Method for shaping laminates, method for manufacturing composite material parts, shaping mold, and shaping jig

Abstract

By controlling the size and location of wrinkles, composite material parts with the intended shape and superior strength can be molded. [Solution] The method for shaping the laminate 2 is a method for manufacturing a composite material part having a curved portion using a plurality of laminates of prepreg 21 containing reinforcing fibers 22 and resin 23 as constituent materials. The method includes the following steps: Prepare a mold 3 and a shaping jig 4 including an installation surface 42 to be attached to the mold 3 and a contact surface 41 that contacts the laminate 2. Attach the installation surface 42 of the shaping jig 4 to a predetermined position on the mold 3 to create a shaping mold 5. Form a state in which the laminate 2 is placed on the shaping mold 5. Apply pressure to the laminate 2 on the shaping mold 5 to bring the laminate 2 into contact with the mold 3 and the contact surface 41 and shape it.

Description

Technical Field

[0001] The present disclosure relates to a method of shaping a laminate for manufacturing a composite part using the laminate of prepregs containing reinforcing fibers and resin as a structural material, a method of manufacturing a composite part, and a shaping mold or shaping jig used in these methods.

Background Art

[0002] For example, as described in Patent Document 1, there is known a method of impregnating reinforcing fibers with resin to form a prepreg, shaping the prepreg into a desired three-dimensional shape using a molding die, and obtaining a composite part by heating and pressurizing after shaping. When shaping, wrinkles may occur in the prepreg. The same applies when shaping a laminate of prepregs. In particular, wrinkles are likely to occur in the curved portion of the composite part. When wrinkles occur, the strength of the composite part decreases. In Patent Document 1, cuts are made in the prepreg, and the portions on both sides of the cuts are overlapped to prevent the occurrence of wrinkles.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the method of Patent Document 1, even if the occurrence of wrinkles can be suppressed, the portion where the portions on both sides of the cuts are overlapped thickens unintentionally. That is, in the formed composite part, there may be an unnecessary portion that thickens unavoidably for manufacturing convenience. In addition, when cuts are made in the prepreg, the reinforcing fibers are cut, so the strength of the formed composite part may decrease.

[0005] By applying this disclosure to the manufacturing process of composite material parts, operators can generate wrinkles of any size and at any location in the laminate during shaping, instead of the relatively large wrinkles that typically occur in unintended sizes and locations. In other words, the object of this disclosure is to provide a method for shaping a laminate, a method for manufacturing a composite material part, a shaping mold, and a shaping jig that can control the size and location of wrinkles and form a composite material part with the intended shape and superior strength. [Means for solving the problem]

[0006] A method for shaping a laminate according to one aspect of the present disclosure is a method for manufacturing a composite material part having a curved portion using a plurality of laminates of prepregs containing reinforcing fibers and resin as constituent materials, the method comprising: preparing a mold and a shaping jig including an installation surface to be attached to the mold and a contact surface to contact the laminate; attaching the installation surface of the shaping jig to a predetermined position on the mold to create a shaping mold for the laminate; forming the laminate in a state where it is placed on the shaping mold; applying pressure to the laminate on the shaping mold to shape the laminate by bringing it into contact with the mold and the contact surface.

[0007] A method for manufacturing a composite material part relating to another aspect of the present disclosure is a method for manufacturing a composite material part having a curved portion using a plurality of laminates of prepregs containing reinforcing fibers and resin as constituent materials, wherein a mold and a shaping jig including an installation surface to be attached to the mold and a contact surface to contact the laminate are prepared, the installation surface of the shaping jig is attached to a predetermined position in the mold to create a shaping mold for the laminate, the laminate is placed on the shaping mold, a first treatment including a first pressurizing treatment is applied to the laminate on the shaping mold, the laminate is shaped by bringing it into contact with the mold and the contact surface, the shaping jig is removed, the shaped laminate is placed on a final mold, a second treatment including a second pressurizing and heat treatment is applied, and the portion of the processed laminate after the second treatment corresponding to the contact surface of the shaping jig is cut off.

[0008] A shaping mold relating to yet another aspect of the present disclosure is a shaping mold for a laminate, for manufacturing a composite material part having a curved portion using a plurality of laminates of prepregs containing reinforcing fibers and resin as constituent materials, comprising: a mold including a shaping surface that contacts the laminate; and a projection disposed on the shaping surface and including a contact surface with the laminate, wherein the projection has a longitudinal direction, and in a cross section perpendicular to the longitudinal direction, the cross-sectional area gradually decreases toward one end in the longitudinal direction.

[0009] A shaping jig relating to yet another aspect of the present disclosure is a shaping jig used when shaping a laminate for manufacturing a composite material part having a curved portion using a laminate of multiple prepregs containing reinforcing fibers and resin as constituent materials, comprising a jig body having a contact surface with the laminate, and an installation surface for attaching the jig body to a mold for shaping the laminate. [Effects of the Invention]

[0010] According to this disclosure, it is possible to provide a method for shaping a laminate, a method for manufacturing a composite material part, a shaping mold, and a shaping jig that can control the size and location of wrinkles and form a composite material part with a desired shape and excellent strength. [Brief explanation of the drawing]

[0011] [Figure 1] Figure 1 shows a perspective view of an example of a composite material part and the constituent materials of that composite material part. [Figure 2] Figure 2 shows a conventional method for shaping a laminate used as a component of composite material parts, and the state of the laminate after shaping. [Figure 3] Figure 3 is a perspective view showing a mold and shaping jig according to an embodiment of this disclosure. [Figure 4] Figure 4 is a perspective view showing a shaping type according to an embodiment of this disclosure. [Figure 5] Figure 5 is a perspective view showing another example of a shaping jig, with cross-sections of each part in the longitudinal direction indicated. [Figure 6] Figure 6 is a process chart showing a first embodiment of the method for manufacturing composite material parts. [Figure 7] Figure 7 shows the execution status of a portion of the process chart of the first embodiment. [Figure 8A] Figure 8A shows the execution status of a part of the process chart of the first embodiment. [Figure 8B] Figure 8B is a diagram showing the cross-section along line VIIIB-VIIIB in Figure 8A with the shaping equipment added. [Figure 9] Figure 9 shows the execution status of a portion of the process chart of the first embodiment. [Figure 10] Figure 10 is a perspective view of a composite material part manufactured by the manufacturing method of the second embodiment. [Figure 11] Figure 11 is a perspective view showing the implementation of the manufacturing method for composite material parts according to the second embodiment. [Figure 12] Figure 12 is a perspective view showing the implementation of the manufacturing method for composite material parts according to the second embodiment. [Figure 13] Figure 13 is a process chart showing a second embodiment of the method for manufacturing composite material parts. [Modes for carrying out the invention]

