Method for forming laminated structure

Abstract

To mold a lamination structure with functional parts while reducing the processing cost.SOLUTION: In a method for molding a lamination structure, unit layers are laminated in a laminating direction to mold the lamination structure. The lamination structure includes a composite material part comprising a composite material including a first resin and reinforcing fibers, and a functional part having a predetermined function provided over the laminating direction of the composite material part. A step of forming the unit layers is repeatedly performed to form the lamination structure. The step of forming the unit layers includes: a step of molding the composite material part using the composite material; and a step of molding the functional part using a second resin that is softer than the composite material.SELECTED DRAWING: Figure 6

Description

[Technical field]

[0001] The present disclosure relates to a method for forming a laminated structure. By law This is related to. [Background technology]

[0002] Conventionally, as a method for forming a laminated structure, a three-dimensional printing method is known in which a first continuous material containing resin and a second continuous material containing fibers are individually fed into a head having a nozzle, and a print material based on the first continuous material and the second continuous material is laminated on a platform to form a structure (see, for example, Patent Document 1). In this three-dimensional printing method, for example, when forming a honeycomb board, a plate-shaped portion is formed from CFRP (Carbon-fiber-reinforced plastic) or CFRTP (Carbon-fiber-reinforced thermoplastics), and a honeycomb structure portion is formed from resin. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] International Publication No. 2015 / 065300 Summary of the Invention [Problem to be solved by the invention]

[0004] Incidentally, a laminated structure manufactured by a three-dimensional additive manufacturing method such as a three-dimensional printing method may have through holes for inserting fastening members. When through holes are provided along the stacking direction of the laminated structure, the manufacturing method of Patent Document 1 requires that all layers (unit layers) be layers of composite material (fiber layers in Patent Document 1).

[0005] However, when a laminated structure including through holes is molded in which all layers are fiber layers, if the molding accuracy of the through holes is lower than the required accuracy, it is necessary to perform post-processing on the through holes to satisfy the required accuracy. In this case, since the post-processing is performed on the layers of the composite material, there is a problem that the processing cost increases due to the high processing difficulty.

[0006] Therefore, an object of the present disclosure is to provide a method for manufacturing a laminated structure that can manufacture a laminated structure having functional portions while reducing processing costs, and the laminated structure. [Means for solving the problem]

[0007] The method for forming a laminated structure disclosed herein is a method for forming a laminated structure by stacking unit layers in a stacking direction, the laminated structure including a composite part made of a composite material including a first resin and reinforcing fibers, and a functional part having a predetermined function that is provided across the stacking direction of the composite part, and the step of forming the unit layers is repeatedly performed to form the laminated structure, and the step of forming the unit layers includes a step of forming the composite part using the composite material, and a step of forming the functional part using a second resin that is softer than the composite material.

[0008] The laminated structure of the present disclosure is a laminated structure formed by stacking unit layers in a stacking direction, the unit layers comprising a composite portion formed using a composite material containing a first resin and reinforcing fibers, and a functional portion having a predetermined function, the composite portion being provided across the stacking direction and formed using a second resin that is softer than the composite material, the functional portion having a predetermined function, the unit layers each having a boundary between the composite portion and the functional portion, and the boundaries between adjacent unit layers in the stacking direction are located at different positions in the in-plane direction of the unit layers. Effect of the Invention

[0009] According to the present disclosure, it is possible to manufacture a laminated structure having a functional portion while reducing processing costs. [Brief description of the drawings]

[0010] [Figure 1] FIG. 1 is a perspective view of an example of a laminated structure according to the first embodiment. [Diagram 2] FIG. 2 is a schematic cross-sectional view of the laminated structure according to the first embodiment. [Diagram 3] FIG. 3 is a schematic cross-sectional view of a through hole of the laminated structure. [Figure 4] FIG. 4 is a schematic cross-sectional view of an end portion of the laminated structure. [Diagram 5] FIG. 5 is a schematic cross-sectional view of a covering portion of the laminated structure. [Figure 6] FIG. 6 is an explanatory diagram relating to a method for manufacturing a laminated structure according to the first embodiment. [Figure 7] FIG. 7 is a schematic cross-sectional view of a through-hole of the laminated structure according to the second embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] Hereinafter, the embodiments of the present disclosure will be described in detail with reference to the drawings. Note that the present invention is not limited to these embodiments. In addition, the components in the following embodiments include those that are easily replaceable by those skilled in the art, or those that are substantially the same. Furthermore, the components described below can be appropriately combined, and when there are multiple embodiments, the respective embodiments can be combined.

