Manufacturing method for fiber-reinforced composite members
A separable mold system for fiber-reinforced composite members addresses the complexity and cost issues in existing methods by enabling efficient, cost-effective production of complex shapes with strong joints and diverse mechanical properties using RTM molding.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- TOYOTA JIDOSHA KK
- Filing Date
- 2024-11-27
- Publication Date
- 2026-06-08
AI Technical Summary
The existing methods for manufacturing fiber-reinforced composite members, such as carbon fiber composites, involve complex processes that increase manufacturing costs and time due to the need for surface activation and bonding, posing a risk of material breakage and decreased strength.
A separable and connectable mold system is used to laminate fiber substrates, allowing for the formation of preforms with diverse mechanical properties and complex shapes without requiring surface activation, electrodeposition, or partial curing processes, using RTM molding to integrate fiber substrates with different orientations and materials.
This method reduces manufacturing costs and time while maintaining material strength and enabling the production of complex shapes with strong joints and diverse mechanical properties, facilitating the creation of hollow parts and varied fiber substrate configurations.
Smart Images
Figure 2026092938000001_ABST
Abstract
Description
Technical Field
[0001] The present disclosure relates to a method for manufacturing a fiber-reinforced composite member.
Background Art
[0002] In recent years, fiber-reinforced composite members such as carbon fiber composites (CFRP: Carbon Fiber Reinforced Plastics), which are lighter than metal materials, have been used in automobile structures and the like. Such fiber-reinforced composite members are manufactured, for example, by bonding composite materials together (see Patent Document 1).
Prior Art Documents
Patent Documents
[0003]
Patent Document 1
Summary of the Invention
Problems to be Solved by the Invention
[0004] However, in the above manufacturing method, when bonding composite materials together, it is necessary to perform complicated processes such as a process for activating the surface of the composite material. Therefore, there is a risk that the manufacturing cost and manufacturing time will increase.
[0005] The present disclosure has been made in view of such problems, and a main object thereof is to provide a method for manufacturing a fiber-reinforced composite member capable of reducing the manufacturing cost and manufacturing time.
Means for Solving the Problems
[0006] One aspect of the present disclosure for achieving the above object is that a mold for molding a fiber-reinforced composite member is configured to be separable and connectable between a mold body and a split mold at a sectional surface of a step of the mold, and on the mold body in the separated state, a step of laminating a fiber base material by a height of the step is performed. The steps include trimming the end of the fibrous material that protrudes from one end of the mold body on the stepped side to match the end of the mold body, The steps include: connecting the detachable mold to one end of the mold body, The steps include forming a first laminated fiber substrate by laminating a further fiber substrate on the outer surface of the fiber substrate laminated on the mold body and on the outer surface of the separate mold that is adjacent to the outer surface in a planar manner, The steps include releasing the mold body and the separation mold from the first laminated fiber substrate, The process involves forming a preform by laminating and bonding another fiber substrate so as to cover the stepped portion of the first laminated fiber substrate, The steps include: impregnating the molded preform with resin to form the fiber-reinforced composite member; including, Manufacturing method for fiber-reinforced composite members That is the case. On this flight, A pair of the aforementioned first laminated fiber substrates are formed, and the resulting pair of first laminated fiber substrates are joined together. Using the methods of each of the above steps, a pair of second laminated fiber substrates is produced that have a larger diameter and shorter axial length than the pair of first laminated fiber substrates. The pair of second laminated fiber substrates are joined so as to cover the outside of the joined pair of first laminated fiber substrates, with the joints of the pair of first laminated fiber substrates and the joints of the pair of second laminated fiber substrates offset in the circumferential direction. The joined first and second laminated fiber substrates may have a stepped, gradually changing shape formed on them, and a preform may be formed by laminating and joining another fiber substrate to the gradually changing shape. On this flight, The fiber substrate of the first laminated fiber substrate and the other fiber substrate may be made of different materials. On this flight, The fiber orientation of the fiber substrate of the first laminated fiber substrate and the fiber orientation of the other fiber substrate may be different. On this flight, The fibrous substrate may be a sheet-shaped CFRP (Carbon Fiber Reinforced Plastics) member. [Effects of the Invention]
