WO2017126159A1 - 繊維強化複合部材の成形装置及び繊維強化複合部材の成形方法 - Google Patents
繊維強化複合部材の成形装置及び繊維強化複合部材の成形方法 Download PDFInfo
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- WO2017126159A1 WO2017126159A1 PCT/JP2016/077847 JP2016077847W WO2017126159A1 WO 2017126159 A1 WO2017126159 A1 WO 2017126159A1 JP 2016077847 W JP2016077847 W JP 2016077847W WO 2017126159 A1 WO2017126159 A1 WO 2017126159A1
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- Prior art keywords
- molding die
- fiber
- reinforced composite
- molding
- composite member
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- 238000000465 moulding Methods 0.000 title claims abstract description 135
- 239000003733 fiber-reinforced composite Substances 0.000 title claims abstract description 64
- 238000000034 method Methods 0.000 title claims description 13
- 238000001816 cooling Methods 0.000 claims abstract description 39
- 229920005989 resin Polymers 0.000 claims description 38
- 239000011347 resin Substances 0.000 claims description 38
- 238000003780 insertion Methods 0.000 claims description 17
- 230000037431 insertion Effects 0.000 claims description 17
- 230000007246 mechanism Effects 0.000 claims description 15
- 239000002131 composite material Substances 0.000 claims description 13
- 238000010438 heat treatment Methods 0.000 claims description 12
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 11
- 239000004917 carbon fiber Substances 0.000 claims description 11
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 8
- 239000000835 fiber Substances 0.000 claims description 7
- 238000013459 approach Methods 0.000 claims description 4
- 238000010030 laminating Methods 0.000 claims description 4
- 238000003825 pressing Methods 0.000 claims description 3
- 230000002787 reinforcement Effects 0.000 claims 1
- 229920005992 thermoplastic resin Polymers 0.000 abstract description 19
- 239000002826 coolant Substances 0.000 abstract description 16
- 230000032798 delamination Effects 0.000 abstract description 11
- 238000003475 lamination Methods 0.000 description 15
- 239000000463 material Substances 0.000 description 7
- 238000013461 design Methods 0.000 description 4
- 238000007493 shaping process Methods 0.000 description 4
- 239000011159 matrix material Substances 0.000 description 3
- 239000004696 Poly ether ether ketone Substances 0.000 description 2
- 239000004697 Polyetherimide Substances 0.000 description 2
- 239000003822 epoxy resin Substances 0.000 description 2
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 229920000647 polyepoxide Polymers 0.000 description 2
- 229920002530 polyetherether ketone Polymers 0.000 description 2
- 229920001601 polyetherimide Polymers 0.000 description 2
- 239000009719 polyimide resin Substances 0.000 description 2
- 230000002035 prolonged effect Effects 0.000 description 2
- 239000002344 surface layer Substances 0.000 description 2
- 229920001187 thermosetting polymer Polymers 0.000 description 2
- 101100270417 Homo sapiens ARHGEF6 gene Proteins 0.000 description 1
- 102100033202 Rho guanine nucleotide exchange factor 6 Human genes 0.000 description 1
- 230000004308 accommodation Effects 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 239000004918 carbon fiber reinforced polymer Substances 0.000 description 1
- 230000008602 contraction Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000010410 layer Substances 0.000 description 1
- 235000013372 meat Nutrition 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000008188 pellet Substances 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 229920001721 polyimide Polymers 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 229920006259 thermoplastic polyimide Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
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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
-
- 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
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/02—Moulds or cores; Details thereof or accessories therefor with incorporated heating or cooling means
-
- 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
-
- 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
- B29C43/361—Moulds for making articles of definite length, i.e. discrete articles with pressing members independently movable of the parts for opening or closing the mould, e.g. movable pistons
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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
- B29C43/54—Compensating volume change, e.g. retraction
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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
- B29C70/465—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 and impregnating by melting a solid material, e.g. sheets, powders of fibres
-
- 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
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
- B29C70/541—Positioning reinforcements in a mould, e.g. using clamping means for the reinforcement
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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
- B29C43/361—Moulds for making articles of definite length, i.e. discrete articles with pressing members independently movable of the parts for opening or closing the mould, e.g. movable pistons
- B29C2043/3613—Moulds for making articles of definite length, i.e. discrete articles with pressing members independently movable of the parts for opening or closing the mould, e.g. movable pistons applying pressure locally
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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
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/30—Mounting, exchanging or centering
- B29C33/308—Adjustable moulds
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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
- B29K2101/00—Use of unspecified macromolecular compounds as moulding material
- B29K2101/12—Thermoplastic materials
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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
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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
- B29K2105/0881—Prepregs unidirectional
-
- 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
- B29K2307/00—Use of elements other than metals as reinforcement
- B29K2307/04—Carbon
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
Definitions
- the present disclosure relates to a fiber reinforced composite member forming apparatus and a fiber used for forming a fiber reinforced composite member including a plurality of prepregs that are formed into a sheet shape by impregnating a resin into a long carbon fiber and laminated together.
