WO2012008235A1 - 樹脂基複合材の製造方法 - Google Patents
樹脂基複合材の製造方法 Download PDFInfo
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- WO2012008235A1 WO2012008235A1 PCT/JP2011/062768 JP2011062768W WO2012008235A1 WO 2012008235 A1 WO2012008235 A1 WO 2012008235A1 JP 2011062768 W JP2011062768 W JP 2011062768W WO 2012008235 A1 WO2012008235 A1 WO 2012008235A1
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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
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
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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
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/10—Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies
- B29C43/12—Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies using bags surrounding the moulding material or using membranes contacting the moulding material
-
- 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
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
- B29C43/3642—Bags, bleeder sheets or cauls for isostatic pressing
-
- 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
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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
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
- B32B37/1054—Regulating the dimensions of the laminate, e.g. by adjusting the nip or platen gap
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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
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
- B29C43/3642—Bags, bleeder sheets or cauls for isostatic pressing
- B29C2043/3644—Vacuum bags; Details thereof, e.g. fixing or clamping
-
- 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
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/20—Making multilayered or multicoloured articles
- B29C43/203—Making multilayered articles
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- 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 method for producing a resin matrix composite material.
- Resin-based composite materials such as fiber reinforced resins are widely used as structural members for aircraft, automobiles, ships, and the like because they are lightweight and have high strength.
- the resin matrix composite is generally formed by laminating a plurality of prepregs made of a resin reinforced with fibers and heating and pressurizing with an autoclave or the like.
- the resin matrix composite when a resin matrix composite is applied to a helicopter rotor spar, the resin matrix composite has sufficient strength to support a tensile load due to centrifugal force, and the rotating blade has a natural frequency (dynamic The accuracy of rigidity to maintain the characteristics) is required. It is known that the rigidity is proportional to the cube of the plate thickness of a member made of a resin matrix composite. For this reason, in order to realize a rotor spar made of a resin-based composite material, it is necessary to make the variation in the plate thickness with respect to the design value as small as possible (for example, within ⁇ 2%).
- Patent Document 1 discloses a method of forming a composite material by sequentially laying up (stacking) a plurality of prepreg plies on the molding surface of a base mold member.
- a step of laying up a predetermined number of prepregs a step of autoclaving the prepregs at about room temperature, and a step of laying up an auxiliary ply pack on the autoclaved laminate to adjust fluctuations in plate thickness
- the composite material is formed while repeating the above.
- JP 2000-507517 A (Claim 1, page 14, line 13 to page 23, line 4, FIG. 3)
- An object of this invention is to provide the manufacturing method which can control the board thickness of a resin matrix composite material with higher precision.
- the present invention provides a prepreg laminating step of laminating a prepreg made of a resin reinforced with fibers to a predetermined thickness on a jig having a predetermined shape, the laminated prepreg, and the jig.
- a semi-molded product forming step in which a first semi-molded product and a second semi-molded product are formed by applying heat treatment while pressing the packaging material, and the first semi-molded product.
- a thickness measuring step for measuring the thickness of the second semi-molded product, the measured thickness, the desired thickness of the resin matrix composite, and the physical properties of the additional ply
- An additional ply number determining step for determining the number of additional plies, and the determined number between the first semi-molded product and the second semi-molded product installed in the jig having the predetermined shape.
- a laminated body in which additional plies are laminated is formed, and the laminated body and the jig are covered with a packaging material.
- the resin-based composite material of the present invention has a first semi-molded product and a second molded product by placing a prepreg in a jig having a desired shape and subjecting the prepreg to pressure and heat treatment in a state of being accommodated in the jig.
- a semi-molded product is manufactured. For this reason, at the time of the semi-molded product which is a semi-finished product, it is possible to suppress variation in the plate thickness with respect to the design value. Further, a laminated body in which an additional ply is disposed between the first semi-molded product and the second semi-molded product is formed and subjected to pressure heat treatment to produce a resin-based composite material as a product.
- the number of additional plies is determined in consideration of the plate thicknesses of the first and second semi-molded products, the desired plate thickness of the resin-based composite material, and the physical properties of the additional plies. By doing so, the thickness of the resin matrix composite can be accurately controlled. Moreover, since the resin-based composite material of the present invention is manufactured using a jig having a predetermined shape, there is an advantage that adjustment of a component width by machining is unnecessary.
- the jig is composed of a bottom jig and a side jig, and a resin leakage preventing material is disposed on a contact surface between the bottom jig and the side jig.
