Method of manufacturing a fiber-reinforced composite part

Abstract

The present application can reduce manufacturing cost and time. In the manufacturing method of the fiber-reinforced composite member of the present application, a fiber base material is stacked on a molding mold body in a separated state to a height equivalent to that of a step, an end portion of the fiber base material protruding from one end portion of the molding mold body on the step side is aligned with the one end portion of the molding mold body and trimmed, a separation mold is combined with the one end portion of the molding mold body, a fiber base material is further stacked on an outer surface of the fiber base material stacked on the molding mold body and an outer surface of the separation mold continuous with the outer surface in the same plane, a first stacked fiber base material is molded, the molding mold body and the separation mold are demolded from the first stacked fiber base material, another fiber base material is stacked and combined in a manner to cover a step portion of the first stacked fiber base material to mold a preform, and a resin is impregnated in the preform, thereby molding the fiber-reinforced composite member.

Description

Technical Field

[0001] This invention relates to a method for manufacturing a fiber-reinforced composite component. Background Technology

[0002] In recent years, fiber-reinforced composite components, such as carbon fiber reinforced plastics (CFRP), which are lighter than metal materials, have been used in automotive structures and other applications. These fiber-reinforced composite components are manufactured, for example, by bonding the composite materials together (see Patent Document 1).

[0003] Patent Document 1: Japanese Patent Application Publication No. 2021-014093 Summary of the Invention

[0004] However, in the above manufacturing method, complex processes such as surface activation of the composite materials are required when bonding them together. Therefore, this may increase manufacturing costs and time.

[0005] The present invention was made in view of these problems, and its main objective is to provide a method for manufacturing fiber-reinforced composite components that can reduce manufacturing costs and manufacturing time.

[0006] One aspect of the present invention for achieving the above-mentioned objective is a method for manufacturing a fiber-reinforced composite component, wherein the molding die for molding the fiber-reinforced composite component is configured to be separable into a molding die body and a separation die at a parting surface of a step in the molding die, and to be capable of combining the molding die body and the separation die.

[0007] The method for manufacturing the fiber-reinforced composite component includes the following steps:

[0008] On the mold body in the separated state, the fiber substrate is stacked to the same height as the step;

[0009] The end of the fiber substrate protruding from one end of the step side of the molding die body is aligned with one end of the molding die body and trimmed;

[0010] The separation mold is attached to one end of the molding mold body;

[0011] On the outer surface of the fiber substrate stacked on the main body of the molding die and on the outer surface of the separation die which is in the same plane and continuous with the outer surface, a first layer of fiber substrate is further stacked to form a first layer of fiber substrate.

[0012] Demold the molding die body and the separation die from the first layer of fiber substrate;

[0013] By layering and bonding other fiber substrates in a manner that covers the stepped portion of the first layer of fiber substrate, a preform is formed; and

[0014] The fiber-reinforced composite component is formed by impregnating the preform with resin.

[0015] In this approach, it can also be as follows:

[0016] A pair of the first laminated fiber substrates are formed, and the resulting pair of first laminated fiber substrates are joined together.

[0017] Using the methods described in each step, a pair of second-layer fiber substrates with a diameter larger than the pair of first-layer fiber substrates and a shorter axial length are generated.

[0018] With the joint portions of the pair of first-layer fiber substrates and the pair of second-layer fiber substrates circumferentially offset, the resulting pair of second-layer fiber substrates are joined in a manner that covers the outside of the joined pair of first-layer fiber substrates.

[0019] A stepped gradient shape is formed on the first and second laminated fiber substrates, and another fiber substrate is laminated and bonded on the gradient shape to form a preform.

[0020] In this approach, it can also be as follows:

[0021] The first layer of fiber substrate and the other fiber substrate are made of different materials. Alternatively, in this embodiment, it can be as follows:

[0022] The fiber orientation of the first layer of fiber substrate is different from that of the other fiber substrate.

[0023] In this approach, it can also be as follows:

[0024] The fiber substrate can be a sheet-like carbon fiber reinforced plastic (CFRP) component.