[0012] Embodiments of this disclosure will be described in detail below with reference to the drawings. This disclosure includes a method for manufacturing a composite material component comprising a laminate of a plurality of prepregs, a method for shaping the laminate which is an intermediate molded product of the composite material component, a shaping mold and a shaping jig used in the shaping method. The prepreg comprises reinforcing fibers and a resin. The resin is preferably a thermosetting resin, but may also be a thermoplastic resin. The manufactured composite material component includes curved parts such as mountain folds or valley folds, concave or convex dome-shaped curved surfaces, flat curved surfaces, or composite parts thereof. Specific examples of composite material components include frames, plates, beams, or exterior materials for structures having curved parts. The composite material component is used, for example, as a component of a structure such as an aircraft, railway vehicle, or automobile.

[0013] [Problems in the Structure and Manufacture of Composite Material Parts] FIG. 1 is a perspective view of a beam part 1A as an example of a composite material part. The beam part 1A includes a flat plate part 11, a first bent part 12, and a second bent part 13, and has a C-shaped cross section. The first bent part 12 is continuously provided on one side in the longitudinal direction of the flat plate part 11, and the second bent part 13 is continuously provided on the other side in the longitudinal direction of the flat plate part 11. Between the flat plate part 11 and the first bent part 12, there is a first corner part 121 which is a curved part bent at a right angle. Between the flat plate part 11 and the second bent part 13, there is a second corner part 131 which is a curved part bent at a right angle. The second bent part 13 has a curved part 132 that bends in a direction approaching the first bent part 12. At the curved part 132, the second corner part 131 has a curved part that bends along the bending shape of the second bent part 13.

[0014] FIG. 1 shows the layer structure of the beam part 1A. The beam part 1A is manufactured using a laminate 2 formed by laminating a plurality of sheet-like prepregs 21 as a constituent material. After the final heat and pressure treatment following the shaping of the laminate 2, the prepregs 21 are welded between layers. The prepreg 21 includes reinforcing fibers 22 and a resin 23. Examples of the prepreg 21 include, for example, a prepreg obtained by mixing short fibers or long fibers as the reinforcing fibers 22 with a thermosetting resin, a fiber array body in which continuous fibers are arranged in a predetermined direction, or a prepreg obtained by impregnating a woven fabric of continuous fibers with a thermosetting resin.

[0015] As the reinforcing fibers 22, for example, carbon fibers, glass fibers, ceramic fibers, metal fibers, or organic fibers can be used. Examples of the resin 23 include epoxy resins, phenolic resins, melamine resins, urea resins, unsaturated polyester resins, alkyd resins, silicone resins, polyurethanes, thermosetting polyimides, and the like.

[0016] Figure 1 illustrates the first prepreg 21A, the second prepreg 21B, and the third prepreg 21C, which are parts of the multiple prepregs 21 forming the laminate 2. The reinforcing fibers 22 contained in the first prepreg 21A, the second prepreg 21B, and the third prepreg 21C are continuous fibers. The first prepreg 21A is a sheet in which a large number of continuous fibers are arranged in a predetermined arrangement direction, and a thermosetting resin is impregnated into this arrangement to form a unified sheet. The second prepreg 21B and the third prepreg 21C are sheets similar to the above. However, the arrangement directions of the continuous fibers in the first prepreg 21A, the second prepreg 21B, and the third prepreg 21C are different from each other. In this way, by laminating three types of sheets with the arrangement directions of the continuous fibers as reinforcing fibers 22 in three different axial directions, a laminate 2 having pseudo-isotropy or desired anisotropy can be obtained.

[0017] When forming a composite material part such as a beam part 1A having corners 121, 131 and curved parts 132, using a substantially flat laminate 2 made by stacking multiple prepreg sheets 21 as a constituent material, it is difficult to directly form the laminate 2 from its substantially flat shape to the final shape. The difficulty in forming is due to the fact that when a laminate 2 made by stacking two-dimensional prepreg sheets 21 is processed into a curved shape, wrinkles caused by localized expansion and contraction occur in the prepreg 21 of each layer. Therefore, a method is employed to form the laminate 2 in two steps: intermediate forming and final forming. Intermediate forming is a process in which a shaping die is used to shape the laminate 2 into a shape that approaches the final shape. Final forming is a process in which the laminate 2 shaped in the intermediate forming is heated and pressurized using a final forming die to obtain the composite material part in the final shape.

[0018] Figure 2 shows a conventional method for shaping a laminate 2 and the arrangement of prepreg 21 within the laminate 2 after shaping. The laminate 2, placed on the mold 3 which serves as the shaping mold, is subjected to pressure treatment and, if necessary, heat treatment, so that the laminate 2 comes into contact with the mold 3 and is shaped. This heat treatment is applied, for example, when the thickness of the laminate 2 is relatively thick and shaping the laminate 2 is difficult with pressure alone. Of course, for laminates 2 that are relatively thin, both pressure and heat treatment may be applied. Even in shaping to alleviate the difficulty of molding, wrinkles may occur in the prepreg 21 of the laminate 2 when molding into a complex shape.

[0019] Figure 2 shows that although the outer surface of the laminate 2 is flat, wavy wrinkles Wr are occurring in the prepreg 21 inside. Wrinkles Wr tend to occur in the first bent portion 12 and the second bent portion 13, which are bent by the first corner portion 121 and the second corner portion 131, respectively. In particular, large wrinkles Wr tend to occur in the second bent portion 13 where the second corner portion 131 and the curved portion 132 are combined. In the areas where wrinkles Wr occur, the reinforcing fibers 22 become wavy and distorted, resulting in uneven fiber density, which ultimately leads to a decrease in the strength of the beam component 1A after final molding. If a method is adopted in which the worker manually shapes and laminates the prepreg 21 one sheet at a time on the mold 3, the occurrence of wrinkles Wr can be suppressed to some extent even in areas with complex shapes. However, the manual lamination of prepreg 21 requires skilled workers and involves a relatively large amount of labor, making it unsuitable for composite material parts that require mass production.