- a jig composed of a bottom jig and a side jig is used.
- the resin may flow out from the contact surface between the jigs, which may affect the plate thickness variation.
- the resin leakage prevention material is installed on the contact surface between the bottom surface jig and the side surface jig to prevent the resin from flowing out, the plate thickness control accuracy can be improved.
- the semi-molded product forming step and the laminating step it is preferable to perform heat treatment while maintaining the inside of the packaging material in a reduced-pressure atmosphere.
- the inside of the packaging material is decompressed and then pressurized from the outside of the packaging material, and then the interior of the packaging material is opened to the atmosphere before the temperature is raised.
- the air remaining between the layers is not discharged to the outside during the pressure heat treatment, or the air flows backward when the atmosphere is released, and remains inside the resin matrix composite material.
- the bonding step is a step of bonding the cured semi-molded products to each other, and air retention is likely to occur between the semi-molded product and the additional ply due to release to the atmosphere.
- the air between the layers can be easily discharged by heat-treating the inside of the packaging material in a reduced pressure atmosphere.
- an air discharge means on the cross section of the laminated prepreg or the laminated body.
- a jig is used.
- the thickness of the resin matrix composite can be controlled with high accuracy. Moreover, generation
- a resin-based composite material is produced using a predetermined jig, it is advantageous because steps such as machining of the part width can be omitted.
- FIG. 1 is a bird's-eye view of a helicopter rotor spar fabricated using a resin matrix composite.
- the rotor spar 10 is composed of a resin plate reinforced with fibers.
- the resin plate reinforced with fibers is, for example, glass fiber reinforced resin, carbon fiber reinforced resin, or the like.
- the manufacturing method of the resin matrix composite of this embodiment includes a prepreg lamination step, a semi-molded product formation step, a plate thickness measurement step, an additional ply number determination step, and a bonding step.
- a prepreg 30 made of a resin reinforced with fibers is laminated inside the jig 20.
- the jig 20 includes a bottom jig 21 and a side jig 22.
- the side jig 22 is installed so as to surround the periphery of the prepreg.
- the jig 20 has the same surface shape as the final product (for example, the rotor spar 10 of FIG. 1).
- a silicone sheet 23 is preferably installed as a resin leakage preventing material on the contact surface between the bottom surface jig 21 and the side surface jig 22.
- the resin leakage prevention material may be curable silicone resin or heat resistant grease in addition to silicone.
- a peel ply 24 may be installed on the surface of the side jig 22 that comes into contact with the prepreg 30 as air discharge means.
- the air discharge means may be, for example, a Teflon (registered trademark) coated release fabric or a perforated film in addition to a fabric such as peel ply.
- An FEP (tetrafluoroethylene / hexafluoropropylene copolymer resin) film can be disposed as the release sheet 25 on the surface of the bottom jig 21 that contacts the prepreg 30. At this time, the release sheet 25 may be fixed by spraying or the like.
- the prepreg 30 is appropriately cut so as to conform to the inner shape of the jig 20, and is disposed and laminated on the inner side of the jig 20.
- the thickness t of the semi-molded product obtained in the semi-molded product forming step satisfies the formula (1).
- T Lotus spur plate thickness design value
- d Film thickness after curing per additional ply
- n Assumed additional ply number (n is an integer of 1 or more)
- the prepreg is placed in the jig so that the fibers have a predetermined orientation according to the strength required for each part.
- the fiber orientation direction of each prepreg with respect to the rotor spar longitudinal direction (L direction in FIG. 1) It arrange
- the stacking order and the number of stacked prepregs in each orientation direction are appropriately determined according to the required strength.
- the prepreg is arranged and laminated so that the fiber orientation direction with respect to the longitudinal direction L is mainly 0 °.
- FIG. 4 the graph explaining the temperature conditions and pressure conditions at the time of the hot compaction process in a semi-molded article formation process is shown.
- 4A shows the temperature of the prepreg
- FIG. 4B shows the pressure inside the autoclave
- FIG. 4C shows the pressure inside the bag film.
- the inside of the region covered with the bag film 35 is exhausted through a deaeration circuit (not shown) provided between the bag film 35 and the bottom jig 21.
- the pressure inside the bag film is a reduced pressure atmosphere of about ⁇ 101.3 kPa to ⁇ 74.7 kPa (ie, 0.025 kPa to 26.625 kPa) with respect to the atmospheric pressure (101.325 kPa) (FIG. 4). (See (c)).
