Manufacturing method of the structure

Abstract

To provide a manufacturing method of a structure capable of reducing an assembly cost through simplifying an assembly process.SOLUTION: A manufacturing method of a structure having a hollow part includes: a step of blocking an opening 21 of an inner structure 11 by a protective film 31; a step of filling a filler 61 in a hollow part 23 of the inner structure; a step of bonding an outer structure 41 outside the protective film 31 with its opening 21 blocked to integrate with the inner structure 11; and a step of discharging the filler 61 filled in the hollow part 23.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present disclosure relates to a method for manufacturing a structure having an internal hollow portion, and to the structure. [Background technology]

[0002] In the manufacture of a structure having a hollow portion inside, for example, there is a method of first integrating a hollow internal structure having an opening in the vertical direction with an upper outer plate and a lower outer plate that close the opening of the internal structure. Then, the lower outer plate is bonded to the lower surface of the internal structure, and the upper outer plate is bonded to the upper surface of the internal structure. In this case, when the internal structure has a complex shape, it is possible to manufacture the internal structure by a three-dimensional lamination method. On the other hand, since the upper outer plate and the lower outer plate have a plate shape, the three-dimensional lamination method does not provide good manufacturing efficiency, and therefore the upper outer plate and the lower outer plate are manufactured by molding CFRP (carbon fiber reinforced composite material) or the like. Examples of manufacturing methods for such structures include those described in the following patent documents. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2003-062961 A [Patent Document 2] JP 2015-143007 A Summary of the Invention [Problem to be solved by the invention]

[0004] In a conventional method for manufacturing a structure, the internal structure is manufactured by a three-dimensional lamination method, and the upper and lower outer panels are manufactured by molding CFRP or the like. In this case, an internal structure having a complex shape can be manufactured at low cost by the three-dimensional lamination method. However, when manufacturing the upper and lower outer panels by molding CFRP or the like, a manufacturing jig is required. In addition, processes such as gap management are required when assembling the internal structure with the upper and lower outer panels. Therefore, there is a problem in that the assembly cost increases due to the assembly of the internal structure with the upper and lower outer panels.

[0005] The present disclosure is devised to solve the above-mentioned problems, and has an object to provide a manufacturing method for a structure and a structure that reduce assembly costs by simplifying the assembly process. [Means for solving the problem]

[0006] In order to achieve the above-mentioned object, the manufacturing method of the structure disclosed herein for manufacturing a structure having a hollow portion includes the steps of blocking an opening of an internal structure with a protective film, filling the hollow portion of the internal structure with a filler, joining an external structure to the outside of the protective film that blocks the opening to integrate it with the internal structure, and discharging the filler that has been filled in the hollow portion.

[0007] The structure of the present disclosure includes an inner structure having an opening, a protective film that closes the opening, and an outer structure that is joined to the outside of the protective film that closes the opening. Effect of the Invention

[0008] According to the manufacturing method of a structure and the structure of the present disclosure, the assembly process can be simplified, thereby reducing assembly costs. [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 is an exploded perspective view of a structure, illustrating a method for manufacturing a structure according to the present embodiment. [Diagram 2]FIG. 2 is a cross-sectional view showing the structure of this embodiment. [Diagram 3] FIG. 3 is an explanatory diagram showing the steps of the method for producing the structure. [Figure 4] FIG. 4 is an explanatory diagram showing the procedure of a modified example of the method for manufacturing a structure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Preferred embodiments of the present disclosure will be described in detail below with reference to the drawings. Note that the present disclosure is not limited to these embodiments, and when there are multiple embodiments, the present disclosure also includes a configuration in which each embodiment is combined. In addition, the components in the embodiments include those that a person skilled in the art can easily imagine, those that are substantially the same, and those that are within the so-called equivalent range.

[0011] [Method of manufacturing the structure] FIG. 1 is an exploded perspective view of a structure, illustrating a method for manufacturing a structure according to the present embodiment.