[0020] In light of the above circumstances, this disclosure allows for the formation of wrinkles Wr in the shaping of the laminate 2, but employs means to generate the wrinkles Wr in a manner that conforms to the operator's intentions regarding their location, number, and size. For example, the means according to this disclosure generates small wrinkles Wr in a dispersed manner without generating large wrinkles Wr. These small wrinkles Wr are of a degree that does not affect the strength of the final composite material part. In order to form the composite material part into its final shape, it may be necessary to cut off a portion of the composite material part after heating and pressurizing the laminate 2 using a final molding die. In this case, the wrinkles Wr are induced to concentrate in the portion to be cut off. In the following description, the former will be described as the first embodiment and the latter as the second embodiment.

[0021] [Explanation of excipient types] Figure 3 is a perspective view showing a mold 3 and a shaping jig 4 according to an embodiment of the present disclosure. Figure 4 is a perspective view of a shaping mold 5 with the shaping jig 4 attached to the mold 3. In Figure 3, for simplification, a simple rectangular parallelepiped mold 3 is shown, having a corner 31 that bends at a right angle and being longitudinal in the X direction. The mold 3 has a shaping surface 30 that is in contact with the laminate 2. The shaping surface 30 has a surface shape for shaping the laminate 2 into the required shape. The shaping surface 30 shown in Figures 3 and 4 includes a part of the top surface 301 of the mold 3 and a part of the side surface 302 that connects to the top surface 301 via the corner 31. The laminate 2 to be shaped is placed on the shaping surface 30.

[0022] The shaping jig 4 is attached to the mold 3 to create dispersed small wrinkles Wr in the prepreg 21 of the laminate 2. When attached to the mold 3, the shaping jig 4 becomes a projection positioned on the shaping surface 30. The shaping jig 4 has a longitudinal shape. The shaping jig 4 includes a jig body 40 and an mounting surface 42.

[0023] The jig body 40 is the part involved in shaping the laminate 2. The jig body 40 has a contact surface 41 with respect to the laminate 2. In Figure 3, a dome-shaped contact surface 41 with a semicircular cross-section is shown as an example. The cross-sectional shape of the contact surface 41 may be a triangle, trapezoid, a polygon with more than one quadrilateral, or a semi-ellipse. The width and height of the contact surface 41 may be determined as appropriate depending on the wrinkles Wr to be generated. The width and height of the contact surface 41 may differ, for example, in the longitudinal direction of the jig body 40, or they may be the same as in the example in Figure 3. The mounting surface 42 is the surface for attaching the jig body 40 to the shaping surface 30 of the mold 3. The mounting surface 42 is provided on the opposite side of the contact surface 41, sandwiching the jig body 40. The surface shape of the mounting surface 42 is such that it closely conforms to the surface shape of the shaping surface 30 to which it is attached.

[0024] The shaping jig 4 is attached to the jig installation position 3P, which is a predetermined position on the molding die 3, when the shaping die 5 is manufactured. The jig installation position 3P is set at a location where relatively large wrinkles Wr are expected to occur in the laminate 2 when the laminate 2 is pressed for shaping. Specifically, the jig installation position 3P is set at a position on the molding die 3 that corresponds to the curved portion of the composite material part. Note that the occurrence of relatively large wrinkles Wr in the laminate 2 can occur not only when pressing for shaping, but also when heating is applied. In a composite material part made up of a laminate 2 of multiple prepreg 21, the curved portion is a particularly prone area for the occurrence of large wrinkles Wr. By setting the jig installation position 3P at a position corresponding to the curved portion, the occurrence of large wrinkles Wr can be suppressed.

[0025] In the example shown in Figure 3, the laminate 2 is placed so as to hang down from the top surface 301 to both side surfaces 302. In this case, wrinkles Wr are less likely to occur in the portion of the laminate 2 that is in contact with the top surface 301. However, wrinkles Wr are more likely to occur in the portion of the laminate 2 that is in contact with the side surfaces 302, because the laminate 2 is bent at the corners 31. In particular, when the corner 31 includes a curved portion, as in the example of the curved portion 132 in Figure 2, large wrinkles Wr are more likely to occur in the portion of the laminate 2 that is in contact with the side surfaces 302. In view of the above, Figure 3 shows an example in which the jig installation position 3P is set in an area close to the corner 31 of the side surface 302.

[0026] When attaching the shaping jig 4 to the mold 3, the longitudinal direction of the shaping jig 4 is attached in a direction that intersects with the extending direction of the corner 31. In the mold 3 of Figure 3, the extending direction of the corner 31 is the X direction. In Figure 3, the Y direction is defined as the direction perpendicular to the X direction. The width direction of the mold 3 in Figure 3 is the Y direction. The shaping jig 4 is attached to the jig installation position 3P, facing the Z direction which is perpendicular to both the X and Y directions. The upper end of the shaping jig 4 is located close to the corner 31. Wrinkles Wr tend to occur in a direction perpendicular to the extending direction of the corner 31. By arranging the shaping jig 4 perpendicular to the extending direction of the corner 31, dispersed small wrinkles Wr can be generated in the vicinity of the corner 31 in a direction approximately perpendicular to the extending direction of the corner 31. In other words, by devising the arrangement of the shaping jigs 4, the worker can generate small wrinkles Wr of the size and position intended by the worker. The longitudinal direction of the shaping jig 4 does not necessarily have to coincide with the Z direction; the longitudinal direction may be inclined relative to the Z direction. The number of shaping jigs 4 installed at the jig installation position 3P, the installation pitch, etc., are determined appropriately according to the characteristics of the wrinkles Wr that the worker intends to generate, such as the size, position, and degree of distribution of the wrinkles Wr.