[0012] [Embodiment 1] The method for manufacturing the laminated structure 10 according to the first embodiment is a so-called three-dimensional additive manufacturing method in which the laminated structure 10 is manufactured by stacking unit layers 11 in a stacking direction. First, the laminated structure 10 to be manufactured will be described with reference to Figs. 1 and 2.

[0013] (Laminated structure) Fig. 1 is a perspective view of an example of a laminated structure according to embodiment 1. Fig. 2 is a schematic cross-sectional view of the laminated structure according to embodiment 1. The laminated structure 10 is a structure in which a plurality of unit layers 11 are laminated in the lamination direction, and is, for example, a plate-shaped member. The laminated structure 10 has a composite material portion 14 made of a composite material and a functional portion 15 made of a resin. Therefore, a portion of the composite material portion 14 and the functional portion 15 are provided in a predetermined unit layer 11.

[0014] The composite part 14 is formed by using a composite material including a first resin and reinforcing fibers. The composite part 14 is formed by laminating a part of the composite part 14 included in the unit layer 11. The first resin is, for example, a resin such as a thermoplastic resin or a thermosetting resin. Specifically, the first resin may be PPS (Polyphenylenesulfide), PEI (Polyetherimide), PEEK (Poly Ether Ether Ketone), PAEK (Poly Aryl Ether Ketones), PEKK (Poly Ether Ketone Ketone), nylon, etc., and may be any resin material used when forming a composite material by a three-dimensional additive manufacturing method. The reinforcing fibers may be any fiber such as carbon fiber, glass fiber, aramid fiber, etc., and are not particularly limited. The composite material after curing is harder than the functional part 15.

[0015] The functional portion 15 is a portion having a predetermined function, such as a portion having a fastening function to which a fastening member is fastened, a portion having a processable function to be processed, a portion having a joinable function to be joined to another member, or a portion having a covering function to cover the composite portion 14. Specifically, in the first embodiment, the through hole 17 and the end portion 18 are used as the functional portion 15.

[0016] Fig. 3 is a schematic cross-sectional view of a through hole of a laminated structure. As shown in Fig. 3, through hole 17 is a portion having a fastening function to which a fastening member is fastened, and is provided penetrating in the lamination direction. Through hole 17 has, for example, a hollow cylindrical shape. As shown in Fig. 2, a bolt serving as a fastening member is inserted into this through hole 17.

[0017] Fig. 4 is a schematic cross-sectional view of an end of the laminated structure. As shown in Fig. 4, the end 18 is an end in an in-plane direction perpendicular to the lamination direction of the laminated structure 10. The end 18 is a part having a function to be processed and a part having a function to be joined. As shown in Fig. 2, this end 18 is processed for joining after molding, and is joined to another member.

[0018] The functional portion 15 is formed by using a second resin. The functional portion 15 is formed by laminating a part of the functional portion 15 included in the unit layer 11. The second resin is, like the first resin, a resin such as a thermoplastic resin or a thermosetting resin. A resin different from the first resin is used as the second resin. Specifically, the second resin is softer than the composite material portion 14 after curing. Here, the softness of the second resin may be such that the hardness is lower than that of the composite material after curing, and further, the Young's modulus may be low. Note that the following resins may be selected as the second resin to impart a function to the functional portion 15. Heat resistance may be imparted by applying PPS as the second resin. Furthermore, functions such as self-lubrication, high hardness, and high strength (low machinability) may be imparted by applying PEEK as the second resin. Furthermore, a function of high coatability may be imparted by applying PEI as the second resin.

