Window frame manufacturing method and aircraft window frame

Abstract

Provided is a window frame manufacturing method including the following procedures. A first process, including stacking a plurality of sheet-like first fiber-reinforced composite materials containing a plurality of continuous fibers and a first resin with which the plurality of continuous fibers are impregnated, and heating, is executed to form an annular base part extending in the circumferential direction. A second process, including placing a substantially annular additional part formed of a second fiber-reinforced composite material containing a reinforcing fiber and a second resin and extending along the circumferential direction on the base portion, and heating, is executed to integrate the base part and the additional part.

Description

Window frame manufacturing method and window frame for aircraft

[0001] The present disclosure relates to a method for manufacturing a window frame using a fiber-reinforced composite material, and to a window frame for an aircraft formed by the manufacturing method.

[0002] An aircraft window frame is a frame body that holds a transparent window panel and includes a base portion and an additional portion that is integrated with the base portion. The base portion is supported in a window opening opened in the skin of the aircraft. The additional portion supports the periphery of the window panel. Patent Document 1 discloses a method for manufacturing an aircraft window frame that includes a base portion and an additional portion. In the manufacturing method of Patent Document 1, the base portion formed by stamp molding is placed in a mold, and injection molding is performed to extrude the material of the additional portion into the cavity of the mold.

[0003] When forming an additional part using injection molding, the material from which the additional part is formed is limited to materials that can be used in injection molding. For example, in order to improve the strength and quality of window frames, a manufacturing method for aircraft window frames that allows for greater design freedom is required.

[0004] Japanese Patent Application Laid-Open No. 2023-10612

[0005] An object of the present disclosure is to provide a manufacturing method for a window frame that allows for increased design freedom, and to provide a window frame for an aircraft produced by the manufacturing method.

[0006] A method for manufacturing a window frame according to one aspect of the present disclosure includes stacking a plurality of sheets of a first fiber-reinforced composite material including a plurality of continuous fibers and a first resin impregnated into the plurality of continuous fibers, and performing a first process including heating to form an annular base portion extending in a circumferential direction, and performing a second process including placing a substantially annular additional portion formed of a second fiber-reinforced composite material including reinforcing fibers and a second resin and extending along the circumferential direction on the base portion, and heating the additional portion to integrate the base portion and the additional portion.

[0007] An aircraft window frame according to another aspect of the present disclosure is an aircraft window frame manufactured by the above-described window frame manufacturing method.

[0008] According to the present disclosure, it is possible to provide a manufacturing method for a window frame that allows for increased freedom in design of the window frame. According to the present disclosure, it is possible to provide a window frame for an aircraft produced by the manufacturing method.

[0009] FIG. 1 is a perspective view of a window frame produced by the window frame manufacturing method of the present disclosure. FIG. 2 is a cross-sectional view taken along line II-II of FIG. 1. FIG. 3 is a cross-sectional view showing the window frame assembled to an aircraft body. FIG. 4 is a flowchart showing a first embodiment of a window frame manufacturing method according to the present disclosure. FIG. 5 is a plan view with an enlarged view showing an annular prepreg used as a constituent material of the base portion. FIG. 6 is a diagram showing steps P11 to P14 of the first process for forming the base portion. FIG. 7 is a diagram showing steps P21 to P24 of the second process for integrating an additional portion with the base portion. FIG. 8 is a diagram showing steps P31 to P34 of the third process for forming the additional portion and the fourth process for integrating the additional portion with the base portion. FIG. 9A is a diagram showing variations in the formation of a prepreg laminate. FIG. 9B is a diagram showing variations in the formation of a prepreg laminate. FIG. 9C is a diagram showing variations in the formation of a prepreg laminate. FIG. 10 is a diagram showing a specific example of a second fiber-reinforced composite material. FIG. 11 is a flowchart showing a second embodiment of a window frame manufacturing method. Fig. 12 is a flowchart showing a third embodiment of a method for manufacturing a window frame. Fig. 13 is a cross-sectional view showing steps P41 and P42 of the manufacturing method of the third embodiment. Fig. 14 is a flowchart showing a fourth embodiment of a method for manufacturing a window frame. Fig. 15 is a cross-sectional view showing a manufacturing example using a consolidation mold according to a modified example. Fig. 16 is a cross-sectional view showing a manufacturing example using a consolidation mold according to another modified example.