- the jig 20 in which the inside of the bag film 35 is decompressed is carried into the autoclave.
- the inside of the autoclave is pressurized to about 588 kPa to 686 kPa (see FIG. 4B).
- the temperature inside the autoclave is raised from room temperature to a temperature range in which the resin can flow (see FIG. 4A).
- the temperature is raised from 95 ° C. to 100 ° C.
- the temperature rising rate is 3 ° C./min or less.
- the rate of temperature rise is preferably 1 ° C./min or more.
- the inside of the autoclave After reaching the softening temperature of the resin, the inside of the autoclave is held under conditions of 4 hours or more and 6 hours or less. After holding, the temperature inside the autoclave is lowered at a temperature lowering rate of 3 ° C./min. In consideration of the time required for the semi-molded product forming step, the temperature decreasing rate is preferably 1 ° C./min or more.
- the inside of the autoclave reaches 60 ° C., the inside of the autoclave is opened (that is, the atmospheric pressure is set).
- the pressure inside the bag film is brought to atmospheric pressure.
- the resin does not flow out to the outside of the jig during the hot compaction process.
- the prepreg is integrated and the shape is stabilized. For this reason, the fluctuation
- the peel ply is installed on the side surface of the prepreg and the bag film is maintained in vacuum to perform the hot compaction process, the air accumulated between the layers is discharged to the outside during the process, and the occurrence of air accumulation between the layers is suppressed.
- Plate thickness measurement step The plate thickness at a predetermined part of the semi-molded product is measured.
- the plate thickness measurement may be performed after the semi-molded product is released from the jig, or may be performed in a state of being installed in the jig.
- the thickness of each part of the semi-molded product obtained by the prepreg laminating step and the semi-molded product forming step varies about ⁇ 5% with respect to the above formula (1).
- the additional ply is determined in consideration of the thickness of each part of the semi-molded product measured in the thickness measurement process, the thickness design value of the resin-based composite material product, and the properties of the additional ply.
- the number (n in equation (1)) is determined. That is, in this step, one or more additional plies are always selected.
- the physical properties of the additional ply include the material of the additional ply (for example, the type of resin), the film thickness variation when cured at various temperatures, and the like.
- the physical properties of the additional ply are preferably stored in a database in advance so that they can be appropriately selected according to product specifications.
- FIG. 2C the flat surface of one semi-molded product 40a installed in a jig 41a having the same shape as the jig used in the prepreg lamination process (the pressure sheet is formed in the semi-molded product forming process).
- the determined number of additional plies 42 are stacked on the surface).
- Another semi-molded product 40b installed in a jig 41b having the same shape as the jig used in the prepreg laminating step is installed on the additional ply 42 so that the flat surface is in contact with each other, and the laminate 43 is formed.
- the side jig 44 is disposed on the side surface of the stacked body 43.
- a peel ply 45 is preferably installed on the surface where the laminate 43 and the side jig 44 come into contact.
- the upper surface of the jig 41a, the jig 41b, and the side jig 44 are covered with a breather cloth 46 and a bag film 47.
- the bag film 47 is fixed to the jig 41 a with a sealant tape 48.
- FIG. 5 is a graph showing an example of the temperature condition and pressure condition of the pressure heating treatment in the bonding step.
- 5A shows the temperature of the laminate
- FIG. 5B shows the pressure inside the autoclave
- FIG. 5C shows the pressure inside the bag film.
- the inside of the region covered with the bag film 47 is exhausted through a deaeration circuit (not shown) provided between the bag film 47 and the jig 41a.
- the pressure inside the bag film is a reduced pressure atmosphere of about ⁇ 101.3 kPa to ⁇ 74.7 kPa (that is, 0.025 kPa to 26.625 kPa) with respect to the atmospheric pressure (101.325 kPa) (FIG. 5). (See (c)).
- the jig whose bag film 47 is decompressed is carried into the autoclave.
- the inside of the autoclave is pressurized in a state where the inside of the bag film 47 is decompressed (see FIG. 5B).
- the temperature inside the autoclave (laminated body) is raised from room temperature to the curing temperature of the resin.
- the temperature is raised from 175 ° C. to 180 ° C.
- the temperature is raised from 175 ° C. to 180 ° C.
- the rate of temperature rise is set in two stages, from room temperature to 120 ° C., 3 ° C./min or less, and from 120 ° C. to resin curing temperature, 0.5 ° C./min or less.
- the heating rate may be constant up to the curing temperature.