[0019] In the first embodiment, one type of second resin is used in the functional portion 15, but there is no particular limitation, and multiple types may be used.

[0020] Moreover, the functional portion 15 may be as shown in Fig. 5. Fig. 5 is a schematic cross-sectional view of a covering portion of a laminated structure. The functional portion 15 shown in Fig. 5 is applied as a covering portion 19. The covering portion 19 is a portion having a covering function for covering the composite portion 14, and is provided so as to cover the surface of the composite portion 14. The covering portion 19 has, for example, a function of absorbing electromagnetic waves, or an insulating function of blocking the conduction of electric current.

[0021] Next, the unit layer 11 will be described. A given unit layer 11 of the laminated structure 10 is formed in a layered form of a part of the composite material portion 14 and a part of the functional portion 15. In the unit layer 11 in which the composite material portion 14 and the functional portion 15 are formed, a boundary 21 is formed between the composite material portion 14 and the functional portion 15.

[0022] Here, the boundaries 21 between the unit layers 11 adjacent in the stacking direction are at different positions in the in-plane direction of the unit layers 11. For example, as shown in FIG. 3, the functional portion 15 as the through hole 17 has a shape with a step 25 with respect to the composite portion 14 in order to improve the bonding to the composite portion 14. Specifically, when the uneven shape shown in FIG. 3 is used, one boundary of the adjacent unit layers 11 is positioned on the side farther from the through hole 17 in the in-plane direction, and the other boundary of the adjacent unit layers 11 is positioned on the side closer to the through hole 17 in the in-plane direction. Then, by alternately stacking one and the other of the adjacent unit layers 11, the shape of the functional portion 15 on the composite portion 14 side becomes an uneven shape that is wavy along the stacking direction. In other words, the shape of the functional portion 15 side of the composite portion 14 becomes an uneven shape that is wavy along the stacking direction, and becomes a shape complementary to the functional portion 15. That is, the step portion 25 is formed by the intersection of the boundary of the unit layers 11 and the interface between the unit layers 11. Here, in the in-plane direction, the step portion 25 has a length between one boundary of the adjacent unit layers 11 and the other boundary of the adjacent unit layers 11 of 0.2 mm or more. The length between one boundary of the adjacent unit layers 11 and the other boundary of the adjacent unit layers 11 may be 0.2 mm or more and 3 mm or less.

[0023] (Method of forming laminated structure) Next, a method for forming the above-mentioned laminated structure 10 will be described with reference to Fig. 6. Fig. 6 is an explanatory diagram of the method for forming the laminated structure according to the first embodiment. In this method, the step of forming unit layers 11 is repeated to form the laminated structure 10. In Fig. 6, a through hole 17 is used as the functional portion 15.

[0024] In the step of forming the unit layer 11, step S11 of forming the composite material portion 14 and step S12 of forming the functional portion 15 are performed. Note that, depending on the unit layer 11 to be formed, there may be only the composite material portion 14 or only the functional portion 15, so step S11 of forming the composite material portion 14 and step S12 of forming the functional portion 15 are not necessarily performed for all unit layers 11.

[0025] In step S11 of modeling the composite part 14, a discharge nozzle 31 provided in a modeling device (not shown) moves in an in-plane direction perpendicular to the stacking direction while discharging a composite material 26 from the discharge nozzle 31, thereby modeling (a part of) the composite part 14 in the unit layer 11. Note that in step S11 of modeling the composite part 14, the moving speed in the in-plane direction may be faster than in step S12 of modeling the functional part 15.

[0026] In step S12 for modeling the functional portion 15, the discharge nozzle 31 or a discharge nozzle 32 different from the discharge nozzle 31 moves in an in-plane direction perpendicular to the stacking direction while discharging the second resin 27 from the discharge nozzles 31, 32, thereby modeling (a part of) the functional portion 15 in the unit layer 11. Note that the discharge nozzles 31, 32 may be a single nozzle or a plurality of nozzles for discharging the composite material 26 and the second resin 27, respectively, as long as they are capable of switching between discharging the composite material 26 and the second resin 27. In step S12 for modeling the functional portion 15, the moving speed in the in-plane direction may be slower than that in step S11 for modeling the composite material portion 14. In step S12 for modeling the functional portion 15, by slowing down the moving speed, it is possible to increase the modeling accuracy of the functional portion 15 compared to the composite material portion 14.