[0007] According to this disclosure, it is possible to provide a method for manufacturing fiber-reinforced composite members that can reduce manufacturing costs and manufacturing time. [Brief explanation of the drawing]
[0008] [Figure 1] This is a perspective view showing an example of a mold according to this embodiment. [Figure 2] This is a cross-sectional view of the mold shown in Figure 1, when it is cut perpendicularly along line AA. [Figure 3] This figure illustrates the method for manufacturing a fiber-reinforced composite member according to this embodiment. [Figure 4] This figure shows an example of a flared cylindrical member formed by joining a pair of first laminated fiber substrates. [Figure 5] This diagram shows the state in which a pair of second laminated fiber substrates are joined so as to cover the outside of a pair of first laminated fiber substrates that have been joined together. [Figure 6] This figure shows a state in which the joints of a pair of first laminated fiber substrates and the joints of a pair of second laminated fiber substrates are misaligned in the circumferential direction. [Modes for carrying out the invention]
[0009] This embodiment will be described below with reference to the drawings. The manufacturing method for the fiber-reinforced composite member according to this embodiment involves, for example, molding the fiber-reinforced composite member using the RTM (Resin Transfer Molding) molding method. Alternatively, the manufacturing method for the fiber-reinforced composite member according to this embodiment involves shaping a fiber base material using a mold of a predetermined shape to produce a preform (intermediate structure).
[0010] FIG. 1 is a perspective view showing an example of a mold according to the present embodiment. FIG. 2 is a cross-sectional view when the mold shown in FIG. 1 is vertically cut along line A-A.
[0011] As shown in FIG. 1, the product shape is transferred onto the surface of the mold 1. The mold 1 has a step 11. As shown in FIG. 2, the mold 1 is configured to be separable and connectable into a mold body 2 and a split mold 3 at the separating surface of the step 11 of the mold 1.
[0012] When the mold body 2 and the split mold 3 are connected, the above-described step 11 is formed between the outer surface of the mold body 2 and the outer surface of the split mold 3.
[0013] FIG. 3 is a diagram for explaining a method of manufacturing a fiber-reinforced composite member according to the present embodiment. Note that, for easy understanding of the explanation, FIG. 3 shows a simplified shape of the mold body 2, the split mold 3, and the fiber base material.
[0014] Hereinafter, a method of manufacturing a fiber-reinforced composite member according to the present embodiment will be described with reference to FIG. 3.
[0015] First, a fiber base material 100 is laminated on the mold surface of the separated mold body 2 by the height of the step 11 (FIG. 3(1)) (step S101). For example, the sheet-like fiber base material 100 is laminated on the mold surface of the mold body 2 by arranging the sheet-like fiber base material 100 on the mold surface of the mold body 2.
[0016] The fiber base material 100 is, for example, a sheet-like CFRP member. The CFRP member is formed by combining a plurality of carbon fibers and a matrix resin as a base material. The carbon fiber is a material mainly composed of carbon, and examples thereof include PAN-based carbon fibers using polyacrylonitrile fibers as a raw material, pitch-based carbon fibers using coal pitch or petroleum pitch as a raw material, and the like.
[0017] The matrix resin is preferably a thermosetting epoxy resin. Examples of epoxy resins include bisphenol A type epoxy resin, bisphenol AD type epoxy resin, bisphenol F type epoxy resin, etc. The epoxy resin may be used alone or in combination of two or more types. Other thermosetting resins include, for example, phenolic resins, nylon resins, and acrylic resins.
[0018] The protruding portion 101 of the fiber base material 100 that extends beyond one end 21 on the stepped 11 side of the mold body 2 is trimmed by cutting it with a cutting machine, for example, so that it aligns with the end 21 of the mold body 2 (Figure 3(2)) (Step S102).
[0019] The separation mold 3 is joined to one end 21 of the mold body 2, for example, by fitting it (Figure 3(3)) (Step S103). At this time, as described above, the fiber base material 100 is laminated on the outer surface of the mold body 2 to the height of the step 11, so the outer surface of the fiber base material 100 laminated on the mold body 2 and the outer surface of the separation mold 3 are aligned on the same plane.
