WO2012002355A1 - Matrice de moulage de matériau composite et procédé de production de celle-ci - Google Patents

Matrice de moulage de matériau composite et procédé de production de celle-ci Download PDF

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Publication number
WO2012002355A1
WO2012002355A1 PCT/JP2011/064745 JP2011064745W WO2012002355A1 WO 2012002355 A1 WO2012002355 A1 WO 2012002355A1 JP 2011064745 W JP2011064745 W JP 2011064745W WO 2012002355 A1 WO2012002355 A1 WO 2012002355A1
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WIPO (PCT)
Prior art keywords
composite material
tapered portion
core material
layer
core
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Application number
PCT/JP2011/064745
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English (en)
Japanese (ja)
Inventor
隆之 清水
勇也 永友
大輔 三輪
宗平 荒川
Original Assignee
三菱重工業株式会社
社団法人日本航空宇宙工業会
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Application filed by 三菱重工業株式会社, 社団法人日本航空宇宙工業会 filed Critical 三菱重工業株式会社
Publication of WO2012002355A1 publication Critical patent/WO2012002355A1/fr

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B29C70/342—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using isostatic pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/84—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks by moulding material on preformed parts to be joined
    • B29C70/845—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks by moulding material on preformed parts to be joined by moulding material on a relative small portion of the preformed parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0872—Prepregs

Definitions

  • the present invention relates to a composite material mold and a manufacturing method thereof.
  • the composite material is a molding material including a binding material (matrix) and fine particles or a fibrous material.
  • the composite material is composed of a plastic typified by an epoxy resin and hard fibers made of carbon or glass, and is used as a prepreg or the like.
  • a step of curing the composite material matrix in a high temperature and high pressure environment is essential. Therefore, a molding jig in which a core material is coated with a composite material is manufactured by being installed inside a high-temperature and high-pressure pot called an autoclave.
  • molding jigs for large structures can be manufactured by aircraft manufacturers that have large autoclaves, but they can be manufactured by general jig manufacturers that do not have large autoclaves. There is a problem that you can not.
  • the present invention has been made in view of such circumstances, and an object thereof is to provide a method for manufacturing a composite material forming jig that can be manufactured regardless of the size of the autoclave.
  • the present invention provides a step of processing the upper surface of the core material into a shape corresponding to the shape of the molded body, and the other core material of the core material when the core materials are arranged side by side.
  • Forming a step on the side surface facing the surface laminating an uncured composite material on the surface of the core material and curing it by heating and pressurizing to form a composite material layer, orthogonal to the side surface
  • a method for manufacturing a composite material mold comprising a
  • a single composite material mold is manufactured by combining a plurality of constituent members, it is possible to manufacture a composite material mold for a large structure even in a small and medium autoclave. .
  • the coupling area is increased and the direction of the coupling surface is dispersed, so that the strength of the coupling portion can be increased.
  • the taper portion provided in the composite material layer can be further enhanced in strength by bonding the constituent members and then filling and curing with an uncured composite material.
  • stacked on the taper part can be hardened with the heat source arrange
  • the process of creating the said structural member includes the step which forms a hole in the said side surface, the process of couple
  • the method includes a step of inserting one end of the guide member into the hole formed in one component member and inserting the other end of the guide member into another hole formed in the other component member.
  • the taper portion is formed in the composite material layer on the upper surface side of the component member, the step is formed on the side surface on the lower surface side of the component member, and the component members are joined to each other. Thereafter, a step of applying a patch to the step and fixing it with an adhesive, laminating an uncured composite material on the surface of the patch, arranging a heat source on the composite material, and then laminating the stacked composite material And curing with the uncured composite material laminated on the tapered portion.
  • the upper surface of the composite material mold is the tool surface that comes into contact with the workpiece.
  • a compressive force is applied to the upper surface.
  • the strength of the joint portion of the composite material layer can be increased.
  • the contact material from the lower surface it becomes a connecting portion having a strength capable of withstanding the weight of each component member and the shearing force when the material to be molded is placed.
  • the tapered portion may be formed in a composite material layer on the lower surface side of the constituent member, and an uncured composite material may be laminated on the surface of the pad according to the shape of the tapered portion. .