[0027] Here, the order of step S11 of modeling the composite part 14 and step S12 of modeling the functional part 15 will be described. The order of step S11 of modeling the composite part 14 and step S12 of modeling the functional part 15 is determined based on the melting temperature of the resin. Specifically, in the step of forming the unit layer, the step using the resin having the lower melting temperature of the first resin and the second resin is performed first, and the step using the resin having the higher melting temperature is performed later. For example, when the melting temperature of the first resin is higher than that of the second resin, step S12 of modeling the functional part 15 is performed first, and then step S11 of modeling the composite part 14 is performed. On the other hand, when the melting temperature of the second resin is higher than that of the first resin, step S11 of modeling the composite part 14 is performed first, and then step S12 of modeling the functional part 15 is performed.

[0028] In addition, in the method for forming the laminated structure 10, when the step of forming the unit layers 11 described above is repeatedly performed, the unit layers 11 are formed so that the boundaries 21 between the unit layers 11 adjacent to each other in the stacking direction are located at different positions in the in-plane direction of the unit layers 11. As shown in Figs. 3 and 6, in the method for forming the laminated structure 10, one boundary of the adjacent unit layers 11 is formed so as to be located on the side farther from the through-hole 17 in the in-plane direction. Thereafter, in the method for forming the laminated structure 10, the other boundary of the adjacent unit layers 11 is formed so as to be located on the side closer to the through-hole 17 in the in-plane direction. In the method for forming the laminated structure 10, the adjacent unit layers 11 are alternately stacked to form the laminated structure 10 shown in Fig. 3.

[0029] In the first embodiment, the positions of the boundaries 21 in the in-plane direction of the unit layers 11 are different, but they may be at the same position.

[0030] [Embodiment 2] Next, a laminated structure 40 according to a second embodiment will be described with reference to Fig. 7. In the second embodiment, in order to avoid repetitive description, only parts different from the first embodiment will be described, and parts having the same configuration as the first embodiment will be described with the same reference numerals. Fig. 7 is a schematic cross-sectional view of a through hole of the laminated structure according to the second embodiment.

[0031] (Laminated structure) In the laminated structure 40 of the second embodiment, the boundary 21 of the unit layer 11 has a different position in the in-plane direction depending on the load distribution applied to the functional portion 15. Specifically, when the functional portion 15 is a through hole 17 to which a fastening member is fastened, the load is large on the outer layer side of the laminated structure 40 and small on the inner layer side. In this case, in order to form a load path, the laminated structure 40 is shaped so that the boundary 21 of the unit layer 11 is on the functional portion 15 side on the outer layer side of the laminated structure 40 and the boundary 21 of the unit layer 11 is on the composite portion 14 side on the inner layer side of the laminated structure 40. In other words, in the laminated structure 40, the ratio of the functional portion 15 in the unit layer 11 on the outer layer side is high and the ratio of the functional portion 15 in the unit layer 11 on the inner layer side is low.

[0032] As described above, the method for manufacturing the laminated structures 10, 40 and the laminated structures 10, 40 described in this embodiment can be understood, for example, as follows.

[0033] The method for forming the laminated structure 10, 40 in the first aspect is a method for forming the laminated structure 10, 40 by stacking unit layers 11 in a stacking direction, the laminated structure 10, 40 including a composite portion 14 made of a composite material containing a first resin and reinforcing fibers, and a functional portion 15 having a predetermined function that is provided across the stacking direction, the step of forming the unit layer 11 is repeated to form the laminated structure 40, and the step of forming the unit layer 11 includes a step S11 of forming the composite portion 14 using the composite material, and a step S12 of forming the functional portion 15 using a second resin that is softer than the composite material.