[0012] In this embodiment, as shown in FIG. 1, the method for manufacturing the structure includes a step of closing the openings 21, 22 of the inner structure 11 with protective films 31, 32, a step of filling a filler into the hollow portion 33 of the inner structure 11, a step of joining outer structures 41, 42 to the outside of the protective films 31, 32 that close the openings 21, 22, and a step of discharging the filler filled in the hollow portion 23.

[0013] [Structure] FIG. 2 is a cross-sectional view showing the structure of this embodiment.

[0014] In this embodiment, as shown in FIG. 2, the structure 10 includes an inner structure 11, protective films 31 and 32, and outer structures 41 and .

[0015] The internal structure 11 has a rectangular shape. The internal structure 11 has a frame body 24 and a plurality of ribs 25. The frame body 24 is configured by joining four plate materials to form a quadrangle. The plurality of ribs 25 are disposed inside the frame body 24. The plurality of ribs 25 are joined to each other and to the inner surface of the frame body 24. The plurality of ribs 25 are formed with communication holes 26. The frame body 24 is formed with at least one communication hole 27. The communication holes 26, 27 are holes for reducing the weight of the internal structure 11.

[0016] 1 are formed by the frame 24 and the plurality of ribs 25. The inner structure 11 has a first opening 21 formed on one (lower) side of the plurality of through holes 28, and a second opening 22 formed on the other (upper) side of the plurality of through holes 28. The inner structure 11 has all of the regions of the plurality of through holes 28 communicated with each other by the communication holes 16.

[0017] The internal structure 11 is made of CFRP. The internal structure 11 is manufactured by a three-dimensional lamination method using CFRP. The internal structure 11 is a molded member in which a fibrous reinforcement is impregnated with a thermoplastic resin and hardened.

[0018] The protective films 31 and 32 are films formed of a thermoplastic resin material. The first protective film 31 has an area similar to that of the surface (lower surface) of the internal structure 11 on the first opening 21 side. The first protective film 31 closes the first opening 21 by being adhered to one surface of the internal structure 11. The second protective film 32 has an area similar to that of the surface (upper surface) of the internal structure 11 on the second opening 22 side. The second protective film 32 closes the second opening 22 by being adhered to the other surface of the internal structure 11.

[0019] Here, the first protective film 31 is fused to one surface of the internal structure 11, and the second protective film 32 is fused to the other surface of the internal structure 11. In the internal structure 11, the openings 21, 22 are closed by the protective films 31, 32, and thus the multiple through holes 28 are closed to form the hollow portion 23.

[0020] The outer structures 41 and 42 are made of FRP. The outer structures 41 and 42 are manufactured by a three-dimensional lamination method using CFRP. The outer structures 41 and 42 are molded members obtained by impregnating a fibrous reinforcement with a thermoplastic resin and hardening the structure. The first outer structure 41 is joined to the outside of the first protective film 31 fused to one surface of the inner structure 11. The second outer structure 42 is directly laminated and joined to the outside of the second protective film 32 fused to the other surface of the inner structure 11 by a three-dimensional lamination method. In this case, the three-dimensional lamination method may be an automatic operation using a three-dimensional lamination device or a manual operation by an operator. When the outer structures 41 and 42 are manufactured by the three-dimensional lamination method, the protective films 31 and 32 melt due to heat received from the outer structures 41 and 42, and are integrated with the outer structures 41 and 42 and fused to the inner structure 11 to be joined.

[0021] [Specific examples of manufacturing methods for structures] FIG. 3 is an explanatory diagram showing the steps of the method for producing the structure.

[0022] First, the inner structure 11 is manufactured using CFRP by a three-dimensional lamination device (not shown). As shown in Fig. 3(a), the inner structure 11 is composed of a frame 24 and a plurality of ribs 25, and a plurality of through holes 28 and openings 21, 22 are formed therein.

[0023] The inner structure 11 is positioned and placed on the workbench 100 so that the first opening 21 is located at the top. As shown in FIG. 3(b), first, the first protective film 31 is fused to the upper surface of the inner structure 11 to close the first opening 21. At this time, the first protective film 31 is fused to the end face of the frame 24 and the end faces of the multiple ribs 25 in the inner structure 11. It is preferable to increase the surface roughness of the end face of the frame 24 and the end faces of the multiple ribs 25 to increase the surface area and improve the adhesion with the first protective film 31. In other words, it is preferable to make the end face of the frame 24 and the end faces of the multiple ribs 25 uneven to increase the adhesion area and improve the bite with the first protective film 31 by the anchor effect.