[0025] Invention Effects

[0026] According to the present invention, a method for manufacturing fiber-reinforced composite components that can reduce manufacturing costs and manufacturing time can be provided. Attached Figure Description

[0027] Figure 1 This is a perspective view showing an example of the molding die involved in this embodiment.

[0028] Figure 2 It is Figure 1 The cross-sectional view shown is taken when the molding die is cut perpendicularly along line AA.

[0029] Figure 3 This is a diagram illustrating the manufacturing method of the fiber-reinforced composite component according to this embodiment.

[0030] Figure 4 This is a diagram illustrating an example of a cylindrical component with outwardly extending ends joined to a pair of first-layer fiber substrates.

[0031] Figure 5 This diagram illustrates a state in which a pair of second-layer fiber substrates are joined in such a way that they are covered from the outside of the joined pair of first-layer fiber substrates.

[0032] Figure 6 This diagram shows the state in which the joint of a pair of first-layer fiber substrates and the joint of a pair of second-layer fiber substrates are offset in the circumferential direction. Detailed Implementation

[0033] Hereinafter, this embodiment will be described with reference to the accompanying drawings. The method for manufacturing the fiber-reinforced composite component according to this embodiment, for example, uses resin transfer molding (RTM) to mold the fiber-reinforced composite component. Furthermore, the method for manufacturing the fiber-reinforced composite component according to this embodiment uses a molding die of a predetermined shape to shape the fiber substrate, thereby manufacturing a preform (intermediate structure).

[0034] Figure 1 This is a perspective view showing an example of the molding die involved in this embodiment. Figure 2 It is Figure 1 The cross-sectional view shown is taken when the molding die is cut perpendicularly along line AA.

[0035] like Figure 1 As shown, the product shape is transferred onto the surface of the molding die 1. The molding die 1 has a step 11. Figure 2 As shown, the molding die 1 is configured to be able to separate into a molding die body 2 and a separation die 3 at the parting surface of the step 11 of the molding die 1, and to be able to combine the molding die body 2 and the separation die 3.

[0036] If the forming mold body 2 and the separating mold 3 are combined, the aforementioned step 11 is formed between the outer surface of the forming mold body 2 and the outer surface of the separating mold 3.

[0037] Figure 3 This is a diagram illustrating the manufacturing method of the fiber-reinforced composite component according to this embodiment. Additionally, for ease of explanation, Figure 3The shapes of the molding die body 2, the separation die 3, and the fiber substrate are simplified in the figure.

[0038] The following is for reference. Figure 3 The manufacturing method of the fiber-reinforced composite component involved in this embodiment will be described.

[0039] First, on the mold surface of the mold body 2 in the separated state, the fiber substrate 100 is stacked with steps 11 of varying heights ( Figure 3 (1) (Step S101). For example, the sheet-like fiber substrate 100 is stacked on the mold surface of the molding die body 2 by disposing of the sheet-like fiber substrate 100 on the mold surface of the molding die body 2.

[0040] The fiber substrate 100 is, for example, a sheet-like CFRP component. The CFRP component is composed of multiple carbon fibers and a matrix resin that serves as the parent material. The carbon fiber is a material with carbon as its main component, such as PAN-based carbon fiber made from polyacrylonitrile fiber, or pitch-based carbon fiber made from coal tar or petroleum pitch.

[0041] The matrix resin is preferably a thermosetting epoxy resin. Examples of epoxy resins include bisphenol A type epoxy resin, bisphenol AD ​​type epoxy resin, and bisphenol F type epoxy resin. The epoxy resin can be a single type or a combination of two or more types. Other examples of thermosetting resins include phenolic resins, nylon resins, and acrylic resins.

[0042] The protruding portion 101 of the fiber substrate 100, which protrudes from one end 21 on the step 11 side of the molding die body 2, is aligned with one end 21 of the molding die body 2, and trimmed, for example, by cutting with a cutting machine. Figure 3 (2) (Step S102).

[0043] For example, the separating mold 3 is joined to one end 21 of the forming mold body 2 by fitting. Figure 3 (3) (Step S103). At this time, as described above, since the fiber substrate 100 of the height of the step 11 is stacked on the outer surface of the molding die body 2, the outer surface of the fiber substrate 100 stacked on the molding die body 2 is on the same plane and continuous with the outer surface of the separation die 3.