  • an uncured composite material may be laminated on the surface of the pad according to the shape of the tapered portion.
  • the tapered portion may be formed so that the core material is exposed at an end portion of the component member.
  • the core material By exposing the core material to the end portion, it is possible to form a flat bottom surface on the surface of the coupling portion when the two constituent members are disposed by abutting the tapered portion. Accordingly, when a plate-like body such as a prepreg is used as the composite material, the composite material can be arranged more in accordance with the shape of the tapered portion.
  • the core material is preferably a carbon foam.
  • the composite material mold can be reduced in weight.
  • an upper surface is processed into a shape corresponding to the shape of a molded body, and a core material having a step formed on at least one side surface and another surface of the core material orthogonal to the side surface on which at least the step is formed are provided.
  • a composite material layer having a tapered portion whose thickness is gradually reduced toward the side surface, the side surface on which one of the component members is formed, and the other configuration
  • a composite material having a surface of the joined component member that is bonded to the side surface on which the step of the member is formed via an adhesive layer, and another composite material layer is formed on the tapered portion, and is polished.
  • the composite material mold according to the above invention is formed by combining a plurality of constituent members, it is possible to manufacture a composite material mold for a large structure even in a small and medium autoclave. Since the step is formed on the side surface of the core material, a composite material mold having a high strength of the joint portion between the constituent members is obtained. Since another composite material layer is formed on the tapered portion provided in the composite material layer, a composite material mold having a higher strength of the joint portion is obtained. Since the surface of the composite material layer is polished, it becomes a composite material mold having a smooth surface having accuracy applicable as a tool surface to be contacted with the workpiece.
  • the side surface on which the step is formed has a hole, and includes guide members inserted into holes corresponding to each other in the adjacent component members.
  • the tapered portion is formed on the composite material layer on the upper surface side of the component member, the step is formed on the side surface on the lower surface side of the component member, and the contact material is interposed through the adhesive layer. It is preferable that another composite material layer is formed on the surface of the padding material, which is fixed to the step.
  • the tapered portion may be formed in the composite material layer on the lower surface side of the component member, and the other composite material layer may be formed on the surface of the pad according to the shape of the tapered portion. good.
  • the said taper part may be formed so that the said core material may be exposed to the edge part of the said structural member.
  • a plurality of angle members are provided on the side surface of the component member.
  • the said core material is a carbon foam.
  • a composite material mold for a large structure can be manufactured even with a medium-sized autoclave.
  • FIG. 1 It is an image figure of the manufacturing method of the composite material shaping
  • FIG. It is the schematic of the adhesive strength test 2.
  • FIG. It is a graph which shows the change of the adhesive strength before and after high temperature exposure. It is a graph which shows an example of the hardening cycle of a composite material layer. It is a graph which shows an example of the hardening cycle of a to-be-molded body.
  • FIG. 1 the image figure of the manufacturing method of the composite material shaping
  • the method for manufacturing a composite material mold according to the present invention is characterized by manufacturing a large composite material mold 100 by combining a plurality of constituent members 1.
  • the component 1 includes a core material and a composite material layer.
  • the core material is a carbon foam or the like. By providing the core material, it becomes stronger in bending rigidity than a component member made of only a composite material.
  • the composite material layer is made of a resin plate (composite material) reinforced with fibers.
  • the resin reinforced with fibers is, for example, an epoxy resin reinforced with carbon fibers.
  • the size of the constituent member 1 can be appropriately set according to the size of the autoclave to be used. In the present embodiment, it is assumed that the constituent member 1 to be coupled has a side of about 0.5 m to 2 m. These can be assembled into a composite material mold for producing a molded body of about 6 to 30 m.
  • FIG. 2 shows the combined specifications of the composite material mold in the method of manufacturing the composite material mold according to this embodiment.
  • FIG. 3 shows a state after the composite material mold of FIG. 2 is joined.
  • FIG. 4 is a schematic diagram for explaining a method for manufacturing a composite material mold according to this embodiment.
  • NC processing is performed in the order of the lower surface, the side surface, and the upper surface.
  • NC means a control method for instructing the position of the tool with respect to the workpiece with numerical information corresponding thereto in the numerically controlled machine tool.
  • NC processing may be performed after a plurality of carbon foams are bonded with an inorganic adhesive to obtain a desired size.