[0010] A method for manufacturing a window frame according to the present disclosure will be described below with reference to the drawings. The window frame manufactured according to the present disclosure includes an integrated product of an annular base portion and an annular additional portion. The "annular" form of the window frame is not limited. For example, as long as the "annular" form has an opening in the central region, the outer shape may be various shapes such as a circle, an ellipse, a square, a rectangle, a rectangle with some or all curved corners, a triangle, or a polygon with pentagons or more. "Annular" includes not only a completely closed annular shape, but also a substantially annular shape that is interrupted at one or more points in the circumferential direction. One application of window frames manufactured by the manufacturing method according to the present disclosure is window frames for aircraft. The window frames according to the present disclosure can also be used for window frames for flying objects other than aircraft, railway vehicles, linear motor vehicles, automobiles, ships, submarines, and the like. The following embodiment illustrates a method for manufacturing a window frame for an aircraft.

[0011] [Configuration of the window frame] Figure 1 is a perspective view of a window frame 1 produced by a manufacturing method described below. Figure 2 is a cross-sectional view taken along line II-II in Figure 1. The window frame 1 includes a base portion 11 and an additional portion 12. The window frame 1 includes a pair of semicircular ring portions and a straight portion connecting the ends of the semicircular ring portions. The window frame 1 has an annular shape similar to the Arabic numeral zero in a plan view. In other words, the window frame 1 has a shape similar to an oval in a plan view, or a shape similar to the letter O in a plan view.

[0012] The base portion 11 includes an annular body extending in the circumferential direction. The base portion 11 includes an outer circumferential portion 111, an inner circumferential portion 112, and a step portion 113. The outer circumferential portion 111 is formed in a flat plate shape along a first plane. The inner circumferential portion 112 is formed in a flat plate shape along a second plane substantially parallel to the first plane. The inner circumferential portion 112 is offset from the outer circumferential portion 111 in a first direction X1 perpendicular to the first and second planes. The step portion 113 is connected to the outer circumferential portion 111 and the inner circumferential portion 112 and is formed in a curved plate shape whose cross section perpendicular to the circumferential direction and the first and second planes is curved in an S-shape. The step portion 113 connects the outer circumferential portion 111 and the inner circumferential portion 112 and forms a step between the outer circumferential portion 111 and the inner circumferential portion 112. The step portion 113 has a first bent portion 1A and a second bent portion 1B. The first bent portion 1A is continuous with the outer peripheral portion 111. The second bent portion 1B is continuous with the inner peripheral portion 112. The inner peripheral edge of the inner peripheral portion 112 corresponds to the inner peripheral edge 1C of the window frame 1. The inner peripheral edge 1C defines the opening 13 of the window frame 1. The outer peripheral edge of the outer peripheral portion 111 corresponds to the outer peripheral edge 1D of the window frame 1.

[0013] The additional portion 12 includes an annular body extending along the circumferential direction of the base portion 11. In this embodiment, the additional portion 12 has a circumferentially continuous shape, in other words, a circularly connected shape. While the additional portion 12 has a circumferentially continuous shape in this embodiment, the additional portion 12 does not have to be circumferentially continuous as long as it includes discontinuous portions in the circumferential direction and has a substantially circular shape. The additional portion 12 is integrated with the inner circumferential portion 112 and the stepped portion 113. The additional portion 12 is disposed on the first surface 112a of the inner circumferential portion 112 in the first direction X1 and fills a portion of the step between the outer circumferential portion 111 and the inner circumferential portion 112. The thickness of the additional portion 12 in the first direction X gradually decreases from the stepped portion 113 toward the inner circumferential edge 1C. In other words, the exposed surface of the additional portion 12 in the first direction X1 includes an inclined surface SL that slopes downward from the vicinity of the first bent portion 1A toward the inner circumferential edge 1C. 2 is an example. For example, the exposed surface may include a plane parallel to the first plane or the second plane instead of the inclined plane SL, or may include a stepped surface.

[0014] The base portion 11 is formed by stacking multiple sheets of a first fiber-reinforced composite material, the first fiber-reinforced composite material including a plurality of continuous fibers and a first resin impregnated into the plurality of continuous fibers, and performing a first process including heating. The additional portion 12 is formed from a second fiber-reinforced composite material including reinforcing fibers and a second resin. The additional portions 12 are annularly arranged on the base portion 11, and a second process including heating is performed, thereby integrating the base portion 11 and the additional portions 12. In the present disclosure, the additional portions 12 are integrally molded with the base portion 11 by a consolidation process rather than injection molding. By integrally molding the additional portions 12 with the base portion 11 by a consolidation process, the design freedom of the window frame 1 can be improved compared to when injection molding is used. The manufacturing method of the window frame 1 of the present disclosure has the advantage, in particular, of improving the isotropy of the linear expansion coefficient of the additional portions 12 and suppressing the generation of thermal stress between the additional portions 12 and the base portion 11.