[0027] Figure 5 is a perspective view showing a shaping jig 4A relating to another example. The shaping jig 4A has a shape with the Z direction shown in Figure 5 as its longitudinal direction. Here, the direction perpendicular to the Z direction is defined as the Y direction in Figure 5. The direction perpendicular to both the Z and Y directions is defined as the X direction in Figure 5. Figure 5 includes XY cross-sections of each part of the shaping jig 4A with respect to its longitudinal direction. The shaping jig 4A has a base portion 43 at one end in the longitudinal direction and a tip portion 44 at the other end. The base portion 43 is the part of the shaping jig 4A where the width W in the X direction and the height H in the Y direction are maximum. The tip portion 44 is the part where the width W and height H are minimum. One side between the base portion 43 and the tip portion 44 is the contact surface 41A with the laminate 2. The back side of the contact surface 41A is the mounting surface 42A to be attached to the mold 3. The height H is the cross-sectional width in the direction away from the installation surface 42A.

[0028] In a cross-section in the X direction perpendicular to the longitudinal direction, the shaping jig 4A has a tapered shape in which the cross-sectional area gradually decreases from one end to the other in the longitudinal direction. In other words, in a cross-section in the X direction perpendicular to the longitudinal direction, the shaping jig 4A has a gradually decreasing cross-sectional area from the base 43 to the tip 44. In the example in Figure 5, the base 43 has a rectangular cross-section with width W and height H. The contact surface 41A has an inclined surface in which both corners of the rectangular cross-section are cut at an angle. The width of the angled cut at the corners gradually increases from the base 43 to near the midpoint towards the tip 44. The flat surface of the contact surface 41A in the XZ plane is triangular in shape in which the width in the X direction gradually narrows toward the midpoint. From the midpoint to the tip 44, the cross-section of the shaping jig 4A is triangular. That is, the width W and height H gradually decrease toward the midpoint to the tip 44.

[0029] For example, when the shaping jig 4A is attached to the mold 3 in Figure 4, the tip 44 is located near the corner 31 and is attached so that its longitudinal direction is perpendicular to the corner 31. When attaching the shaping jig 4A to the mold 3, the tip 44 may reach the corner 31. Also, when attaching it, the longitudinal direction of the shaping jig 4A may be inclined with respect to the Z direction in Figure 4. When the shaping jig 4A is attached to the mold 3, the laminate 2 can be brought into contact with the contact surface 41A at a gentle incline, which is suitable for forming small wrinkles Wr within an acceptable range that does not affect strength.

[0030] [First Embodiment] Figure 6 is a process chart showing a first embodiment of a method for manufacturing a composite material part. Figures 7 to 9 are diagrams showing the execution status of parts of the process chart of the first embodiment. In the first embodiment, an example is shown in which the object to be manufactured is the beam part 1A illustrated in Figure 1. When manufacturing the beam part 1A, a mold 3 and a shaping jig 4A illustrated in Figure 5 are used. The mold 3 includes a corner portion 31 and a curved surface portion 32. The corner portion 31 shapes the first corner portion 121 and the second corner portion 131 of the laminate 2 shown in Figures 1 and 2. The curved surface portion 32 exclusively shapes the curved portion 132.

[0031] In process S1, the workers involved in the manufacturing of beam component 1A prepare the mold 3 and the required number of shaping jigs 4A. The mold 3 has a rectangular parallelepiped shape and includes a top surface 301 and side surfaces 302. The jig installation position 3P is set on the side surface 302 of the mold 3 where a corner 31 and a curved surface 32 are combined. The jig installation position 3P is a position on the side surface 302 that corresponds to a place where relatively large wrinkles Wr are likely to occur in the laminate 2 when it comes into contact with the laminate 2 during shaping. A part of the top surface 301 of the mold 3 and the upper part of the side surface 302 near the corner 31 are the shaping surfaces 30 of the laminate 2.

[0032] In process S2, as shown in Figure 7, the worker attaches the shaping jig 4A to the jig installation position 3P of the mold 3 to create the shaping mold 5. The worker attaches the installation surface 42A of the shaping jig 4A to the surface of the jig installation position 3P. The shaping jig 4A can be attached to the jig installation position 3P by methods such as applying adhesive to the installation surface 42A, attaching an adhesive sheet, or using tape. The size and number of shaping jigs 4A are selected so that the geometrically estimated amount of excess material in the part of the laminate 2 that is in contact with the jig installation position 3P, i.e., the estimated amount of wrinkles Wr, is equal to the sum of the perimeters of the installation surface 42A that protrudes from the jig installation position 3P.

[0033] In parallel with processes S1 and S2, the laminate 2 is fabricated in process S3. As illustrated in Figure 1, the laminate 2 is fabricated by stacking the required number of prepregs 21, which are made by impregnating reinforcing fibers 22 with a thermosetting resin 23. At the stage of process S3, the resin 23 of the prepreg 21 has not hardened. That is, at the stage of process S3, the prepreg 21 and the laminate 2 are flexible.

[0034] In the following explanation of steps S3 and S4, please refer to Figures 8A and 8B. In Figures 8A and 8B, the longitudinal direction of the mold 5 is the X direction, the direction perpendicular to the X direction and the horizontal plane is the Y direction, and the direction perpendicular to both the X and Y directions is the Z direction. The Y direction is the width direction of the mold 5, and the Z direction is the height direction of the mold 5. In step S4, as shown in Figure 8A, the worker places the laminate 2 made in step S3 on the forming surface 30 of the mold 5 made in step S2. Alternatively, the laminate 2 may be formed by laminating multiple prepreg 21 on the mold 5. Regardless of the method, it is sufficient that the laminate 2 is placed on the mold 5. The central region of the laminate 2 in the width direction of the mold 5 abuts against the top surface 301 by its own weight. The side portion of the laminate 2 hangs downward from the corner portion 31 and faces or contacts the side surface 302 and the contact surface 41 of the shaping jig 4A.