[0024] Next, as shown in (c) of Fig. 3, the inner structure 11 is turned upside down and positioned and placed on the workbench 100 so that the second opening 22 is located at the top. Then, as shown in (d) of Fig. 3, a lid 51 is attached to the communication hole 27 of the inner structure 11 from the outside to close it, and a filler 61 is filled into the inside of the inner structure 11 from the second opening 22. In this case, the filler 61 is filled into the multiple through holes 28 (hollow portion 23) where the first opening 21 is closed by the first protective film 31. Here, as the filler 61, a granular material such as water-soluble gypsum or sand may be used.

[0025] When the filler 61 is filled inside the internal structure 11, as shown in (e) of Fig. 3, the second protective film 32 is fused to the upper surface of the internal structure 11 to close the second opening 22. At this time, the second protective film 32 is fused to the end face of the frame 24 and the end faces of the multiple ribs 25 in the internal structure 11. It is preferable to increase the surface roughness of the end face of the frame 24 and the end faces of the multiple ribs 25 to increase the surface area and improve the adhesion with the second protective film 32. In other words, it is preferable to make the end face of the frame 24 and the end faces of the multiple ribs 25 uneven in shape to increase the adhesion area and improve the bite with the second protective film 32 by the anchor effect.

[0026] By the above-mentioned work, the inner structure 11 is in a sealed state with the openings 21, 22 closed by the protective films 31, 32 and the internal hollow portion 23 filled with the filler 61.

[0027] 3(f), the second outer structure 42 is fusion-bonded to the outside of the second protective film 32. In this case, the second outer structure 42 is manufactured using CFRP by a three-dimensional lamination device (not shown). At this time, by laminating molten resin on the second protective film 32, the second protective film 32 is partially or entirely melted and partially or entirely integrated with the second outer structure 42.

[0028] After the second outer structure 42 is manufactured, when the second outer structure 42 is cooled and solidified, the integrated inner structure 11 and the second outer structure 42 are turned upside down and positioned and placed on the workbench 100 so that the first protective film 31 (first opening 21) is located at the top. Then, as shown in FIG. 3(g), the first outer structure 41 is fusion-bonded to the outside of the first protective film 31. In this case, the first outer structure 41 is manufactured using CFRP by a three-dimensional lamination device (not shown). At this time, by laminating molten resin on the first protective film 31, the first protective film 31 is partially or entirely melted and partially or entirely integrated with the first outer structure 41.

[0029] After the first outer structure 41 is manufactured, when the first outer structure 41 is cooled and solidified, the lid 51 attached to the communication hole 27 of the inner structure 11 is removed, and the filler 61 filled in the hollow portion 23 is discharged to the outside through the communication hole 27, as shown in (h) of FIG. 3. In this case, the communication hole 27 is used as a filler discharge hole. In addition, since the multiple hollow portions 23 are communicated with each other through the communication hole 26 of the rib 25, all of the filler 61 filled inside can be discharged. Then, the structure 10 having the multiple hollow portions 23 provided therein is manufactured.

[0030] [Modification of the manufacturing method of the structure] FIG. 4 is an explanatory diagram showing the procedure of a modified example of the method for manufacturing a structure.

[0031] First, the inner structure 11 is manufactured using CFRP by a three-dimensional lamination device (not shown). As shown in Fig. 4(a), the inner structure 11 is composed of a frame 24 and a plurality of ribs 25, and a plurality of through holes 28 and openings 21, 22 are formed therein.

[0032] The inner structure 11 is positioned and placed on the workbench 100 so that the first opening 21 is located at the top. As shown in (b) of Fig. 4, first, a first protective film 31 is fused to the upper surface of the inner structure 11 to close the first opening 21. At this time, the first protective film 31 is fused to the end surface of the frame 24 and the end surfaces of the multiple ribs 25 in the inner structure 11.