- the present invention relates to a method for forming a reinforced composite member.
- thermoplastic CFRP member fiber reinforced composite member
- a molding method using an autoclave is used.
- a mold hot press molding method using a molding apparatus is being constructed as a molding method replacing the molding method using the autoclave.
- a prepreg laminate in which a plurality of sheet-like prepregs are laminated is placed between a pair of molding dies in a molding apparatus and melt temperature (matrix In the case where the resin is a thermosetting resin, the prepreg laminate in which the thermoplastic resin is melted is pressed with a pair of molding dies. And after this pressurization, by cooling the thermoplastic resin through a pair of molding dies to a temperature at which the molded product is not damaged or deformed even if the mold is opened, a fiber-reinforced composite member having a desired shape is obtained. .
- Patent Document 1 Conventionally, as a molding apparatus for the above-described fiber reinforced composite member, for example, there is one described in Patent Document 1, and this molding apparatus is a heater for heating each design surface in contact with a prepreg laminate of a pair of molding dies. It has.
- This heater heats the design surface by heating the air supplied from the air supply source at the heat generating portion and spraying it on the back side of the design surface of the molding die.
- this heater functions as a cooler by stopping the supply of power to the heat generating portion and blowing air directly to the back side of the design surface of the molding die.
- thermoplastic resin when the thermoplastic resin is cooled, the pressurization by the pair of molding dies is continued as the thermoplastic resin contracts, so that the accommodation space (cavity) of the prepreg laminate can be obtained. ) To reduce the volume.
- the present disclosure has been made paying attention to the above-described conventional problems, and even if the laminated thickness of the end portion of the prepreg laminated body is thicker than other parts, the molding time can be prolonged.
- the object of the present invention is to provide a fiber-reinforced composite member forming apparatus and a fiber-reinforced composite member forming method capable of forming a fiber-reinforced composite member without delamination at the end of a prepreg laminate.
- a prepreg laminate including a molding die having a cavity and a plurality of prepregs that are formed in a sheet shape by impregnating a resin into a long carbon fiber and laminated to each other is provided as the one molding die.
- the other molding die that is sandwiched between and pressed by the cavity, a heat source that heats the resin of the prepreg laminate through the one molding die and the other molding die, and the prepreg lamination
- a control section for causing the pressure body to project into the cavity of the one molding die by the pressure body driving section and applying pressure by bringing the pressure body into contact with the prepreg laminate It has a configuration.
- the prepreg laminate can be obtained without prolonging the molding time even when the laminate thickness of the end portion of the prepreg laminate is thicker than other portions.
- the fiber-reinforced composite member having no delamination at the end of the sheet can be formed, which is an excellent effect.
- FIG. 2 is a partial plan view showing the lower mold of the fiber-reinforced composite member forming apparatus in FIG.
- FIG. 6 is a perspective explanatory view showing a modification of a sleeve used in the fiber-reinforced composite member forming apparatus of FIG. 5.