- the rate is preferably 0.5 ° C./min.
- the rate of temperature rise is preferably 0.25 ° C./min or more.
- the inside of the autoclave After reaching the curing temperature, the inside of the autoclave is maintained under the conditions of 2 hours to 2.5 hours. After holding, the temperature inside the autoclave is lowered at a temperature lowering rate of 3 ° C./min. In consideration of the time required for the bonding process, the temperature lowering rate is preferably 1 ° C./min or more.
- the inside of the autoclave reaches 60 ° C., the autoclave is opened and the inside is brought to atmospheric pressure. Further, when the temperature inside the autoclave becomes stable or becomes 50 ° C. or lower, the pressure inside the bag film is brought to atmospheric pressure. After unloading the jig from the autoclave, the resin matrix composite is released from the jig.
- the cured half-molded product and the additional ply are laminated and autoclaved. Due to a mismatch in the shape of the bonding surface between the semi-molded product and the additional ply at the portion (for example, the attachment portion of the rotor spar), an air pocket tends to be generated on the bonding surface. Further, when there is a twisted portion, a gap is generated between the jig and the semi-molded product, and there is a possibility that the pressure of the twisted portion becomes insufficient.
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Abstract
Description
樹脂基複合材は、一般的に、繊維で強化された樹脂からなるプリプレグを複数枚積層し、オートクレーブなどにより加熱・加圧処理されて形成される。
しかしながら、オートクレーブにより形成される樹脂基複合材では、プリプレグ自体の板厚のばらつき、加熱時の樹脂の流動性のばらつきやそれに伴う樹脂の損失、積層工程のばらつき、層間に残留する空気層などにより、板厚のばらつきが上記ばらつきの要求値よりも大きくなる場合が生じる。このため、厳密に樹脂基複合材の板厚を制御できる成形方法が求められている。
本発明は、樹脂基複合材の板厚をより高精度に制御することができる製造方法を提供することを目的とする。
また、本発明の樹脂基複合材は、所定形状の治具を使用して製造されるため、機械加工による部品幅の調整などが不要であるという利点を有する。
本発明は、包装材内部を減圧雰囲気にして加熱処理することにより、層間の空気を排出しやすくすることができる。
本発明では治具を使用している。そのため、プリプレグや半成形品と追加プライとの積層体の側面に空気排出手段を設置して、層間の空気を外部に排出させる経路を確保すると良い。
本発明では所定の治具を使用して樹脂基複合材を作製するため、部品幅の機械加工などの工程を省略することができるので有利である。
図1は、樹脂基複合材を使用して作製されるヘリコプタのロータスパーの鳥瞰図である。ロータスパー10は、繊維で強化された樹脂板で構成される。繊維で強化された樹脂板は、例えばガラス繊維強化樹脂、炭素繊維強化樹脂などとされる。
本実施形態の樹脂基複合材の製造方法は、プリプレグ積層工程、半成形品形成工程、板厚計測工程、追加プライ数決定工程、及び、貼合せ工程を備える。
治具20の内側に、繊維で強化された樹脂からなるプリプレグ30を積層する。治具20は、底面治具21と側面治具22とで構成される。側面治具22は、プリプレグの周囲を囲繞するように設置される。治具20は、最終製品(例えば図1のロータスパー10)の表面形状と同一とされる。図3に示すように、底面治具21と側面治具22との接触面には、樹脂漏れ防止材料としてシリコーンシート23が設置されることが好ましい。なお、樹脂漏れ防止材料は、シリコーンの他、硬化性シリコーン樹脂や耐熱グリースとされても良い。