[0020] The first laminated fiber substrate 102 is formed by laminating a further fiber substrate 110 on the outer surface of the fiber substrate 100 laminated on the mold body 2 and on the outer surface of the separating mold 3 which is aligned in the same plane as the outer surface of the fiber substrate 100 (Figure 3(4)) (Step S104).
[0021] Although the already laminated fiber base material 100 and the further fiber base material 110 are made of the same material, they may be made of different materials. Also, although the fiber orientation of the already laminated fiber base material 100 and the fiber orientation of the further fiber base material 110 are the same, they may be different. This makes it possible to manufacture composite materials with diverse mechanical properties and characteristics.
[0022] The mold body 2 and the separation mold 3 are released from the first laminated fiber substrate 102 (Figure 3(5)) (Step S105). As described above, the first laminated fiber substrate 102 having the stepped portion 1022 is produced.
[0023] As described above, by separating the mold 1 into the mold body 2 and the separate mold 3 and molding the fiber base material 100, it is possible to prevent the fiber base material 100 from breaking due to the step 11 of the mold 1. Therefore, especially when molding complex shapes such as curved surfaces, it is possible to suppress wrinkles in the fiber base material 100 and prevent a decrease in its strength.
[0024] A preform 106 is formed by laminating and joining a separate fiber base material 104 so as to cover the stepped portion 1022 of the first laminated fiber base material 102 (Figure 3(6)) (Step S106).
[0025] Although the fiber base materials 100 and 110 of the first laminated fiber base material 102 and the other fiber base material 104 are made of the same material, they may be made of different materials. Also, although the fiber orientation of the fiber base materials 100 and 110 of the first laminated fiber base material 102 and the fiber orientation of the other fiber base material 104 are the same, they may be different.
[0026] As described above, by bonding fiber base materials 100 with different fiber directions or fiber base materials 100 made of different materials, it becomes possible to manufacture composite materials with diverse mechanical properties and characteristics. For example, composite materials with different properties can be obtained for each part of a fiber-reinforced composite member.
[0027] As described above, a fiber-reinforced composite member is formed by impregnating the molded preform 106 with resin. Fiber-reinforced composite members are, for example, automotive parts made from composite materials by automobile manufacturers, parts manufacturers, and material suppliers.
[0028] Alternatively, a pair of first laminated fiber substrates 102 may be generated using the method described above (steps S101) to (steps S105), and the generated pair of first laminated fiber substrates 102 may be joined together as shown in Figure 4 to generate a flared cylindrical member.
[0029] Furthermore, a pair of second laminated fiber substrates 107 having a larger diameter and shorter axial length than the pair of first laminated fiber substrates 102 may be produced using the same method as described above in (steps S101) to (steps S105).
[0030] As shown in Figure 5, a pair of second laminated fiber substrates 107 are joined so as to cover the outside of the pair of first laminated fiber substrates 102 that have been joined together as described above.
[0031] In this case, as shown in Figure 6(a), it is preferable that the joint portion 1021 of the pair of first laminated fiber base materials 102 and the joint portion 1071 of the pair of second laminated fiber base materials 107 are offset in the circumferential direction. This allows the joint portion 1071 of the first laminated fiber base material 102 to be wrapped by the second laminated fiber base material 107, thereby making the bond of the first laminated fiber base material 102 stronger.
[0032] Although the fiber base material 100 of the first laminated fiber base material 102 and the fiber base material 100 of the second laminated fiber base material 107 are made of the same material, they may be made of different materials. Also, although the fiber orientation of the fiber base material 100 of the first laminated fiber base material 102 and the fiber orientation of the fiber base material 100 of the second laminated fiber base material 107 are the same, they may be different.
[0033] As described above, the first and second laminated fiber substrates 102 and 107 joined together form a stepped, gradually changing shape 108, as shown in Figure 6. By laminating and joining another fiber substrate 104 to this gradually changing shape 108, for example, by wrapping it around as shown in Figure 6(b), a preform in a substantially cylindrical shape can be formed. As described above, by stacking and joining multiple preforms, a desired hollow part can be easily formed.