- FIG. 6 is a perspective explanatory view showing another modified example of the sleeve used in the fiber-reinforced composite member forming apparatus of FIG. 5.
- FIG. 1 to 3 show an embodiment of a fiber-reinforced composite member molding apparatus according to the present disclosure.
- the fiber-reinforced composite member is a composite fan rotor blade.
- This composite fan rotor blade is formed by alternately laminating a plurality of prepregs each having a long carbon fiber formed into a sheet of a thermoplastic resin and having different fiber orientation directions.
- the prepreg lamination thickness of the part (tab tail part) is thick.
- the composite fan rotor blade molding apparatus 1 includes a lower mold (one molding mold) 2 and an upper mold (the other molding mold) 3.
- the lower mold 2 has a cavity 21.
- the upper die 3 that descends and rises and approaches and separates from the lower die 2 is fitted with the cavity 21 of the lower die 2 in a clamped state, and a prepreg laminate (a plurality of prepregs laminated between the cavities 21). It has a core 31 that sandwiches a composite fan rotor blade (P) before molding.
- the lower mold 2 includes a plurality of cartridge heaters 4 as a heat source for heating the molding surface 21a in contact with the prepreg laminate P of the cavity 21 for each of a plurality of regions to melt the thermoplastic resin of the prepreg laminate P.
- the upper mold 3 is also provided with a plurality of cartridge heaters 4 as heat sources for heating the molding surface 31a in contact with the prepreg laminate P of the core 31 for each of a plurality of regions.
- the heat source is not limited to the cartridge heater 4, and for example, heated steam can be employed as the heat source.
- the molding apparatus 1 also includes a plurality of cooling medium flow paths (cooling mechanisms) 5 that cool the molding surface 21a in the cavity 21 of the lower mold 2 and the molding surface 31a in the core 31 of the upper mold 3 for each of a plurality of regions. ing.
- These cooling medium flow paths 5 are formed such that their respective tips are positioned on the back sides of the molding surfaces 21a and 31a, respectively, and when the prepreg laminate P is cooled after melting the thermoplastic resin, the lower mold
- the molding surface 21 a in the second cavity 21 and the molding surface 31 a in the core 31 of the upper mold 3 are uniformly cooled.
- the cooling medium can be cooled air, or can be cooled water or oil.
- thermoplastic resin of the prepreg laminate P contracts. Therefore, in this molding apparatus 1, the upper mold 3 is lowered to reduce the volume of the cavity 21 of the lower mold 2 in accordance with the shrinkage of the thermoplastic resin. Thus, the composite fan rotor blade is formed.
- a plurality of insertion holes 22a are formed in the cavity wall 22 located on the end (tab tail portion) Pt side of the prepreg laminate P in the cavity 21 of the lower mold 2 as shown in FIGS. 22 is formed along the width direction (vertical direction in FIG. 3), and pins (pressurizing bodies) 11 that appear and disappear in the cavities 21 of the lower mold 2 are inserted into these insertion holes 22 a.
- pins 11 are each formed with a flat tip end surface, and each base end portion is fixed to a pin support 12.
- the pin support 12 is fixed to the tip of a cylinder rod 13a of a cylinder (pressurizing body drive unit) 13, and the plurality of pins 11 are integrally projected and retracted in the cavity 21 by the operation of the cylinder 13.
- the front end surface comes into contact with and separates from the portion where the end portion (tab tail portion) Pt of the prepreg laminate P is easy to delaminate, in this embodiment, the central portion Po of the prepreg laminate thickness of the laminate surface Pf.
- the plurality of pins 11 are constrained so as not to protrude from the insertion hole 22a into the cavity 21 of the lower mold 2 as necessary. That is, when molding a fiber reinforced composite member having a small difference in the prepreg lamination thickness as a whole, the plurality of pins 11 are restrained by the cylinder 13 in the insertion holes 22 a of the cavity wall 22.