[0034] According to this configuration, the functional portion 15 can be formed using the second resin that is softer than the composite material. Therefore, the required precision of the functional portion 15 can be achieved by deformation of the functional portion 15, and hence post-processing is unnecessary, and thus processing costs can be reduced. Furthermore, even if the precision required of the functional portion 15 is higher, the functional portion 15 is easy to process, so that post-processing becomes easy, and processing costs can be reduced. As described above, the laminated structure 10, 40 having the functional portion 15 can be formed while reducing processing costs.

[0035] In a second embodiment, the first resin and the second resin are different.

[0036] According to this configuration, it is possible to use a first resin suitable for forming the composite material portion 14, and also to use a second resin suitable for forming the functional portion 15. Therefore, it is possible to suitably form the functional portion 15, which is made of a resin softer than the composite material.

[0037] In a third aspect, a boundary 21 between the composite portion 14 and the functional portion 15 is formed in the unit layer 11, and in the step of forming the unit layer 11, the unit layer 11 is formed so that the boundaries 21 between adjacent unit layers 11 in the stacking direction are at different positions in the in-plane direction of the unit layer 11.

[0038] According to this configuration, the bond between the composite material portion 14 and the functional portion 15 can be made strong.

[0039] In a fourth aspect, the functional portion has at least one of the following functions: a portion having a fastening function to which a fastening member is fastened, a portion having a processable function to be processed, a portion having a joinable function to be joined to another member, and a portion having a covering function to cover the composite portion.

[0040] This configuration can be applied to functional sites 15 having various functions, making it highly versatile.

[0041] As a fifth aspect, the functional portion 15 is a through hole 17 provided so as to penetrate throughout the stacking direction.

[0042] According to this configuration, the laminated structures 10, 40 having the through holes 17 can be manufactured while reducing processing costs.

[0043] In a sixth embodiment, the functional portion is an end portion of the laminated structure.

[0044] According to this configuration, the laminated structures 10, 40 having the end portions 18 can be manufactured while reducing processing costs.

[0045] In a seventh aspect, the functional portion is a covering portion that covers the composite material portion.

[0046] According to this configuration, the laminated structures 10, 40 having the covering portion 19 can be manufactured while reducing processing costs.

[0047] As an eighth aspect, in the step of forming the unit layer, a step using a resin having a lower melting temperature than the melting temperature of the first resin and the melting temperature of the second resin is performed first, and a step using a resin having a higher melting temperature is performed later.

[0048] According to this configuration, it is possible to make it easier for a resin with a high melting temperature to dissolve in a resin with a low melting temperature, thereby making it possible to strengthen the bond between the composite portion 14 and the functional portion 15.

[0049] As a ninth aspect, in the step of forming the unit layer, the moving speed for modeling in step S11 of modeling the composite portion 14 is faster than the moving speed for modeling in step S12 of modeling the functional portion 15.

[0050] According to this configuration, in step S11 of forming the composite portion 14, the moving speed is increased, so that the reinforcing fibers can be stretched in the fiber direction. This makes it possible to appropriately form the composite portion 14. Also, in step S12 of forming the functional portion 15, the moving speed is decreased, so that the functional portion 15 can be formed with high precision.

[0051] The laminated structure of the tenth aspect is a laminated structure formed by stacking unit layers in a stacking direction, the unit layers comprising a composite portion formed using a composite material containing a first resin and reinforcing fibers, and a functional portion having a predetermined function, the composite portion being formed using a second resin that is softer than the composite material and provided across the stacking direction, the functional portion having a predetermined function, the unit layers each having a boundary between the composite portion and the functional portion, and the boundaries between adjacent unit layers in the stacking direction are at different positions in the in-plane direction of the unit layers.

[0052] According to this configuration, it is possible to fabricate the laminated structures 10, 40 in which the composite material portion 14 and the functional portion 15 are firmly bonded to each other.

[0053] As an eleventh aspect, the boundary is positioned in the in-plane direction according to a load distribution applied to the functional portion.