[0034] In this embodiment, the preform is molded from a CFRP member using the RTM molding method, but this is not limited to this. The RTM molding method may also be used to mold a preform from other fiber-reinforced plastics, such as glass fiber.
[0035] According to the manufacturing method for fiber-reinforced composite members of this embodiment, complex preforms can be molded while maintaining their shape using a simple mold 1 as described above, without requiring complex processes such as activating the composite material surface, electrodeposition processes applying voltage to the fiber substrate, hot press molding processes, and partial curing processes, as in the conventional method. Therefore, the manufacturing cost and time of fiber-reinforced composite members can be reduced.
[0036] Furthermore, it enables the creation of strong joints even in complex shapes that would otherwise require bonding multiple fiber substrates together. This increases the freedom of shape while allowing for the easy manufacture of hollow parts. For example, the ability to arbitrarily change the bonding area of the fiber substrates, the type of fiber substrate, the number of steps, and the thickness of the steps is also a significant advantage.
[0037] While several embodiments of this disclosure have been described, these embodiments are presented as examples only and are not intended to limit the scope of the invention. These novel embodiments can be carried out in a variety of other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their variations are included in the scope and spirit of the invention, as well as in the claims and their equivalents. [Explanation of symbols]
[0038] 1 mold 2. Molding mold body 3 Separate type 11 steps 21 One end 100 Fiber base material 101 Overhang 102 First Laminated Fiber Substrate 104 Another fiber base material 106 Preform 107 Second Laminated Fiber Substrate 108 Gradually changing part shape 1021 Joint 1022 Step section 1071 Joint
Claims
1. A mold for forming a fiber-reinforced composite member is configured such that it can be separated into a mold body and a separate mold at a step-shaped dividing surface of the mold, and the mold body and the separate mold can be joined together, and the process involves stacking a fiber substrate on the separated mold body to the height of the step, The steps include trimming the end of the fibrous material that protrudes from one end of the mold body on the stepped side to match the end of the mold body, The steps include: connecting the detachable mold to one end of the mold body, The steps include forming a first laminated fiber substrate by laminating a further fiber substrate on the outer surface of the fiber substrate laminated on the mold body and on the outer surface of the separate mold that is adjacent to the outer surface in a planar manner, The steps include releasing the mold body and the separation mold from the first laminated fiber substrate, The process involves forming a preform by laminating and bonding another fiber substrate so as to cover the stepped portion of the first laminated fiber substrate, The steps include: impregnating the molded preform with resin to form the fiber-reinforced composite member; including, A method for manufacturing fiber-reinforced composite materials.
2. A method for manufacturing a fiber-reinforced composite member according to claim 1, A pair of the aforementioned first laminated fiber substrates are formed, and the resulting pair of first laminated fiber substrates are joined together. Using the methods of each of the above steps, a pair of second laminated fiber substrates is produced that have a larger diameter and a shorter axial length than the pair of first laminated fiber substrates. The pair of second laminated fiber substrates are joined so as to cover the outside of the joined pair of first laminated fiber substrates, with the joints of the pair of first laminated fiber substrates and the joints of the pair of second laminated fiber substrates offset in the circumferential direction. The joined first and second laminated fiber substrates have a stepped, gradually changing shape, and a preform is formed by laminating and joining another fiber substrate to this gradually changing shape. A method for manufacturing fiber-reinforced composite materials.
3. A method for manufacturing a fiber-reinforced composite member according to claim 1, The fiber substrate of the first laminated fiber substrate and the other fiber substrate are composed of different materials. A method for manufacturing fiber-reinforced composite materials.
4. A method for manufacturing a fiber-reinforced composite member according to claim 1, The fiber orientation of the fiber substrate of the first laminated fiber substrate and the fiber orientation of the other fiber substrate are different. A method for manufacturing fiber-reinforced composite materials.
5. A method for manufacturing a fiber-reinforced composite member according to claim 1, The aforementioned fibrous substrate is a sheet-like CFRP (Carbon Fiber Reinforced Plastics) member. A method for manufacturing fiber-reinforced composite materials.