  • step 5 5 a, 5 b
  • the size of the hole 7 is appropriately set depending on the size of the core material 2, the size and weight of the object to be molded, and the like.
  • the step 5 and the hole 7 are formed only on the side surface 4, but when the component member 1 is formed, the step 5 and the hole 7 are similarly formed on the side surface combined with the other component member 1. .
  • bond together may mutually be fitted.
  • the upper surface 3 of the core material is a molding surface (tool surface) with which the workpiece is in contact, and NC machining is performed according to the shape of the workpiece.
  • the composite material layer 8 is provided on the surface of the core material 2 other than the side surface on which the step 5 is formed.
  • a prepreg (composite material) made of a resin reinforced with a film adhesive and fibers is sequentially laminated on the surface of the core material 2.
  • a plurality of film adhesives and prepregs may be laminated as necessary.
  • the core material 2 is a porous body, it is preferable to laminate two or more film adhesives.
  • the periphery After laminating the prepreg, the periphery is covered with a bag film 9 and pressurized while heating in an autoclave to cure the film adhesive and the prepreg (not shown). Between the prepreg and the back film, a peel ply, a release film, a vent mat, and the like may be appropriately disposed.
  • the curing reaction conditions are appropriately set according to the film adhesive and prepreg used.
  • the tapered portion 10 is formed so that the thickness of the composite material layer gradually decreases toward the end portion coupled with the other component 1.
  • the taper is formed at 15: 1, for example.
  • the tapered portion 10 may be provided not only on the upper surface but also on the lower and side composite material layers. Moreover, you may form the taper part 10 in the state which exposed the core material to the edge part. A flat bottom surface can be formed on the surface of the coupling portion when the two constituent members are arranged by abutting the tapered portion 10. Accordingly, when a plate-like body such as a prepreg is used as the composite material, the composite material can be arranged more in accordance with the shape of the tapered portion.
  • the upper surface of the composite material layer 8 is polished using an abrasive or a compound to obtain a smooth surface having accuracy applicable to the tool surface.
  • the angle member 11 is attached with a bolt to the side surface on which the composite material layer 8 of the component member 1 is formed, and the upper surface hole is reamed.
  • an aluminum angle member 11 is used.
  • the adhesive 12 is applied to at least one of the side surfaces 4 of the constituent member 1a and the constituent member 1b.
  • the adhesive is an inorganic adhesive and is preferably cured at room temperature.
  • the side surface 4 is butted and the constituent member 1a and the constituent member 1b are arranged, and one end of the guide member 13 is inserted into the hole 7a of the one constituent member 1a.
  • the other end of the guide member 13 is inserted into the hole 7b of the other constituent member 1b to join the constituent member 1a and the constituent member 1b.
  • a material having a linear expansion coefficient close to that of the core material 2 may be used.
  • a guide pin made of ceramics is used as the guide member 13. If the linear expansion coefficient of the guide pin 13 is lower than the linear expansion coefficient of the core material 2, it is possible to avoid large expansion when exposed to high temperatures and to apply a load to the core material 2.
  • a reflector is mounted on the angle member 11 provided on the side surface of the core member, and the position of the constituent member is finely adjusted using a three-dimensional measuring instrument.
  • Adhesion process of the pad 14 (FIGS. 4 (i) and 4 (ii)) An inorganic adhesive is applied to the step 5a and the step 5b provided on the lower surface side of the constituent member 1a and the constituent member 1b combined in the step (2). A pad 14 according to the shape of the steps 5a and 5b is prepared. An inorganic adhesive is appropriately applied also to the surface of the pad 14 and then bonded to the steps 5a and 5b. If necessary, the inorganic adhesive may be cured while applying a load to the pad 14 from the lower surface side. In addition, when the step 5a and the step 5b are stepped, the adhesive bonding step may be omitted.
  • the adhesive film and the prepreg are laminated in the same manner as the upper surface 3 side according to the shape of the taper portion.
  • the heat source 16 is arranged on the top of the laminated prepreg so as to cover the prepreg, these are covered with the bag film 9.
  • the heat source 16 is a heat blanket. Specifically, a silicon rubber heater or the like is used.
  • a heat conductive sheet 17 such as a copper foil is preferably disposed under the heat source 16.