側面治具22におけるプリプレグ30と接触する面には、図3に示すように、空気排出手段としてピールプライ24が設置されていても良い。なお、空気排出手段は、ピールプライなどの織物の他に、例えば、テフロン(登録商標)コーテッドリリースファブリックや穴あき状のフィルムなどとされても良い。
底面治具21におけるプリプレグ30と接触する面には、離型シート25としてFEP(四フッ化エチレン・六フッ化プロピレン共重合体樹脂)フィルムを配置することができる。このとき、離型シート25はスプレーのりなどにより固定されても良い。
本工程では、後工程で使用される追加プライの数及び膜厚を考慮して、半成形品形成工程で得られる半成形品の厚さtが式(1)を満たすように、各部位におけるプリプレグの積層枚数が決定される。
t=(T-d×n)/2 ・・・(1)
T:ロータスパー板厚設計値
d:追加プライ1枚あたりの硬化後の膜厚
n:想定追加プライ数(nは1以上の整数)
治具20内側に積層されたプリプレグ30にホットコンパクション処理を施し、層間を加熱接着させる。
プリプレグ30上にピールプライ31及び離型シート(FEPフィルム)32を配置する。離型シート32は、スプレーのりなどにより固定されていても良い。更に、プリプレグ30上に、表面が平滑な型(プレッシャープレート)33を配置する。
図2(b)に示すように、底面治具21の上面、側面治具22、及びプレッシャープレート33をブリーザクロス34及びバッグフィルム(包装材)35で覆う。バッグフィルム35は、シーラントテープ36により底面治具21に固定される。
バッグフィルム35と底面治具21との間に設けられた脱気回路(不図示)を通じて、バッグフィルム35に覆われた領域内部を排気する。このとき、バッグフィルム内部の圧力は、大気圧(101.325kPa)に対して-101.3kPaから-74.7kPa(すなわち、0.025kPaから26.625kPa)程度の減圧雰囲気とされる(図4(c)参照)。
オートクレーブ内部が上記圧力にて安定した後、オートクレーブ内部(プリプレグ)の温度を、室温から樹脂が流動可能な温度領域まで昇温する(図4(a)参照)。例えば樹脂として180℃硬化型エポキシ樹脂を用いたプリプレグの場合、95℃から100℃に昇温する。昇温速度は3℃/分以下とされる。昇温速度を上記範囲とすることにより、プリプレグ全体の温度均一性を確保することができる。なお、半成形品形成工程の所要時間を考慮すると、昇温速度は1℃/分以上とすることが好ましい。
本工程により、プリプレグが加圧・加熱により層間接着した半成形品が得られる。
本実施形態では、1つの樹脂基複合材製品に対して、2つ以上の半成形品が作製される。
また、プリプレグ側面にピールプライを設置しバッグフィルム内を真空に維持してホットコンパクション処理を行うため、層間に溜まった空気を処理時に外部に排出して、層間の空気溜り発生が抑制されている。
半成形品の所定部位における板厚を計測する。板厚計測は、半成形品を治具から離型させてから行っても良いし、治具内に設置された状態で行っても良い。
上記のプリプレグ積層工程及び半成形品形成工程により得られる半成形品の各部位の板厚は、上記式(1)に対して±5%程度のばらつきとなっている。
板厚計測工程で計測された半成形品の各部位における板厚、樹脂基複合材製品の板厚設計値、及び、追加プライの物性を考慮して、追加プライ数(式(1)におけるn)が決定される。すなわち、本工程では、必ず1枚以上の追加プライ数が選択される。
追加プライの物性として、追加プライの材質(例えば、樹脂の種類など)、種々の温度で硬化した場合の膜厚変動などがある。本工程では、追加プライの物性が予めデータベース化され、製品の仕様に合わせて適宜選択できるようにしておくと良い。
図2(c)に示すように、プリプレグ積層工程で使用した治具と同じ形状の治具41a内に設置された1つの半成形品40aの平坦面(半成形品形成工程にてプレッシャーシートが載置された面)上に、決定された枚数の追加プライ42が積層される。プリプレグ積層工程で使用した治具と同じ形状の治具41b内に設置された別の半成形品40bが、追加プライ42上に平坦面が接触するように設置され、積層体43が形成される。
治具41aの上面、治具41b、側面治具44をブリーザクロス46及びバッグフィルム47で覆う。バッグフィルム47は、シーラントテープ48により治具41aに固定される。
バッグフィルム47と治具41aとの間に設けられた脱気回路(不図示)を通じて、バッグフィルム47に覆われた領域内部を排気する。このとき、バッグフィルム内部の圧力は、大気圧(101.325kPa)に対して-101.3kPaから-74.7kPa(すなわち、0.025kPaから26.625kPa)程度の減圧雰囲気とされる(図5(c)参照)。
オートクレーブ内部を588kPaから686kPa程度に加圧されて安定した後、オートクレーブ内部(積層体)の温度を、室温から樹脂の硬化温度まで昇温する。例えば樹脂として180℃硬化型エポキシ樹脂を用いたプリプレグの場合、175℃から180℃まで昇温する。図5(a)では、昇温速度は2段階に設定されており、室温から120℃までは3℃/分以下、120℃から樹脂硬化温度まで0.5℃/分以下とされる。このような昇温条件とすることにより、効率的生産と製品の均質性を確保することができる。昇温速度は、硬化温度まで一定としても良い。昇温速度を一定とする場合、0.5℃/分以下とすると良い。なお、貼合せ工程の所要時間を考慮すると、昇温速度は0.25℃/分以上とすることが好ましい。