[0035] In step S5, forming is performed. More specifically, in step S5, pressure is applied to the laminate 2 on the forming mold 5, and the laminate 2 is brought into contact with the molding die 3 and the contact surface 41A to form it. Figure 8B shows the execution of forming, and is a diagram in which the forming apparatus has been added to the cross section of line VIIIB-VIIIB in Figure 8A. The forming apparatus shown is a base 61 and a rubber sheet 62. Depending on the requirements of the part to be manufactured, heating may be performed during forming. For example, in step S5, pressure and heating may be applied to the laminate 2 on the forming mold 5, and the laminate 2 may be brought into contact with the molding die 3 and the contact surface 41A to form it. This type of forming method is generally called HDF (Hot Drape Forming) forming.

[0036] The base 61 is the base on which the mold 5 on which the laminate 2 is placed is installed. The base 61 includes a vacuum hole 63 that penetrates the base 61 in the thickness direction. The rubber sheet 62 completely covers the mold 5 on which the laminate 2 is placed from above, and has a size such that the peripheral area is in contact with the base 61. The space SP inside the rubber sheet 62 is vacuumed through the vacuum hole 63. Vacuuming improves the adhesion of the laminate 2 to the mold 5. In particular, vacuuming allows the laminate 2 to adhere well to the uneven shape formed by the contact surface 41A of the molding jig 4A. Alternatively, instead of the rubber sheet 62, a molding upper mold with a cavity having a relief portion for the molding jig 4A may be used.

[0037] Subsequently, the laminate 2 on the shaping mold 5 is pressurized by performing the vacuum evacuation. Through these steps, the laminate 2 can be shaped into the required shape, and voids within the laminate 2 can be eliminated. Furthermore, in the portion of the laminate 2 facing the jig installation position 3P, multiple laterally protruding protrusions 2W are formed due to contact and close contact with the contact surface 41A. If a heating-intensive shaping method such as HDF shaping is used instead of this step, the operator further places an infrared heater or the like outside the rubber sheet 62 and operates it to pressurize and heat the laminate 2.

[0038] Next, steps S6 to S9 are performed to perform final molding on the laminate 2 to obtain the beam component 1A as a composite material component. In this embodiment, the mold 3 used to shape the laminate 2 is used as the final mold. When performing the final molding of the laminate 2, a mold prepared separately from the mold 3 may be used as the final mold.

[0039] In step S6, the worker removes the shaping jig 4A from the shaping mold 5, as shown in the upper diagram of Figure 9. Specifically, the shaping jig 4A, which is sandwiched between the side surface 302 of the mold 3 and the side of the laminate 2, is pulled downwards. Wrinkles Wr are formed in the prepreg 21 inside the protruding section 2W. The arrangement and size of these wrinkles Wr are formed to the arrangement and size intended by the worker, depending on the placement of the shaping jig 4A on the mold 3 and the shape of the shaping jig 4A. If a mold different from mold 3 is to be used as the final mold, the shaped laminate 2 is placed on top of the final mold.

[0040] In step S7, bagging is performed on the formed laminate 2. Bagging is a process in which the laminate 2 is covered with a bagging film and the inside of the bagging film is vacuumed. Step S7 may be performed in the same manner as illustrated in Figure 8(B). However, as the bagging film, a sheet with superior hardness to the rubber sheet 62, such as a nylon sheet, is used in order to achieve high-precision molding.

[0041] In step S8, the bagged laminate 2 is pressurized and heated in an autoclave. The heating in step S8 is performed at a temperature that cures the thermosetting resin 23 of the prepreg 21. By performing step S8, the laminate 2 is formed into the final shape of the beam component 1A. That is, the uneven areas where the protrusions 2W of the laminate 2 were formed are molded into a smooth state. Multiple wrinkles Wr of the prepreg 21 remain inside the areas where the protrusions 2W existed. However, the remaining wrinkles wr are small in size and do not substantially affect the strength of the beam component 1A. In other words, instead of large wrinkles Wr, small wrinkles Wr remain dispersed inside the beam component 1A, with their location and size being the size and arrangement intended by the operator through the attachment of the shaping jig 4. Therefore, the wrinkles Wr created by the shaping jig 4 do not lead to a reduction in the strength of the beam component 1A.

[0042] In step S9, the molded beam component 1A is demolded. After the beam component 1A has cooled, the operator removes it from the mold 3 and removes the bagging film. By performing the above steps S1 to S9, a beam component 1A is manufactured, which includes a flat portion 11, a pair of bent portions 12 and 13, a pair of corner portions 121 and 131, and a curved portion 132, as shown in the lower part of Figure 9.

[0043] [Second Embodiment] Figure 10 is a perspective view of a frame component 1B manufactured by a composite material component manufacturing method according to the second embodiment. The frame component 1B is an arc-shaped frame used for reinforcing the strength of a wall that partitions, for example, a cylindrical space or a semicircular or dome-shaped roof. The frame component 1B includes an arc-shaped flat portion 14, a first arc-shaped bent portion 15, a second arc-shaped bent portion 16, and a notch 17.

[0044] The arc-shaped flat plate portion 14 is the part of the flat plate that is curved with a predetermined curvature. The first arc-shaped bent portion 15 is the part of the arc-shaped flat plate portion 14 where the inner diameter side is bent at a right angle at the corner portion 151. The second arc-shaped bent portion 16 is the part of the arc-shaped flat plate portion 14 where the outer diameter side is bent at a right angle at the corner portion 161. The bending direction of the second arc-shaped bent portion 16 is opposite to that of the first arc-shaped bent portion 15. The notch 17 is a part of the arc-shaped flat plate portion 14 and a part of the second arc-shaped bent portion 16 that has been cut off after final molding in order to reduce weight or to prevent interference with other parts. In the second embodiment, during shaping, wrinkles Wr are concentrated in the part to be cut off as a notch 17 in the laminate, and the wrinkles Wr are removed in the notch 17 formation process after final molding.

[0045] Figures 11 and 12 are perspective views showing the implementation of the manufacturing method for frame component 1B. Frame component 1B is manufactured using a laminate 2A formed by stacking multiple fan-shaped prepregs 21 as its constituent material. In the laminate 2A shown in Figure 11, the portion indicated by the dotted line is the excess 17A. The excess 17A is the region corresponding to the notch 17 after final molding. The shaping mold 5A used for shaping the laminate 2A includes a molding die 3A and a shaping jig 4B.