[0015] FIG. 3 is a cross-sectional view showing the window frame 1 mounted to the fuselage of an aircraft. A window opening 14a is formed in an outer panel 14 that constitutes the fuselage wall of the aircraft. A transparent window panel 15 is placed in the window opening 14a. The window frame 1 is a member for attaching the window panel 15 placed in the window opening 14a to the outer panel 14. The outer peripheral portion 111 of the base portion 11 overlaps the interior-side surface of the outer panel 14. The base portion 11 is fixed to the outer panel 14 by, for example, fasteners. The peripheral edge 15a of the window panel 15 overlaps an area close to the inner peripheral edge 1C of the additional portion 12 in the first direction X1. The additional portion 12 supports the peripheral edge 15a of the window panel 15. The peripheral edge 15a of the window panel 15 is machined to include a portion that faces the inner peripheral edge 1C and the inclined surface SL. The adhesive 16 bonds the peripheral edge 15a of the window panel 15 to the inner peripheral edge 1C and the inclined surface SL.

[0016] [Method of Manufacturing Window Frame] Figure 4 is a flowchart showing a first embodiment of a method of manufacturing a window frame 1 according to the present disclosure. In the method of manufacturing the window frame 1, a first process is performed in step S1 to form the annular base portion 11. Next, a second process is performed in step S2 to integrate the additional portion 12 with the base portion 11. The second process in step S2 may be divided into two processes, step S3 and step S4. When the second process in step S2 is divided, the annular additional portion 12 is separately formed in step S3 by a third process, and then the additional portion 12 is integrated with the base portion 11 by a fourth process in step S4.

[0017] When the manufacturing method of the window frame 1 includes the first and second processes, the first and second processes include at least a heating process. When the manufacturing method of the window frame 1 includes the first, third, and fourth processes, the first, third, and fourth processes include at least a heating process. At least one of the first to fourth processes may further include a pressurizing process. At least one of the first to fourth processes may include a pressurizing process simultaneously with the heat treatment, or may be performed as a separate process. At least one of the first to fourth processes may include only the heat treatment, and the pressurizing process may be omitted. Examples of heat treatments include hot press molding, autoclave molding, and oven molding. At least one of the base portion 11 and the additional portion 12 may be formed using a mold. Forming the base portion 11 and the additional portion 12 by heating and pressurizing using a mold is one preferred manufacturing method.

[0018] A specific example of the first process will be described with reference to Figures 5 and 6. In the first process, a plurality of sheets of the first fiber-reinforced composite material are stacked and subjected to a process including heating to produce an annular base portion 11. Figure 5 shows an annular prepreg 2, which is an example of the sheet-like first fiber-reinforced composite material. The annular prepreg 2 is an annular body resembling the Arabic numeral zero, and has a hollow opening 2H.

[0019] Fig. 5 shows a schematic enlarged view of a portion 2a of the annular prepreg 2. The annular prepreg 2 is made of a sheet material including a thermoplastic resin 21, which is an example of a first resin, and continuous fibers 22. The continuous fibers 22 are impregnated into the thermoplastic resin 21 in a state where a plurality of fibers are arranged substantially parallel to each other. Fig. 5 shows an example in which the fiber direction of the continuous fibers 22 is ±45°, but the fiber direction is not limited to ±45° and can be determined arbitrarily.

[0020] The annular prepreg 2 can be formed, for example, by punching a prepreg sheet containing a thermoplastic resin 21 and continuous fibers 22. In the punching process, an annular portion corresponding to the annular prepreg 2 may be punched out as a single piece from the prepreg sheet, or the annular portion corresponding to the annular prepreg 2 may be divided and punched out from the prepreg. In the latter case, the prepreg pieces punched out from the prepreg sheet are arranged in a ring shape to form the annular prepreg 2.

[0021] 6 is a diagram showing steps P11 to P14 of the first process for forming the base portion. In step P11, a required number of annular prepregs 2 are prepared. A prepreg laminate 20 is formed by stacking multiple annular prepregs 2. In step P11, the annular prepregs 2 may be slit to prevent wrinkles and tears from occurring in the annular prepregs 2 in subsequent steps. The slitting includes making linear cuts at a predetermined angle from the outer peripheral edge to the inner peripheral edge of the annular prepregs 2 in a plan view. The predetermined angle includes an angle parallel to the fiber direction of the annular prepregs 2.

[0022] In process P12, the prepreg laminate 20 is set in the base portion mold 3. The base portion mold 3 includes a first molding die 31 and a second molding die 32. The first molding die 31 has a first base 33 having a size equal to or larger than the annular prepreg 2, a first shaping portion 34 provided near the periphery of the first base 33, and a pressing portion 35 on the inside of the first shaping portion 34. The second molding die 32 has a second base 36 having a size equal to or larger than the annular prepreg 2, and a second shaping portion 37 provided near the periphery of the second base 36 in a position facing the first shaping portion 34. The first shaping portion 34 and the second shaping portion 37 are mold parts for shaping the first bent portion 1A and the second bent portion 1B in the base portion 11 to form the step portion 113.