[0054] According to this configuration, the laminated structures 10 and 40 suitable for the load distribution applied to the functional portion 15 can be manufactured. [Explanation of symbols]

[0055] 10. Laminated structure 11 Unit Layer 14 Composite parts 15 Functional parts 17 Through hole 18 End 19 Covering part 21 Boundary 25 Step part 26 Composite material 27 Second resin

Claims

1. A method for manufacturing a laminated structure using a three-dimensional additive manufacturing method in which unit layers are stacked in a stacking direction to manufacture a laminated structure, comprising the steps of: The laminated structure includes a composite portion made of a composite material containing a first resin and reinforcing fibers, and a functional portion having a predetermined function provided across the lamination direction, The step of forming the unit layer is repeated to form the laminated structure; The step of forming the unit layer includes: using the composite material to shape the composite section; and forming the functional portion using a second resin that is softer than the composite material; In the unit layer, a boundary between the composite material portion and the functional portion is formed, In the step of forming the unit layer, A method for manufacturing a laminated structure, in which a step using a resin with a lower melting temperature than the melting temperature of the first resin and the melting temperature of the second resin is performed first, and a step using a resin with a higher melting temperature is performed later.

2. A method for manufacturing a laminated structure using a three-dimensional additive manufacturing method in which unit layers are stacked in a stacking direction to manufacture a laminated structure, comprising the steps of: The laminated structure includes a composite portion made of a composite material containing a first resin and reinforcing fibers, and a functional portion having a predetermined function provided across the lamination direction, The step of forming the unit layer is repeated to form the laminated structure; The step of forming the unit layer includes: using the composite material to shape the composite section; and forming the functional portion using a second resin that is softer than the composite material; In the unit layer, a boundary between the composite material portion and the functional portion is formed, In the step of forming the unit layer, A method for molding a laminated structure, in which the moving speed for molding in the step of molding the composite part is faster than the moving speed for molding in the step of molding the functional part.

3. In the step of forming the unit layer, The method for forming a laminated structure according to claim 1 or 2, wherein the unit layers are formed such that the boundaries between the unit layers adjacent to each other in the stacking direction are at different positions in an in-plane direction of the unit layers.

4. A method for forming a laminated structure by stacking unit layers in a stacking direction to form a laminated structure, comprising the steps of: The laminated structure includes a composite portion made of a composite material containing a first resin and reinforcing fibers, and a functional portion having a predetermined function provided across the lamination direction, The step of forming the unit layer is repeated to form the laminated structure; The step of forming the unit layer includes: using the composite material to shape the composite section; and forming the functional portion using a second resin that is softer than the composite material; In the step of forming the unit layer, A method for manufacturing a laminated structure, in which a step using a resin with a lower melting temperature than the melting temperature of the first resin and the melting temperature of the second resin is performed first, and a step using a resin with a higher melting temperature is performed later.

5. A method for forming a laminated structure by stacking unit layers in a stacking direction to form a laminated structure, comprising the steps of: The laminated structure includes a composite portion made of a composite material containing a first resin and reinforcing fibers, and a functional portion having a predetermined function provided across the lamination direction, The step of forming the unit layer is repeated to form the laminated structure; The step of forming the unit layer includes: using the composite material to shape the composite section; and forming the functional portion using a second resin that is softer than the composite material; In the step of forming the unit layer, A method for molding a laminated structure, in which the moving speed for molding in the step of molding the composite part is faster than the moving speed for molding in the step of molding the functional part.

6. The method for forming a laminated structure according to claim 1 , wherein the first resin and the second resin are different from each other.

7. A method for manufacturing a laminated structure described in any one of claims 1 to 6, wherein the functional portion has at least one of the following functions: a portion having a fastening function to which a fastening member is fastened, a portion having a processable function to be processed, a portion having a joinable function to be joined to another member, and a portion having a covering function to cover the composite portion.

8. The method for forming a laminated structure according to claim 7 , wherein the functional portion is a through hole provided penetrating the laminated structure in the stacking direction.

9. The method for forming a laminated structure according to claim 7 , wherein the functional portion is an end portion of the laminated structure.

10. The method for forming a laminated structure according to claim 7 , wherein the functional portion is a covering portion that covers the composite material portion.

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