[0044] A further layer of fiber substrate 110 is stacked on the outer surface of the fiber substrate 100 stacked on the main body of the molding die 2 and on the outer surface of the separation die 3 which is on the same plane as the outer surface, thereby forming the first layer of fiber substrate 102. Figure 3 (4) (Step S104).

[0045] Furthermore, the laminated fiber substrate 100 and the further fiber substrate 110 may be made of the same material, but they may also be made of different materials. Also, the fiber orientation of the laminated fiber substrate 100 and the further fiber substrate 110 may be the same, but they may also be different. Therefore, it is possible to manufacture composite materials with a variety of mechanical properties or characteristics.

[0046] Demolding the molding die body 2 and the separating die 3 from the first layer of fiber substrate 102. Figure 3 (5) (Step S105). As described above, a first laminated fiber substrate 102 having a stepped portion 1022 is generated.

[0047] Furthermore, as described above, by separating the molding die 1 into the molding die body 2 and the separation die 3 for molding the fiber substrate 100, it is possible to prevent the fiber substrate 100 from being bent by the steps 11 of the molding die 1. Therefore, especially when molding complex shapes such as curved surfaces, wrinkles in the fiber substrate 100 can be suppressed, and its strength can be prevented from decreasing.

[0048] A preform 106 is formed by laminating and bonding another fiber substrate 104 in such a way that it covers the stepped portion 1022 of the first layer of fiber substrate 102. Figure 3 (6) (Step S106).

[0049] Furthermore, the fiber substrates 100 and 110 of the first laminated fiber substrate 102 and the other fiber substrate 104 are made of the same material, but they may also be made of different materials. Also, the fiber orientation of the fiber substrates 100 and 110 of the first laminated fiber substrate 102 is the same as the fiber orientation of the other fiber substrate 104, but they may also be different.

[0050] As described above, by combining fiber substrates 100 with different fiber orientations or fiber substrates 100 made of different materials, it is possible to manufacture composite materials with a variety of mechanical properties or characteristics. For example, it is possible to obtain composite materials with different properties in each part of a fiber-reinforced composite component.

[0051] As described above, a fiber-reinforced composite component is formed by impregnating the preform 106 with resin. Fiber-reinforced composite components are, for example, automotive parts using composite materials for automobile manufacturers, component manufacturers, and material suppliers.

[0052] Alternatively, a pair of first-layer fiber substrates 102 can be generated using the methods described in steps S101 to S105 above, such as... Figure 4 As shown, the pair of first-layer fiber substrates 102 formed by bonding are used to form a cylindrical component with outwardly flared ends.

[0053] Alternatively, the same method as described in steps S101 to S105 above can be used to generate a pair of second-layer fiber substrates 107 with a diameter larger than that of a pair of first-layer fiber substrates 102 and a shorter axial length.

[0054] like Figure 5 As shown, a pair of second-layer fiber substrates 107 are joined in such a way that they cover the outside of the pair of first-layer fiber substrates 102 that are joined above.

[0055] At this time, as Figure 6 As shown in (a), preferably, the joint 1021 of a pair of first-layer fiber substrates 102 and the joint 1071 of a pair of second-layer fiber substrates 107 are offset in the circumferential direction. As a result, the joint 1021 of the first-layer fiber substrates 102 can be covered by the second-layer fiber substrates 107, thus making the joint of the first-layer fiber substrates 102 more secure.

[0056] Furthermore, the fiber substrate 100 of the first laminated fiber substrate 102 and the fiber substrate 100 of the second laminated fiber substrate 107 may be made of the same material, but they may also be made of different materials. Also, the fiber orientation of the fiber substrate 100 of the first laminated fiber substrate 102 and the fiber orientation of the fiber substrate 100 of the second laminated fiber substrate 107 may be the same, but they may also be different.