[0033] 4(c), next, the inner structure 11 is turned upside down and positioned on the workbench 100 so that the second opening 22 is located at the top. Then, as shown in FIG. 4(d), a second protective film 32 is fused to the upper surface of the inner structure 11 to close the second opening 22. At this time, the second protective film 32 is fused to the end face of the frame 24 and the end faces of the multiple ribs 25 in the inner structure 11.

[0034] When the protective films 31, 32 are fused to the upper and lower surfaces of the internal structure 11 to close the openings 21, 22, the filler 61 is filled into the inside of the internal structure 11 through the communication hole 27, as shown in (e) of FIG. 4. In this case, the communication hole 27 is used as a filler supply hole. In addition, since the multiple hollow portions 23 are communicated with each other through the communication hole 26 of the rib 25, the filler 61 filled through the communication hole 27 is filled into all of the hollow portions 23. Then, when the filler 61 is filled into the inside of the internal structure 11, a lid 51 is attached to the communication hole 27 of the internal structure 11 from the outside to close it. At this time, it is preferable to apply a vacuum pressure to the hollow portions 23 through the communication hole 27 to exhaust the air inside, and then attach the lid 51 to the communication hole 27.

[0035] By the above-mentioned work, the inner structure 11 is in a sealed state with the openings 21, 22 closed by the protective films 31, 32 and the internal hollow portion 23 filled with the filler 61.

[0036] 4(f), the second outer structure 42 is fusion-bonded to the outside of the second protective film 32. In this case, the second outer structure 42 is manufactured using CFRP by a three-dimensional lamination device (not shown). At this time, by laminating molten resin on the second protective film 32, the second protective film 32 is melted in part or in whole, and is integrated in part or in whole with the second outer structure 42.

[0037] After the second outer structure 42 is manufactured, when the second outer structure 42 is cooled and solidified, the integrated inner structure 11 and the second outer structure 42 are turned upside down and positioned and placed on the workbench 100 so that the first protective film 31 (first opening 21) is located at the top. Then, as shown in FIG. 4(g), the first outer structure 41 is fusion-bonded to the outside of the first protective film 31. In this case, the first outer structure 41 is manufactured using CFRP by a three-dimensional lamination device (not shown). At this time, by laminating molten resin on the first protective film 31, the first protective film 31 is partially or entirely melted and partially or entirely integrated with the first outer structure 41.

[0038] After the first outer structure 41 is manufactured, when the first outer structure 41 is cooled and solidified, the lid 51 attached to the communication hole 27 of the inner structure 11 is removed, and the filler 61 filled in the hollow portion 23 is discharged to the outside through the communication hole 27, as shown in (h) of FIG. 4. In this case, the communication hole 27 is used as a filler discharge hole. In addition, since the multiple hollow portions 23 are communicated with each other through the communication hole 26 of the rib 25, all of the filler 61 filled inside can be discharged. Then, the structure 10 having the multiple hollow portions 23 provided therein is manufactured.

[0039] [Effects of this embodiment] The manufacturing method of the structure of the first embodiment includes a step of blocking the openings 21, 22 of the internal structure 11 with protective films 31, 32, a step of filling the hollow portion 23 of the internal structure 11 with a filler 61, a step of joining the outer structures 41, 42 to the outside of the protective films 31, 32 that block the openings 21, 22 to integrate them with the internal structure 11, and a step of discharging the filler 61 filled in the hollow portion 23.

[0040] In the manufacturing method of the structure according to the first embodiment, the openings 21, 22 of the internal structure 11 are closed by the protective films 31, 32, and the hollow portion 23 is filled with the filler 61, and the external structures 41, 42 are joined to the outside of the protective films 31, 32. Therefore, the internal structure 11, the filler 61, and the protective films 31, 32 function as jigs that maintain the appropriate external shape to form the external structures 41, 42, and a separate jig for forming the external structures 41, 42 is not required. In addition, when forming the external structures 41, 42, the protective films 31, 32 can prevent leakage of the filler 61 filled in the hollow portion 23 of the internal structure 11 and can maintain the shape, so that the external structures 41, 42 can be formed with high accuracy. As a result, the assembly process of the structure 10 can be simplified to reduce the assembly cost.