  • a peel ply, a release film, a vent mat, and the like may be sequentially disposed between the prepreg and the back film 9. In this case, the heat blanket and the copper foil are preferably disposed between the release film and the vent mat.
  • the bag film 9 is evacuated and then heated with a heat blanket to cure the prepreg.
  • the curing reaction conditions are the same as in step (1) above.
  • a carbon foam (CFOAM20; available from Touchetone Research Laboratory, Ltd.) was used as the core material.
  • CFOAM20 carbon foam
  • the adhesive inorganic adhesive (X-Pando; available from X-Pando Products Company) and epoxy adhesive (ER-0 / EH-208-S; available from Plus Plastics Co., Ltd.) Using.
  • As the inorganic adhesive 300 g of X-Pando mixed with 67 g of water was used.
  • the epoxy adhesive used was a mixture of ER-0 and EH-208-S at a ratio of 2: 1.
  • Specimens were prepared by bonding carbon foams with an inorganic adhesive or an epoxy adhesive, and the following two types of adhesive strength tests were performed.
  • the inorganic adhesive was cured by heating at 93 ° C. for 240 minutes.
  • the epoxy adhesive was first cured by heating at 40 ° C. for 24 hours, and then secondarily cured at 180 ° C. for 2 hours.
  • FIG. 5 shows a schematic diagram of the adhesive strength test 1.
  • FIG. A bending load was applied to the bonded portion in a state where the test pieces (each 3 pieces) were exposed to room temperature or a high temperature of 180 ° C. for 900 hours.
  • AG-X 100 kN manufactured by Shimadzu Corporation, load capacity ⁇ 100 kN
  • DT-30F manufactured by Kyowa Denki Co., Ltd., maximum displacement 30 mm
  • FIG. 6 shows a schematic diagram of the adhesive strength test 2.
  • a bending load and a shear load were applied to the bonded portion in a state where the test pieces (3 pieces each) were exposed to room temperature or a high temperature of 180 ° C. for 900 hours.
  • Bending stress (S F ) was calculated using equation (B) in the same manner as equation (A), and the strengths were compared.
  • S F 3PL 1 / 2wt 2 ⁇ (B)
  • the carbon foam portion was broken regardless of the type of adhesive. All test pieces using an inorganic adhesive were broken at the load. It is considered that the strength of the bonded portion is higher than the test results because the load portion is locally cracked and fractures.
  • the epoxy adhesive generates a residual stress in the carbon foam during bonding, or the adhesive restrains the deformation of the carbon foam during the bending load, and is close to the adhesive of the carbon foam. There is a possibility that cracking is likely to occur.
  • Fig. 7 shows the change in adhesive strength before and after high temperature exposure.
  • the adhesive strength of the test piece using the epoxy adhesive was reduced from about 73% to about 80% by the high temperature exposure.
  • the decrease in the adhesive strength was about 6% to 16%. From the above results, it was confirmed that when the carbon foams were bonded to each other, the adhesive strength was maintained even after high temperature exposure by using an inorganic adhesive.
  • the adhesive strength does not decrease by exposure to high temperature using L-313 (available from JD Lincoln). This has been confirmed by a separate test.
  • a carbon foam (CFOAM20; available from Touchetone Research Laboratory, Ltd.) was used as the core material.
  • an adhesive for adhering the carbon foams an inorganic adhesive (X-Pando; available from X-Pando Products Company) was used.
  • the composite material prepreg
  • TRK510-270GMP available from Mitsubishi Rayon Co., Ltd.
  • the fiber direction of the prepreg was suitably 0 °, ⁇ 45 °, and + 90 °.
  • An epoxy film adhesive (L-313) was used as the film adhesive.
  • two constituent members having dimensions of 500 mm ⁇ 500 mm ⁇ thickness 132 mm were produced and combined to form a 1,000 mm ⁇ 500 mm composite material mold (composite material forming jig).
  • a clamp plate made of the composite material was added to the side surface of the structural member.
  • TRK510-270GMP As a composite layer on the upper surface, 3 ply of TRK510-270GMP was laminated, and then 9 ply of TRK3110-270GMP was laminated. As a composite material layer on the bottom and side surfaces, 3 ply of TRK510-270GMP was laminated, and then 2 ply of TRK3110-270GMP was laminated.