[0046] The mold 3A includes a sector-shaped surface 33, a small-diameter arc surface 34, and a large-diameter arc surface 35. The sector-shaped surface 33 is a sector-shaped plane. The portion of the laminate 2A corresponding to the arc-shaped flat plate portion 14 of the frame component 1B abuts against the sector-shaped surface 33. The small-diameter arc surface 34 is an arc-shaped circumferential surface that connects to the arc-shaped flat plate portion 14 via a valley-fold corner 31A. The bending angle of the corner 31A is right angle, and the small-diameter arc surface 34 and the sector-shaped surface 33 are mutually orthogonal surfaces. The small-diameter arc surface 34 shapes the portion of the laminate 2A corresponding to the first arc-shaped bend portion 15 of the frame component 1B. The large-diameter arc surface 35 is an arc-shaped circumferential surface that connects to the arc-shaped flat plate portion 14 via a mountain-fold corner 31B. The bending angle of the corner 31B is right angle, and the large-diameter arc surface 35 and the sector-shaped surface 33 are mutually orthogonal surfaces. The large-diameter arc surface 35 shapes the portion of the laminate 2A that corresponds to the second arc bend 16.

[0047] The shaping jig 4B has a longitudinal direction and includes a tapered shape portion in a cross section perpendicular to the longitudinal direction, where the cross-sectional area gradually decreases towards the tip. The shaping jig 4B includes a contact surface 41B that contacts the laminate 2A and an installation surface 42B that is attached to the mold 3A. The shaping jig 4B is attached to the large-diameter arc surface 35 at a position where the excess 17A abuts. The shaping jig 4B is attached to the large-diameter arc surface 35 such that the longitudinal direction of the shaping jig 4B and the extending direction of the corner portion 31B are perpendicular to each other.

[0048] The shaping jig 4B may have the same shape as the shaping jig 4A illustrated in Figure 5. However, it is desirable that the size of the shaping jig 4B be set to be the same as the total size of the wrinkles Wr that occur in the laminate 2A in the region opposite the large-diameter arc surface 35 when the shaping jig 4B is not attached. Multiple shaping jigs 4B may be placed in the corresponding parts of the excess 17.

[0049] Figure 12 shows the shaping process of the laminate 2A placed on the shaping mold 5A. Under pressure, the laminate 2A is shaped to conform to the shape of the shaping surface of the shaping mold 5A. That is, the laminate 2A is shaped to have portions corresponding to the arc flat portion 14, the first arc bent portion 15, and the second arc bent portion 16 of the frame part 1B, and a raised ridge portion 2WA is formed at the contact point with the shaping jig 4B. Wrinkles Wr of the prepreg 21 are generated inside the raised ridge portion 2WA. In other words, the arrangement of the shaping jig 4B guides the wrinkles Wr to concentrate on the excess 17A. This allows the operator to generate wrinkles Wr at the intended location. After final molding, the portion corresponding to the hardened excess 17A is cut off to form a notch 17, thereby manufacturing a frame part 1B from which wrinkles Wr have been removed. Thus, a frame part 1B with superior strength and suppressed wrinkle Wr generation can be obtained. In addition, even in the excipient formulations described here, heating-inducing excipient formulations such as HDF formulation may be used as needed.

[0050] Figure 13 is a process chart showing a second embodiment of a method for manufacturing composite material parts. The object to be manufactured in the second embodiment is the frame part 1B illustrated in Figure 10. The process chart of the second embodiment includes processes S11 to S20. Processes S11 to S19, excluding the final process S20, are similar to processes S1 to S9 of the first embodiment.

[0051] In process S1, the worker involved in the manufacture of frame component 1B prepares the molding die 3A and the required number of shaping jigs 4B. In process S12, the worker attaches the shaping jigs 4B to a predetermined position on the molding die 3A to create the shaping die 5A. The predetermined position is the position on the molding die 3A that corresponds to the excess 17A of the laminate 2A during shaping. In parallel with processes S11 and S12, the laminate 2A is manufactured in process S13. The laminate 2A is manufactured by stacking the required number of prepregs 21, which are made by impregnating reinforcing fibers 22 with thermosetting resin 23, as illustrated in Figure 1.

[0052] In step S14, as shown in Figure 11, the worker places the laminate 2A, which was made in step S13, on the mold 5A, which was made in step S12. Alternatively, the laminate 2A may be formed by laminating multiple prepreg 21 on the mold 5A. The method used is not limited to any particular method, as long as the laminate 2A is placed on the mold 5A.

[0053] In step S15, a first process, including a first pressurizing treatment, is performed, i.e., shaping. That is, as shown in Figure 12, pressure is applied to the laminate 2A on the shaping mold 5A, and the laminate 2A is brought into contact with the molding die 3A and the contact surface 41B to be shaped. For this shaping, a shaping apparatus including the base 61 and rubber sheet 62 illustrated in Figure 8B is used. The point that the pressurizing is performed while vacuuming is performed is the same as in the first embodiment. The shaped laminate 2A includes a raised ridge portion 2WA. Wrinkles Wr of the prepreg 21 are present inside the raised ridge portion 2WA.

[0054] In step S16, the worker removes the shaping jig 4B from the mold 3A. In other words, the mold 3A from which the shaping jig 4B has been removed is used as the final mold for the frame part 1B. If the mold 3A is not used as the final mold, the final mold is prepared in step S161, which follows step S15. In step S162, the worker places the shaped laminate 2 on top of the final mold.

[0055] In step S16 or step S162, once the shaped laminate 2A is placed on the final mold, bagging of the laminate 2A is performed in step S17. Specifically, the laminate 2A is covered with a bagging film, and the inside of the bagging film is vacuumed. In step S18, as a second process including a second pressurization and heat treatment, the bagged laminate 2A is pressurized and heated in an autoclave. The processed laminate 2A that has undergone the pressurization and heat treatment is molded into the final shape of the frame part 1B, except for the notched part 17. In step S19, the processed laminate 2A is demolded. The operator removes the processed laminate 2A from the mold 3A after it has cooled, and removes the bagging film.

