、周方向に隣接する成形型10同士の境界部分に帯状のバッグフィルム68を貼って、各成形型10間の全ての隙間を覆う。
(ii)次に、図11に示すように、成形型10の軸方向両端部分を覆うように周方向に帯状のバッグフィルム68を貼り、成形型10の軸方向両端部分とマンドレル61の間の隙間を覆う。以上により、積層体60は成形型10およびバッグフィルム68により全体が覆われて密閉されることになる。
(iii)次に、成形型10およびバッグフィルム68により密閉された空間を真空引きして成形型10を積層体60にさらに密着させる。これにより、内側のバギング(インナーバギング)が完了する。
(iv)次に、全ての保持磁石70を外す。成形型10およびバッグフィルム68により密閉された空間は真空引きされているため、保持磁石70を外しても成形型10が積層体60に密着する状態は保持される。
(v)最後に、成形型10およびマンドレル61をさらに全体バッグフィルム(図示せず)で覆い、その全体バッグフィルムとマンドレル61の間の空間を真空引きする。これにより外側のバギング(アウターバギング)が完了する。以上がバギング工程である。
20 軸方向保持ベルト
30 軸方向スペーサ
31 軸方向保持手段
40 周方向保持ベルト
50 周方向スペーサ
51 周方向保持手段
60 積層体
61 マンドレル
62 プリプレグ
70 保持磁石
100 成形治具
Claims (14)
- プリプレグを積層した積層体を硬化する際、その表面を成形する成形型であって、
平面板形状を有し、当該平面板形状から前記積層体の形状に対応する形状へ弾性変形して前記積層体に密着可能である、成形型。 - 繊維強化プラスチックを材料とする、請求項1に記載の成形型。
- 厚みが1.5mm±0.5mmである、請求項2に記載の成形型。
- 請求項1乃至3のうちいずれか一の項に記載の成形型と、
前記成形型を前記積層体に密着させる保持手段と、
を備えた成形治具。 - 前記保持手段は、
前記成形型の外表面側に張る締め付け可能な保持ベルトと、
前記保持ベルトと前記成形型の間に挿入する複数のスペーサと、
を有する、請求項4に記載の成形治具。 - 前記複数のスペーサには、互いに高さの異なるスペーサが含まれており、
前記積層体が円筒形状を有し、かつ、前記保持ベルトが前記積層体の軸方向に張られたとき、前記複数のスペーサに含まれる各スペーサは、前記保持ベルトの中央に近づくにつれて高くなる順に配置される、請求項5に記載の成形治具。 - 前記プリプレグは磁性体の芯型に積層されており、
前記保持手段は、磁力を発生し、前記成形型及び前記積層体を挟んで前記芯型に吸着可能な複数の保持磁石を有する、請求項4に記載の成形治具。 - 前記保持磁石は、一の面からのみ大きな磁力が発生するように構成されている、請求項7に記載の成形治具。
- プリプレグを積層して積層体を形成する積層工程と、
平面板形状を有する可撓性の成形型を前記積層体の形状に対応するように変形させながら前記積層体に密着させる被覆工程と、
前記成形型を密着させた状態で前記積層体を硬化させる硬化工程と、
を含む成形方法。 - 前記被覆工程において、前記成形型の外表面側に保持ベルトを張るとともに、前記保持ベルトと前記成形型の間に複数のスペーサを配置し、前記保持ベルトを締め付けることにより前記成形型を前記積層体に密着させる、請求項9に記載の成形方法。
- 前記積層体は円筒形状を有しており、
前記被覆工程において、前記保持ベルトを前記積層体の軸方向に張り、前記複数のスペーサを前記保持ベルトの中央に近づくにつれて高くなる順に配置する、請求項10に記載の成形方法。 - 前記プリプレグは磁性体の芯型に積層されており、
前記被覆工程において、磁力を発生する複数の保持磁石を、前記成形型及び前記積層体を挟んで前記芯型に吸着させることにより、前記成形型を前記積層体に密着させる、請求項9に記載の成形方法。 - 前記積層体は円筒形状を有しており、
前記被覆工程において、前記複数の保持磁石を前記成形型上において軸方向に均等に配置するとともに周方向に均等に配置する、請求項12に記載の成型方法。 - 前記被覆工程において、前記積層体の全周に前記成形型を密着させる際、前記積層体を回転させることにより、常に前記積層体の側方側から前記成形型を前記積層体に密着させる作業を行う、請求項11又は13に記載の成形方法。
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