- the molding apparatus 1 includes a control unit 6 that controls the heating operation of the plurality of cartridge heaters 4 and the supply of the cooling medium to the cooling medium flow path 5.
- the control unit 6 causes the pin 11 to protrude into the cavity 21 of the lower mold 2 and cools the thermoplastic resin performed by supplying the cooling medium to the cooling medium flow path 5 and the prepreg laminate P.
- the cylinder 13 is controlled so as to be brought into contact with the laminated surface Pf at the end portion Pt and to apply pressure to the central portion Po of the prepreg laminated thickness of the laminated surface Pf.
- a circuit for electrically connecting the cartridge heater 4 and the controller 6 is not shown.
- a cooling medium supply source that constitutes a cooling mechanism together with the cooling medium flow path 5 and a circuit that electrically connects the cooling medium supply source and the control unit 6 are not shown.
- the upper mold 3 is lowered to form a mold-clamped state, and the core 31 of the upper mold 3 and The prepreg laminate P is sandwiched between the cavities 21 of the lower mold 2.
- the controller 6 applies heat to the prepreg laminate P while controlling the heating operation of the cartridge heater 4 as a plurality of heat sources, and the viscosity is not so soft that the long carbon fibers of each layer of the prepreg laminate P do not meander. (Temperature), and subsequently, pressurization of the prepreg laminate P by the upper mold 3 and the lower mold 2 is started, and this pressurization is continued until the molding of the composite fan rotor blade is completed and the mold is removed. To do.
- control unit 6 controls the heating operation of the cartridge heater 4 to further heat the prepreg laminate P so that the temperature is equal to or higher than the melting temperature of the thermoplastic resin of the prepreg laminate P.
- thermoplastic resin of the prepreg laminate P has melted and a predetermined time has elapsed
- the heating operation of the cartridge heater 4 is stopped under the control of the control unit 6, and the cooling medium for the plurality of cooling medium flow paths 5 is stopped.
- Supply is started and the thermoplastic resin is cooled through the upper mold 3 and the lower mold 2.
- thermoplastic resin of the prepreg laminate P shrinks, but the upper mold 3 that continues to pressurize descends in accordance with the shrinkage of the thermoplastic resin, so the volume of the cavity 21 of the lower mold 2 is reduced. decrease.
- control unit 6 moves the cylinder 13 in the direction of the white arrow in FIG. 3 to project the plurality of pins 11 into the cavity 21 of the lower mold 2, and the front end surfaces of these pins 11 are attached to the prepreg laminate.
- a pressure is applied to a portion where the delamination is likely to occur at the end portion Pt of P, in this embodiment, the central portion Po of the prepreg lamination thickness of the lamination surface Pf, the molding of the composite fan rotor blade is completed.
- the cylinder 13 is operated during the cooling of the thermoplastic resin performed by supplying the cooling medium to the cooling medium flow path 5, and the pin is placed in the cavity 21 of the lower mold 2. 11 is projected, the amount of shrinkage of the end portion Pt in the prepreg laminate P having a large prepreg laminate thickness is offset by the amount that the volume of the cavity 21 of the lower mold 2 is reduced, and the prepreg laminate Delamination hardly occurs at the end portion Pt of P.
- a plurality of pins 11 are constrained by the cylinder 13 to the insertion hole 22a of the cavity wall 22 as necessary, so that the difference in the prepreg lamination thickness is small as a whole. It can also be used for forming members.
- the pin 11 is adopted as a pressurizing body that appears and disappears in the cavity 21, and a plurality of pins are inserted into the plurality of insertion holes 22 a formed along the width direction (vertical direction in FIG. 3) of the cavity wall 22. 11 is inserted, but it is not limited to this.
- the plurality of pins 11 are fixed to one pin support 12, and the plurality of pins 11 are integrated into the cavity 21 by operating the pin support 12 with two cylinders 13.
- the pin support 12 with two cylinders 13.
- the number of pin supports 12 and cylinders 13 are both increased so that a plurality of pins 11 are individually or divided into several groups and operated at different timings. It may be changed and operated.