[0056] In process S20, the worker cuts off the hardened excess 17A portion of the processed laminate 2A to form a notch 17. This cut completes the frame part 1B shown in Figure 10. Wrinkles Wr accumulate in the portion corresponding to the excess 17A that is cut off to form the notch 17, guided by the shaping jig 4B. By cutting off this portion, a frame part 1B from which the wrinkles Wr have been removed can be manufactured.

[0057] [Summary of this disclosure] The specific embodiments described above include disclosures having the following configurations.

[0058] A method for shaping a laminate according to one aspect of the present disclosure is a method for manufacturing a composite material part having a curved portion using a plurality of laminates of prepregs containing reinforcing fibers and resin as constituent materials, the method comprising: preparing a mold and a shaping jig including an installation surface to be attached to the mold and a contact surface to contact the laminate; attaching the installation surface of the shaping jig to a predetermined position on the mold to create a shaping mold for the laminate; forming the laminate in a state where it is placed on the shaping mold; applying pressure to the laminate on the shaping mold to shape the laminate by bringing it into contact with the mold and the contact surface.

[0059] According to the first embodiment, the worker does not simply place the prepreg laminate on the mold to shape it, but shapes it using a shaping mold with a shaping jig attached to a predetermined position on the mold. The contact surface of the shaping jig on the laminate becomes a part that bulges outward in the processed laminate after pressurization. This bulging part corresponds to a wrinkle that occurs at the mounting position of the shaping jig, depending on the size of the shaping jig. In other words, the worker can control the location and size of the wrinkles by installing the shaping jig in the appropriate place on the mold. For example, the worker installs a predetermined number of shaping jigs in areas of the composite material part where the occurrence of large wrinkles is expected, so as to generate small wrinkles that do not affect the strength of the composite material part. That is, the worker generates multiple small wrinkles that correspond to large wrinkles, distributed at predetermined locations. Therefore, the worker can shape composite material parts that include shapes that are prone to generating large wrinkles during shaping, without causing unnecessary bulges, and while suppressing a decrease in strength.

[0060] The second embodiment of the method for shaping a laminate is the method for shaping a laminate according to the first embodiment, wherein the predetermined position of the mold is the position corresponding to the curved portion of the composite material part.

[0061] In composite material parts made of laminates of multiple prepregs, curved sections are particularly prone to the occurrence of large wrinkles. According to the second embodiment, a shaping jig is positioned at a location corresponding to the curved section. Therefore, the worker can shape the curved section without causing large wrinkles.

[0062] A third embodiment of the method for shaping a laminate is the method for shaping a laminate according to the first or second embodiment, wherein the shaping jig has a longitudinal shape, the mold has corners for shaping the curved portion, which is a mountain fold or valley fold, into the composite material part, and in the manufacture of the shaping mold, the shaping jig is attached to the mold in a direction in which the longitudinal direction intersects with the extending direction of the corners.

[0063] In forming the corners of composite material parts, wrinkles occur in a direction intersecting the direction of extension of the corner. According to the third embodiment, the size and location of the wrinkles are controlled by the operator at such corners. Therefore, the operator can easily disperse the large wrinkles that would occur at the corners without the use of shaping jigs into smaller wrinkles.

[0064] A fourth embodiment of the method for manufacturing a composite material part is a method for manufacturing a composite material part having a curved portion using a plurality of laminates of prepregs containing reinforcing fibers and resin as constituent materials, wherein a mold and a shaping jig including an installation surface to be attached to the mold and a contact surface to contact the laminate are prepared, the installation surface of the shaping jig is attached to a predetermined position in the mold to create a shaping mold for the laminate, the laminate is placed on the shaping mold, a first treatment including a first pressurizing treatment is applied to the laminate on the shaping mold, the laminate is shaped by bringing it into contact with the mold and the contact surface, the shaped laminate is placed on a final mold, a second treatment including a second pressurizing and heating treatment is applied, and the portion of the processed laminate after the second treatment corresponding to the contact surface of the shaping jig is cut off.

[0065] According to the fourth embodiment, the worker shapes a prepreg laminate using a molding die with a shaping jig attached to a predetermined position in the molding die. By placing the shaping jig in the appropriate place in the molding die, the worker can control the location of wrinkle formation during the shaping of the laminate by the first process. In the processed laminate by the second process, the area corresponding to the contact surface of the shaping jig becomes the area where wrinkles are concentrated due to the guidance of the shaping jig. By cutting off the aforementioned area, a composite material part without wrinkles can be manufactured. Therefore, the worker can manufacture a composite material part with superior strength and suppressed wrinkle formation.

[0066] The manufacturing method for composite material parts according to the fifth embodiment is as follows: In the manufacturing method according to the fourth embodiment, after the first processing, the shaping jig is removed and the molding die is used as the final molding die.

[0067] According to the fifth embodiment, the worker uses the mold from which the shaping jig has been removed as the final mold. This allows the worker to increase manufacturing efficiency and reduce the number of molds used.

[0068] A shaping mold according to the sixth embodiment is a shaping mold for a laminate to manufacture a composite material part having a curved portion using a plurality of laminates of prepregs containing reinforcing fibers and resin as constituent materials, comprising: a mold including a shaping surface that contacts the laminate; and a projection disposed on the shaping surface and including a contact surface with the laminate, wherein the projection has a longitudinal direction, and in a cross section perpendicular to the longitudinal direction, the cross-sectional area gradually decreases toward one end in the longitudinal direction.

[0069] According to the sixth embodiment, the shaping mold is provided with projections on its shaping surface that include contact surfaces with the laminate. When an operator uses the shaping mold to shape a prepreg laminate, wrinkles can be generated at the locations of the projections. In other words, the operator can control the location and size of the wrinkles. Furthermore, since the projections have a shape in which the cross-sectional area gradually decreases toward one end in the longitudinal direction, the operator can bring the laminate into contact with the contact surface at a gentle incline.

[0070] The seventh embodiment of the shaping type is the shaping type of the sixth embodiment in which the projection has a mounting surface, and the mounting surface is attached to the shaping surface.

[0071] According to the seventh embodiment, the operator can attach the protrusions to the shaping surface of the mold at any position. Furthermore, the operator can retrofit the protrusions to the shaping surface, such as by adding more protrusions to the mold.