[0057] like Figure 6 As shown, a stepped gradient shape 108 is formed on the first and second laminated fiber substrates 102 and 107 joined as described above. By applying, for example, to this gradient shape 108... Figure 6 As shown in (b), additional fiber substrate 104 is layered and bonded in a wound manner to form a preform, for example, a generally cylindrical shape. As described above, by overlapping and joining multiple preforms, the desired hollow component can be easily formed.

[0058] In this embodiment, a preform is formed from a CFRP component using RTM molding, but it is not limited to this method. RTM molding can also be used to form preforms from other fiber-reinforced plastics, such as glass fiber.

[0059] According to the manufacturing method of the fiber-reinforced composite component of this embodiment, complex processes such as surface activation of the composite material, electrodeposition of the fiber substrate by applying voltage, hot pressing, and local curing are not required as in the past. A preform with a complex shape can be formed while maintaining its shape using a simple molding die 1 as described above. Therefore, the manufacturing cost and time of the fiber-reinforced composite component can be reduced.

[0060] Furthermore, it enables the creation of joints that ensure strength, even in complex shapes where multiple fiber substrates cannot be bonded together. This increases the freedom of shape creation and facilitates the manufacture of hollow components. For example, it also allows for arbitrary changes to the bonding area of ​​the fiber substrate, the type of fiber substrate, the number of steps, and the thickness of the steps.

[0061] Several embodiments of the present invention have been described, but these embodiments are presented by way of example and are not intended to limit the scope of the invention. These new embodiments can be implemented in various other ways, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their variations are all included in the scope or spirit of the invention, and are included within the scope of the invention as described in the claims and their equivalents.

[0062] Symbol Explanation

[0063] 1- Molding mold, 2- Molding mold body, 3- Separation mold, 11- Step, 21- One end, 100- Fiber substrate, 101- Protruding part, 102- First layer fiber substrate, 104- Additional fiber substrate, 106- Preform, 107- Second layer fiber substrate, 108- Gradient shape, 1021- Joining part, 1022- Step part, 1071- Joining part.

Claims

1. A method for manufacturing a fiber-reinforced composite component, characterized in that, The molding die for molding fiber-reinforced composite parts is configured such that it can be separated into a molding die body and a separation die at the parting surface of the mold step, and that the molding die body and the separation die can be combined. The method for manufacturing the fiber-reinforced composite component includes the following steps: On the mold body in the separated state, the fiber substrate is stacked to the same height as the step; The end of the fiber substrate protruding from one end of the step side of the molding die body is aligned with one end of the molding die body and trimmed; The separation mold is attached to one end of the molding mold body; On the outer surface of the fiber substrate stacked on the main body of the molding die and on the outer surface of the separation die which is in the same plane and continuous with the outer surface, a first layer of fiber substrate is further stacked to form a first layer of fiber substrate. Demold the molding die body and the separation die from the first layer of fiber substrate; By layering and bonding other fiber substrates in a manner that covers the stepped portion of the first layer of fiber substrate, a preform is formed; and The fiber-reinforced composite component is formed by impregnating the preform with resin.

2. The method for manufacturing the fiber-reinforced composite component according to claim 1, characterized in that, A pair of the first laminated fiber substrates are formed, and the resulting pair of first laminated fiber substrates are joined together. Using the methods described in each step, a pair of second-layer fiber substrates with a diameter larger than the pair of first-layer fiber substrates and a shorter axial length are generated. With the joint portions of the pair of first-layer fiber substrates and the pair of second-layer fiber substrates circumferentially offset, the resulting pair of second-layer fiber substrates are joined in a manner that covers the outside of the joined pair of first-layer fiber substrates. A stepped gradient shape is formed on the first and second laminated fiber substrates, and another fiber substrate is laminated and bonded on the gradient shape to form a preform.

3. The method for manufacturing the fiber-reinforced composite component according to claim 1, characterized in that, The first layer of fiber substrate and the other fiber substrate are made of different materials.

4. The method for manufacturing the fiber-reinforced composite component according to claim 1, characterized in that, The fiber orientation of the first layer of fiber substrate is different from that of the other fiber substrate.

5. The method for manufacturing the fiber-reinforced composite component according to claim 1, characterized in that, The fiber substrate is a sheet-like carbon fiber reinforced plastic component.

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