- a flat plate 11A inserted into an insertion hole 22A formed in the cavity wall 22 may be adopted as a pressurizing body.
- the volume of the cavity 21 of the lower mold 2 can be further reduced as compared with the plurality of pins 11.
- a plurality of flat plates 11A are provided, and the plurality of flat plates 11A are individually or divided into groups, and are operated with a plurality of cylinders 13 shifted in timing or operated with different strokes. May be.
- the pin 11 is directly inserted into the insertion hole 22a of the cavity wall 22.
- the present invention is not limited to this.
- the sleeve 14 having the hole 14a may be inserted into the insertion hole 22a.
- pressure can be locally applied by the central portion Po of the prepreg lamination thickness of the lamination surface Pf.
- a sleeve 15 having a hole 15a at a position eccentric with respect to the shaft center L is adopted, or as shown in FIG.
- a sleeve 16 having holes 16a, 16a at two locations may be employed.
- the position to apply pressure can be adjusted, and when the sleeve 16 having two holes 16a and 16a is adopted. The pressure can be simultaneously applied to two locations in the stacking thickness direction of the prepreg laminate P.
- the fiber-reinforced composite member (composite fan blade) is formed by alternately impregnating a plurality of prepregs formed in a sheet shape by impregnating a resin into a long carbon fiber and having different fiber orientation directions.
- the present invention is not limited to this.
- a sheet-like prepreg of a long carbon fiber similar to the above-described embodiment is adopted as the surface layer Ps of the prepreg laminate PA, and, for example, a chopped material (several tens of prepregs are used in the core portion Pc.
- the core Pc has a short fiber-containing resin (pellet) and a resin material (glass balloon, etc.) It may be a fiber reinforced composite member employing a preformed product (including the case of containing a material).
- the pointed pin 11b as the pressurizing member.
- the core is formed by the pin 11b.
- the tip of the pin 11b enters the end of the core part Pc and pushes it in the direction of the arrow, so that the core part Pc and the surface layer Ps The adhesion between them can be improved.
- examples of the resin as a matrix constituting the prepreg include PEEK (polyether ether ketone resin), PEI (polyether imide resin), and PIXA (thermoplastic polyimide resin). Any of thermoplastic resins such as epoxy resins, and thermosetting resins such as epoxy resins, phenol resins, and polyimide resins are used.
- the fiber-reinforced composite member is a composite fan rotor blade
- the present invention is not limited to this.
- a prepreg laminate including one molding die having a cavity and a plurality of prepregs that are formed into a sheet shape by impregnating a resin into a long carbon fiber and stacked on each other.
- the other molding die that is sandwiched and pressed between the cavities of one molding die, and the heat source that heats the resin of the prepreg laminate through the one molding die and the other molding die And a cooling mechanism for cooling the resin of the prepreg laminate through the one molding die and the other molding die after the resin of the prepreg laminate is heated, and when the cooling by the cooling mechanism
- a cooling mechanism for cooling the resin of the prepreg laminate through the one molding die and the other molding die after the resin of the prepreg laminate is heated, and when the cooling by the cooling mechanism
- the inside of the cavity of the one molding die A pressurizing body that appears and comes in contact with and separates from the prepreg laminated body, a pressurizing body drive unit that causes the pressurizing body to appear in and out of the cavity of the one molding die, and the cooling mechanism by the cooling mechanism Control of applying pressure by causing the pressurizing body to project into the cavity of the one molding die and causing the pressurizing body to contact the prepreg laminated body in accordance with the shrink
- the pressure is applied into the cavity of one molding die by the operation of the pressure body driving unit. Since the body protrudes and abuts against the prepreg laminate and applies pressure, the amount of shrinkage of the thick part of the prepreg laminate is offset by the amount of the cavity of one molding die being reduced. In addition, delamination is unlikely to occur in the prepreg laminate when the pressure member abuts on the prepreg laminate.