[0072] The eighth shaping jig is used when shaping a laminate for manufacturing a composite material part having a curved portion, using a laminate of multiple layers of prepreg containing reinforcing fibers and resin as constituent materials, and comprises a jig body having a contact surface with the laminate, and an installation surface for attaching the jig body to a molding die used for shaping the laminate.

[0073] According to the eighth aspect, the worker can attach a shaping jig to a mold used for shaping the laminate. By shaping the prepreg laminate using the mold to which the shaping jig is attached, the worker can create wrinkles at the attachment point of the shaping jig. In other words, the worker can control the location and size of the wrinkles.

[0074] The shaping jig according to the ninth embodiment is the shaping jig of the eighth embodiment, wherein the shaping jig has a longitudinal shape. According to the ninth embodiment, the worker can generate wrinkles along the longitudinal direction of the shaping jig in the laminate. Furthermore, the worker can easily arrange multiple shaping jigs closely together in a direction perpendicular to the longitudinal direction, which is advantageous for distributing the generation of wrinkles.

[0075] The shaping jig according to the tenth embodiment is a shaping jig according to the eighth or ninth embodiment, which includes a tapered portion in a cross section perpendicular to the longitudinal direction, where the cross-sectional area gradually decreases toward one end in the longitudinal direction.

[0076] According to the tenth embodiment, the shaping jig has a tapered shape in which the cross-sectional area gradually decreases toward one end in the longitudinal direction. Therefore, the worker can bring the laminate into contact with the contact surface at a gentle incline.

[0077] The shaping jig according to the 11th embodiment is the shaping jig according to the 8th to 10th embodiments, wherein in a cross section perpendicular to the longitudinal direction, the cross-sectional width in the direction away from the installation surface gradually decreases toward one end in the longitudinal direction.

[0078] According to the eleventh embodiment, the contact surface becomes a tapered surface in which the protruding height gradually decreases toward one end in the longitudinal direction. Therefore, the worker can bring the laminate into contact with the contact surface at an even gentler incline. [Explanation of symbols]

[0079] 1A Beam component (composite material component) 1B Frame components (composite material components) 121, 131 First corner, second corner (curved section) 132 Curved section 151, 161 Corner section (curved section) 17 Excess 2, 2A laminate 21 Prepreg 22 Reinforcement fibers 23 Resin 3, 3A mold 30 Shaping surface 3P Jig installation position (designated position) 4, 4A, 4B Shaping jig (protrusion) 40 Jig body 41, 41A, 41B contact surface 42, 42A, 42B installation surface 5, 5A shaping mold Wr wrinkles H: Height (cross-sectional width in the direction away from the mounting surface)

Claims

1. A method for shaping a laminate to manufacture a composite material part having a curved portion, using a laminate of multiple layers of prepreg containing reinforcing fibers and resin as constituent materials, A molding die and a shaping jig including an installation surface to be attached to the molding die and a contact surface to contact the laminate are prepared. The mounting surface of the shaping jig is attached to the predetermined position of the molding die to produce the shaping die for the laminate. The laminate is placed on the mold, A method for shaping a laminate, comprising applying pressure to the laminate on the shaping mold and shaping the laminate by bringing it into contact with the molding mold and the contact surface.

2. In the method for shaping a laminate according to claim 1, A method for shaping a laminate, wherein the predetermined position of the molding die is a position corresponding to the curved portion of the composite material part.

3. In the method for shaping a laminate according to claim 2, The shaping jig has a longitudinal shape, The mold has corners for shaping the composite material part into a curved portion, such as a mountain fold or a valley fold. A method for shaping a laminate, wherein in the production of the shaping mold, the shaping jig is attached to the molding mold in a direction in which the longitudinal direction intersects with the extending direction of the corner portion.

4. A manufacturing method for producing a composite material part having a curved portion, using a laminate of multiple layers of prepreg containing reinforcing fibers and resin as constituent materials, A molding die and a shaping jig including an installation surface to be attached to the molding die and a contact surface to contact the laminate are prepared. The mounting surface of the shaping jig is attached to the predetermined position of the molding die to produce the shaping die for the laminate. The laminate is placed on the mold, The laminate on the forming mold is subjected to a first treatment including a first pressurizing treatment, and the laminate is brought into contact with the molding die and the contact surface to form it. The laminate, having undergone the aforementioned shaping, is placed on the final mold, and a second process including a second pressurization and heat treatment is performed. A method for manufacturing a composite material part, comprising cutting off a portion of the processed laminate after the second processing that corresponds to the contact surface of the shaping jig.

5. In the method for manufacturing a composite material part according to claim 4, A method for manufacturing a composite material part, comprising removing the shaping jig after the first processing and using the molding die as the final molding die.

6. A mold for shaping a laminate, for manufacturing a composite material part having a curved portion using a laminate of multiple layers of prepreg containing reinforcing fibers and resin as constituent materials, A mold including a shaping surface that contacts the laminate, The shaping surface comprises a projection that is arranged on the shaping surface and includes a contact surface with the laminate, The projection has a longitudinal direction, and in a cross-section perpendicular to the longitudinal direction, the cross-sectional area gradually decreases toward one end in the longitudinal direction, thus having a shaped form.

7. In the form described in claim 6, The projection has a mounting surface, and the mounting surface is attached to the shaping surface, thus forming a shape.

8. A shaping jig used when shaping a laminate to manufacture a composite material part having a curved portion, using a laminate of multiple layers of prepreg containing reinforcing fibers and resin as constituent materials, A jig body having a contact surface with the laminate, A shaping jig comprising: an mounting surface for attaching the jig body to a mold used to shape the laminate;

9. The shaping jig according to claim 8 has a shape with a longitudinal direction.

10. The shaping jig according to claim 9 is a shaping jig that includes a tapered portion in a cross section perpendicular to the longitudinal direction, wherein the cross-sectional area gradually decreases toward one end in the longitudinal direction.

11. In the shaping jig according to claim 10, The tapered portion of the shaping jig is such that, in a cross-section perpendicular to the longitudinal direction, the cross-sectional width in the direction away from the installation surface gradually decreases toward one end in the longitudinal direction.

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