治具をオートクレーブから搬出後、樹脂基複合材を治具から離型する。
11 取付け部
12 軸部
20,41a,41b 治具
21 底面治具
22,44 側面治具
23 シリコーンシート
24,31,45 ピールプライ
25,32 離型シート
30 プリプレグ
33 プレッシャーシート
34,46 ブリーザクロス
35,47 バッグフィルム(包装材)
36,48 シーラントテープ
40a,40b 成形体
42 追加プライ
43 積層体
Claims (4)
- 所定形状の治具に、繊維で強化された樹脂からなるプリプレグを所定の厚さまで積層するプリプレグ積層工程と、
前記積層されたプリプレグと前記治具とを包装材で被覆し、前記包装材を加圧しながら加熱処理して、第1の半成形品と第2の半成形品とを形成する半成形品形成工程と、
前記第1の半成形品及び前記第2の半成形品の板厚を計測する板厚計測工程と、
前記計測された板厚と、樹脂基複合材の所望の板厚と、追加プライの物性とを基にして、該追加プライの数を決定する追加プライ数決定工程と、
前記所定形状の治具に設置された前記第1の半成形品と前記第2の半成形品との間に、前記決定された数の追加プライを積層した積層体を形成し、前記積層体と前記治具とを包装材で被覆し、該包装材を加圧しながら加熱処理する貼合せ工程とを備える樹脂基複合材の製造方法。 - 前記治具が、底面治具と側面治具とで構成され、前記底面治具と前記側面治具との接触面に樹脂漏れ防止材料を設置する請求項1に記載の樹脂基複合材の製造方法。
- 前記半成形品形成工程及び前記貼合せ工程の少なくとも一方において、前記包装材内部を減圧雰囲気に維持して加熱処理する請求項1または請求項2に記載の樹脂基複合材の製造方法。
- 前記積層されたプリプレグまたは前記積層体の断面に、空気排出手段を設置する請求項3に記載の樹脂基複合材の製造方法。
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JP5785889B2 (ja) * | 2012-03-14 | 2015-09-30 | 積水化成品工業株式会社 | 繊維強化複合体の製造方法 |
JP2014019024A (ja) * | 2012-07-17 | 2014-02-03 | Fuji Heavy Ind Ltd | 複合材の成形治具及び複合材の成形方法 |
TW201438897A (zh) * | 2013-04-12 | 2014-10-16 | Tien Jiang Entpr Co Ltd | 具厚度變化的纖維複合成品 |
EP3006180B1 (en) * | 2013-05-31 | 2020-02-19 | Toray Industries, Inc. | Method and device for manufacturing fiber-reinforced plastic |
CN105172165A (zh) * | 2015-09-14 | 2015-12-23 | 江西洪都航空工业集团有限责任公司 | 一种毫米波天线罩的厚度修正方法 |
KR20180097523A (ko) * | 2015-12-25 | 2018-08-31 | 도레이 카부시키가이샤 | 프리프레그 및 그 제조방법 |
EP3591108B1 (en) * | 2017-03-03 | 2021-01-20 | Teijin Frontier Co., Ltd. | Fiber structure and method for producing same |
EP3566844A4 (en) * | 2017-03-10 | 2020-01-08 | Mitsubishi Heavy Industries, Ltd. | COMPOSITE MATERIAL PRINTING DEVICE AND COMPOSITE MATERIAL MOLDING METHOD |
US11958217B2 (en) | 2017-10-09 | 2024-04-16 | General Electric Company | Systems and methods for compacting composite components |
JP7341638B2 (ja) * | 2018-03-28 | 2023-09-11 | 三菱重工業株式会社 | 成形治具及びその製造方法 |
CN112867593B (zh) * | 2018-10-18 | 2022-11-01 | 株式会社可乐丽 | 热塑性液晶聚合物结构体的制造方法 |
JP2020172077A (ja) * | 2019-04-12 | 2020-10-22 | 三菱重工業株式会社 | 補修装置及び複合材の補修方法 |
JP7341112B2 (ja) * | 2020-10-06 | 2023-09-08 | Towa株式会社 | 樹脂成形品の製造方法 |
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CA2804586A1 (en) | 2012-01-19 |
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