- the prepreg laminate when forming a fiber reinforced composite member having no delamination in the prepreg laminate as described above, the prepreg laminate has a thick portion of the prepreg laminate and other portions. Since it is not necessary to provide a difference in the cooling start time between them, it is possible to avoid an increase in the molding time.
- an insertion hole into which the pressurizing body is inserted is formed in a cavity wall constituting the cavity of the one molding die, and the pressurizing body can be used as necessary.
- the pressurizing body driving unit is constrained so as not to protrude from the insertion hole into the cavity of the one molding die.
- the pressurizing body is constrained to the insertion hole of the cavity wall by the pressurizing body driving unit as necessary. It can also be used to form a fiber-reinforced composite member with a small difference in prepreg lamination thickness.
- a pin is employed as the pressure member.
- pressure can be locally applied to the prepreg laminate.
- the pin is inserted into the insertion hole of the cavity wall through a sleeve.
- a flat plate is adopted as the pressure member.
- the volume of the cavity of one molding die can be further reduced as compared with the pins when the resin of the prepreg laminate is cooled by the cooling mechanism.
- a prepreg is formed by laminating a plurality of prepregs in which long carbon fibers are formed into a sheet shape with a resin between one molding die having a cavity and the other molding die.
- the laminate is sandwiched and pressed, and the resin of the prepreg laminate is heated via the one molding die and the other molding die, and then the one molding die and the other molding die are used.
- a method for forming a fiber reinforced composite member wherein the resin of the prepreg laminate is cooled via a step, and the one mold and the other mold are brought close to each other during the cooling to form a fiber reinforced composite member.
- the pressure body protrudes into the cavity of the one molding die in accordance with the shrinkage of the resin when the resin of the prepreg laminate is cooled, and contacts the prepreg laminate. It is configured to apply pressure by.
- the molding time may be prolonged. Therefore, a fiber-reinforced composite member without delamination can be formed at the end of the prepreg laminate.
- Fiber reinforced composite material molding device 2 Lower mold (one mold) 3 Upper mold (the other mold) 4 Cartridge heater (heat source) 5 Cooling medium flow path (cooling mechanism) 6 Control unit 11, 11a, 11b Pin (pressurizing body) 11A Flat plate (Pressurized body) 13 Cylinder (Pressure body drive part) 21 Cavity 22 Cavity wall 22a, 22A Insertion hole 31 Core P, PA Prepreg laminate (fiber reinforced composite member)