  • the composite material layer was NC processed.
  • the surface of the composite layer was subjected to # 1000 water sharpening and finishing material Chemlease # 2100 application, and then polished with a compound to finish the surface.
  • the upper surface of the component member produced above has a high shape accuracy with a deviation from the reference surface of less than 0.1 mm.
  • the contact material was bonded to the step on the lower surface side.
  • a film adhesive and a prepreg were sequentially laminated on the tapered portion.
  • the prepreg was formed by stacking 3 ply of TRK510-270GMP and then stacking 9 ply of TRK3110-270GMP. At this time, every time 3 ply of prepreg was laminated to remove air remaining between the layers, debulk (Full vacuum ⁇ 10 minutes) was performed. Next, a composite material layer was formed on the surface of the patch.
  • TRK510-270GMP As a composite material layer on the lower surface of the backing material, 5 ply of TRK510-270GMP was laminated, and then 4 ply of TRK3110-270GMP was laminated, followed by debulk (Full vacuum ⁇ 10 minutes). As a composite material layer on the side surface of the padding material, 3 ply of TRK510-270GMP was laminated, and 2 ply of TRK3110-270GMP was laminated, followed by debulk (Full vacuum ⁇ 10 minutes).
  • a peel ply, a release film, copper foil, a silicon rubber heater, and a vent mat were laminated on the prepreg and covered with a bag film. After the bag film was evacuated, the composite material layer was cured by heating with a heat blanket at the same temperature cycle as when the composite material layer of the constituent members was cured.
  • the composite material layer formed on the taper part and the surface of the backing material and its surroundings are polished in the same procedure as the composite material layer of the component member, and surface treatment is performed so that the surface where the two component members are joined is smoothly connected, and the composite A material forming jig was used.
  • a molded object was prepared.
  • 16 layers of prepreg were laminated in a quasi-isotropic manner.
  • a peel ply, a release film, and a vent mat were sequentially laminated thereon, covered with a bag film, and then the bag film was evacuated.
  • This composite material forming jig was placed in an autoclave, and the prepreg was cured by a curing cycle shown in FIG.
  • the bag film was evacuated and then checked for leaks. As a result, it was confirmed that the air leakage amount was the same level as that of a metal forming jig, and there was no practical problem.
  • the composite material forming jig was not applied or damaged throughout the process of producing the molded body. Moreover, the tool surface of the manufactured to-be-molded body was connected smoothly, and it was confirmed that there was no step or depression at the joint between the constituent members of the composite material forming jig.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

L'invention concerne un procédé de production d'une matrice de moulage de matériau composite capable de produire la matrice sans tenir compte de la taille d'un autoclave. L'invention concerne un procédé de production d'une matrice de moulage de matériau composite avec un procédé pour créer des membres constituants (1a, 1b), le procédé comprenant une étape pour former une surface supérieure (3) d'un matériau de noyau (2) à une forme correspondant à la forme d'un corps moulé, une étape pour former des marches (5a, 5b) sur une surface latérale (4) du matériau de noyau (2) faisant face à un autre matériau de noyau (2), une étape pour stratifier un matériau composite non durci sur la surface du matériau de noyau (2) et pour durcir le matériau pour former une couche de matériau composite (8), et une étape pour former une partie inclinée (10) sur la couche de matériau composite (8) située sur une autre surface, qui est perpendiculaire à la surface latérale (4), du matériau de noyau (2) ; un procédé pour revêtir un agent adhésif sur la surface latérale (4) et pour connecter des membres constituants ; un procédé pour stratifier le matériau composite non durci sur la partie inclinée (10), arranger une source de chaleur (16) sur le matériau composite, et durcir le matériau composite ; et un procédé pour polir la surface des membres constituants connectés (1a, 1b).
PCT/JP2011/064745 2010-07-01 2011-06-28 Matrice de moulage de matériau composite et procédé de production de celle-ci WO2012002355A1 (fr)

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JP2010151219A JP5610881B2 (ja) 2010-07-01 2010-07-01 複合材成形型及びその製造方法
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US11981839B2 (en) * 2019-09-30 2024-05-14 The Boeing Company Method and apparatus for fabrication of composite tooling

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