[0041] In the method for manufacturing the structure according to the second embodiment, after filling the hollow portion 23 formed by the first protective film 31 with the filler 61, the second opening 22 is closed by the second protective film 32 to seal the hollow portion 23. This makes it possible to easily fill the hollow portion 23 with the filler 61, thereby improving workability.

[0042] In the method for producing a structure according to the third embodiment, the internal structure 11 has a through hole 28, and after one of the first openings 21 in the through hole 28 is blocked by the first protective film 31, the hollow portion 23 is filled with the filler 61, and then the other of the second openings 22 in the through hole 28 is blocked by the second protective film 32. As a result, after the first opening 21 of the internal structure 11 is blocked by the first protective film 31, the hollow portion 23 is filled with the filler 61, and the filler 61 can be easily filled from the opening 22 into the hollow portion 23. In addition, in this method, for example, a curved protruding portion protruding upward can be formed by the filler 61, and the second opening 22 can be blocked by the second protective film 32 so as to cover the protruding portion, allowing for a highly flexible shape formation.

[0043] In the manufacturing method of the structure according to the fourth embodiment, the openings 21, 22 are closed with the protective films 31, 32, and then the filler 61 is filled into the hollow portion 23 through the communication holes 27 as filler supply holes provided in the internal structure 11. This allows the openings 21, 22 to be properly closed with the protective films 31, 32, and the filler 61 to be filled into the hollow portion 23 without leaving any gaps.

[0044] In the method for producing a structure according to the fifth aspect, inner structure 11 has through hole 28, one first opening 21 of through hole 28 is blocked by first protective film 31, and the other second opening 22 of through hole 28 is blocked by second protective film 32, and then the hollow portion is filled with filler 61. As a result, each opening 21, 22 of inner structure 11 is blocked by each protective film 31, 32, and hollow portion 23 is filled with filler 61, so that hollow portion 23 can be easily filled with filler 61.

[0045] In the manufacturing method of the structure according to the sixth aspect, the filler 61 filled in the hollow portion 23 is discharged from the communication hole 27 as a filler discharge hole provided in the internal structure 11. This makes it possible to easily discharge the filler 61 filled in the hollow portion 23 from the existing communication hole 27, and thus simplifies the structure.

[0046] In the method for manufacturing a structure according to the seventh embodiment, the openings 21, 22 are closed by fusing the protective films 31, 32 to the internal structure 11. This allows the protective films 31, 32 to be adhered to the internal structure 11 without any gaps, and the openings 21, 22 can be appropriately closed.

[0047] In the method for manufacturing a structure according to the eighth embodiment, the outer structures 41, 42 are fused and joined to the outsides of the protective films 31, 32. As a result, since the outer structures 41, 42 are fused to the protective films 31, 32, the outer structures 41, 42 are fused to the inner structure 11 via the protective films 31, 32, and it is possible to appropriately join the inner structure 11, the protective films 31, 32, and the outer structures 41, 42.

[0048] In the method for manufacturing a structure according to the ninth aspect, the protective films 31, 32 are formed from a thermoplastic material. This allows the protective films 31, 32 to be properly adhered to the internal structure 11. If the internal structure 11 is also formed from a thermoplastic material, the protective films 31, 32 can be fused to the internal structure 11 without any gaps, and leakage of the filler 61 can be further prevented.

[0049] In the method for manufacturing a structure according to the tenth embodiment, outer structures 41, 42 are formed by a three-dimensional lamination method on the outside of protective films 31, 32. As a result, since the outer structures 41, 42 are fused to the inner structure 11 together with the protective films 31, 32, there is no need to remove the protective films 31, 32 for preventing leakage of the filler 61, and workability can be improved.