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Moulding By Coating Moulds (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
Abstract
Description
そして、この加圧後に、型開きしても成形品が破損したり変形したりしない温度まで一対の成形金型を介して熱可塑性樹脂を冷却することで、所望形状の繊維強化複合部材を得る。
つまり、上記した従来の成形装置では、加圧後の冷却時において、プリプレグ積層体の端部における積層面の、例えば、積層厚中央部分に、端部の余肉(この成形の後に機械加工で削ぎ落とされる肉)を越えて製品に現れてしまうような層間剥離が生じてしまう可能性がある。
図1~図3は本開示に係る繊維強化複合部材の成形装置の一実施例を示しており、この実施例では、繊維強化複合部材が複合材ファン動翼である場合を示す。
なお、カートリッジヒータ4と制御部6とを電気的に接続する回路は図示を省略している。また、冷却媒体流路5とともに冷却機構を構成する冷却媒体供給源及びこの冷却媒体供給源と制御部6とを電気的に接続する回路も図示を省略している。
軸心Lに対して偏心する位置に孔15aを有するスリーブ15を採用した場合には、圧力を加える位置の調節を行うことができ、2個の孔16a,16aを有するスリーブ16を採用した場合には、プリプレグ積層体Pの積層厚方向の2箇所にも同時に圧力を加えることができる。
2 下型(一方の成形金型)
3 上型(他方の成形金型)
4 カートリッジヒータ(熱源)
5 冷却媒体流路(冷却機構)
6 制御部
11,11a,11b ピン(加圧体)
11A 平板(加圧体)
13 シリンダ(加圧体駆動部)
21 キャビティ
22 キャビティ壁
22a,22A 挿通孔
31 コア
P,PA プリプレグ積層体(繊維強化複合部材)
Claims (6)
- キャビティを有する一方の成形金型と、
長炭素繊維に樹脂を含浸させてシート状に形成されて互いに積層される複数枚のプリプレグを備えたプリプレグ積層体を前記一方の成形金型の前記キャビティとの間で挟み込んで加圧する他方の成形金型と、
前記一方の成形金型及び前記他方の成形金型を介して前記プリプレグ積層体の前記樹脂を加熱する熱源と、
前記プリプレグ積層体の前記樹脂の加熱後に前記一方の成形金型及び前記他方の成形金型を介して前記プリプレグ積層体の前記樹脂を冷却する冷却機構を備え、
前記冷却機構による冷却時に前記一方の成形金型及び前記他方の成形金型が互いに接近して繊維強化複合部材を成形する繊維強化複合部材の成形装置において、
前記一方の成形金型の前記キャビティ内に出没して前記プリプレグ積層体に当接離間する加圧体と、
前記一方の成形金型の前記キャビティ内に前記加圧体を出没させる加圧体駆動部と、
前記冷却機構による冷却時の前記プリプレグ積層体における前記樹脂の収縮に合わせて前記加圧体駆動部により前記一方の成形金型の前記キャビティ内に前記加圧体を突出させると共に前記プリプレグ積層体に当接させて圧力を加える制御部が備えられている繊維強化複合部材の成形装置。 - 前記一方の成形金型の前記キャビティを構成するキャビティ壁には、前記加圧体が挿入される挿通孔が形成され、前記加圧体は、必要に応じて前記挿通孔から前記一方の成形金型の前記キャビティ内に突出しない状態で前記加圧体駆動部によって拘束される請求項1に記載の繊維強化複合部材の成形装置。
- 前記加圧体としてピンが採用されている請求項2に記載の繊維強化複合部材の成形装置。
- 前記ピンがスリーブを介して前記キャビティ壁の前記挿通孔に挿入されている請求項3に記載の繊維強化複合部材の成形装置。
- 前記加圧体として平板が採用されている請求項2に記載の繊維強化複合部材の成形装置。
- キャビティを有する一方の成形金型と他方の成形金型との間に、長炭素繊維を樹脂でシート状に形成したプリプレグを複数枚積層して成るプリプレグ積層体を挟み込んで加圧すると共に、前記一方の成形金型及び前記他方の成形金型を介して前記プリプレグ積層体の前記樹脂を加熱した後、前記一方の成形金型及び前記他方の成形金型を介して前記プリプレグ積層体の前記樹脂を冷却して、該冷却時に前記一方の成形金型及び前記他方の成形金型を互いに接近させて繊維強化複合部材を成形する繊維強化複合部材の成形方法において、
前記プリプレグ積層体の前記樹脂の冷却時における該樹脂の収縮に合わせて前記一方の成形金型の前記キャビティ内に加圧体を突出させると共に前記プリプレグ積層体に当接させて圧力を加える繊維強化複合部材の成形方法。
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CN201680077515.9A CN108472839B (zh) | 2016-01-20 | 2016-09-21 | 纤维增强复合部件的成型装置和纤维增强复合部件的成型方法 |
RU2018129966A RU2691340C1 (ru) | 2016-01-20 | 2016-09-21 | Устройство формования армированного волокном композитного элемента и способ формования армированного волокном композитного элемента |
CA3010172A CA3010172C (en) | 2016-01-20 | 2016-09-21 | Fiber reinforced composite member molding apparatus and fiber reinforced composite member molding method |
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EP3543001A1 (en) * | 2018-03-09 | 2019-09-25 | Rolls-Royce plc | A method of manufacturing a fan blade and a fan blade |
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CN108472839A (zh) | 2018-08-31 |
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JP2017128036A (ja) | 2017-07-27 |
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