[0050] The structure according to the eleventh aspect includes an inner structure 11 having openings 21, 22, protective films 31, 32 that close the openings 21, 22, and outer structures 41, 42 that are joined to the outside of the protective films 31, 32 that close the openings 21, 22. This allows the inner structure 11 and the protective films 31, 32 to function as jigs to mold the outer structures 41, 42, eliminating the need for a separate jig for forming the outer structures 41, 42 and simplifying the assembly process, thereby reducing assembly costs.

[0051] In the above-mentioned embodiment, the internal structure 11 having two openings 21, 22 is applied, and the two openings 21, 22 are closed by the protective films 31, 32, respectively, to prevent leakage of the filler 61 filled in the hollow portion, but the present invention is not limited to this configuration. For example, an internal structure having one opening may be applied, and one opening may be closed by a protective film to prevent leakage of the filler filled in the hollow portion. That is, the shape of the internal structure 11 is not limited to the above-mentioned shape, and may be appropriately set depending on the application. In addition, the structure of the present invention can also be applied to a branched structure such as a manifold. That is, the hollow portion of the structure of the present invention does not need to be an enclosed space, and may be a tunnel shape.

[0052] In addition, in the above-described embodiment, the inner structure 11, the protective films 31, 32, and the outer structures 41, 42 are manufactured using a thermoplastic resin, but a thermosetting resin may be used instead of the thermoplastic resin.

[0053] In the above embodiment, the inner structure 11 and the outer structures 41, 42 are manufactured by a three-dimensional lamination method using CFRP, but the method is not limited to this. For example, a combing method may be applied to use a combing fiber in which a fiberized base resin and carbon fibers are mixed, so that resin is arranged between the carbon fibers in advance.

[0054] In addition, in the above-described embodiment, the inner structure 11 and the outer structures 41, 42 are made of CFRP, but any thin-layer material capable of blocking the openings 21, 22 may be used, and they may be made of, for example, a metal material such as aluminum or an inorganic material such as ceramics. [Explanation of symbols]

[0055] 10 Structure 11 Internal structure 21 First opening 22 Second opening 23 Hollow part 24 Frame 25 Ribs 26,27 Communication hole (penetration part) 31 First protective film 32 Second protective film 41 1st external structure 42 Second external structure 51 Lid 61 Filling material

Claims

1. A method for manufacturing a structure having a hollow portion, comprising the steps of: a step of sealing the opening by adhering a protective film to an end surface of the frame of the internal structure; filling a hollow portion of the internal structure whose opening is closed by the protective film with a filler; a step of joining an outer structure to the outside of the protective film that closes the opening and integrating it with the inner structure; Discharging the filler filled in the hollow portion; A method for manufacturing a structure having the above structure.

2. After filling the hollow portion with the filler, the opening is closed with the protective film to seal the hollow portion. A method for producing the structure according to claim 1.

3. The internal structure has a through-hole, and after a first opening on one side of the through-hole is blocked with a first protective film as the protective film, the hollow portion is filled with the filler, and then a second opening on the other side of the through-hole is blocked with a second protective film as the protective film. A method for producing the structure according to claim 2.

4. After closing the opening with the protective film, the filler is filled into the hollow portion through a filler supply hole provided in the internal structure. A method for producing the structure according to claim 1.

5. The internal structure has a through-hole, and a first opening on one side of the through-hole is blocked by a first protective film as the protective film, and a second opening on the other side of the through-hole is blocked by a second protective film as the protective film, and then the hollow portion is filled with the filling material. A method for producing the structure according to claim 4.

6. The filler filled in the hollow portion is discharged from a filler discharge hole provided in the internal structure. A method for producing the structure according to any one of claims 1 to 5.

7. The opening is closed by fusing the protective film to the internal structure. A method for producing the structure according to any one of claims 1 to 6.

8. The outer structure is fused and bonded to the outside of the protective film. A method for producing the structure according to any one of claims 1 to 7.

9. The protective film is formed of a thermoplastic material. A method for producing the structure according to any one of claims 1 to 8.

10. The outer structure is formed on the outside of the protective film by a three-dimensional lamination method. A method for producing the structure according to any one of claims 1 to 9.

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