[0023] The prepreg laminate 20 is placed between the first molding die 31 and the second molding die 32. The prepreg laminate 20 is formed by sequentially laminating annular prepregs 2 on the surface of the first molding die 31. A prepreg laminate 20 previously formed by sequentially laminating annular prepregs 2 may be placed on the surface of the first molding die 31. The prepreg laminate 20 may be positioned and fixed by providing a tab with a pin hole protruding from the inner periphery of the annular prepreg 2 and inserting a pin provided on the first molding die 31 through the pin hole. The prepreg laminate 20 may be positioned and fixed without providing a tab by sandwiching the vicinity of the inner periphery of the prepreg laminate 20 between the periphery of the pressing portion 35 and the second molding die 32.

[0024] In process P13, the prepreg laminate 20 is heated and pressurized by the base portion mold 3 to produce a shaped base portion 11. The second molding die 32 moves toward the first molding die 31 to press the prepreg laminate 20. The first shaping section 34 and the second shaping section 37 press the prepreg laminate 20, forming a step portion 113. The heating temperature is set to a temperature that allows shaping of the prepreg laminate 20 but does not cause the laminated annular prepregs 2 to weld together. For example, when the melting point of the thermoplastic resin 21 that forms the matrix of the annular prepreg 2 is Th [°C], the heating temperature during shaping in process P13 can be selected from the range of Th [°C] to Th-40 [°C]. By selecting such a heating temperature, even when a press load is applied during shaping, adjacent annular prepregs 2 do not weld together and can slip relative to each other. Therefore, damage to the annular prepregs 2 during shaping can be suppressed.

[0025] In process P14, the molded base portion 11 is removed from the base portion mold 3. The shaped base portion 11 has shape retention, although the laminated annular prepregs 2 are not completely welded together. The base portion 11 undergoes a heat treatment in the second process, resulting in interlayer welding.

[0026] 7 is a diagram showing steps P21 to P24 of the second process for integrating the additional portion 12 with the base portion 11. In the second process, a consolidation mold 5 including a third molding die 51 and a fourth molding die 52 is used. The third molding die 51 has a receiving surface 51A near the outer periphery with which one side of the shaped base portion 11 comes into contact. A positioning pin 53 is erected in the central region of the third molding die 51. The fourth molding die 52 has a molding surface 52A near the outer periphery for molding the additional portion 12 on the base portion 11. A through hole 54 through which the positioning pin 53 is inserted during molding is formed in the central region of the fourth molding die 52. In step P21, the base portion 11 is set on the receiving surface 51A of the third molding die 51.

[0027] In process P22, an additional portion material 120, which is a constituent material of the additional portion 12, is placed on a portion of the base portion 11 set in the third molding die 51 that corresponds to the inner periphery 112. The additional portion material 120 includes a second fiber-reinforced composite material that includes reinforcing fibers and a second resin. The second resin is preferably a resin that has a linear expansion coefficient similar to that of the thermoplastic resin 21 of the annular prepreg 2. When the second resin has a linear expansion coefficient similar to that of the thermoplastic resin 21 of the annular prepreg 2, the occurrence of thermal stress during molding can be suppressed. The additional portion material 120 is placed annularly along the circumferential direction of the inner periphery 112.

[0028] Processes P23 and P24 are consolidation processes. In process P23, the positioning pins 53 of the third molding die 51 are inserted into the through holes 54 of the fourth molding die 52. In process P24, the fourth molding die 52 applies a press load to the laminate of the base portion 11 and the additional portion material 120 under heating. With the additional portion material 120 supported by the receiving surface 51A of the third molding die 51, the molding surface 52A of the fourth molding die 52 presses down on the additional portion material 120 to form the additional portion 12. The heating temperature in process P24 is set to a temperature at which the annular prepregs 2 forming the base portion 11 are welded together. That is, in process P24, press molding is performed by selecting a heating temperature exceeding the melting point Th [°C] of the thermoplastic resin 21. By press molding at a heating temperature exceeding the melting point Th [°C] of the thermoplastic resin 21, the additional portion material 120 is molded into the additional portion 12, the base portion 11 and the additional portion 12 are integrated, and further welding of the annular prepregs 2 to each other is achieved.

[0029] The additional portion 12 may be produced by a separate process, rather than being formed using the consolidation mold 5 as shown in Fig. 7. Fig. 8 is a diagram showing processes P31 to P34, including a third process for forming the additional portion 12 and a fourth process for integrating the additional portion 12 with the base portion 11.

[0030] In process P31, the base portion 11 is produced. The process for producing the base portion 11 is as shown in processes P11 to P14 in Figure 6. In process P32, the additional portion 12 is produced. There is no particular limitation on the method for producing the additional portion 12, but heat treatment using a mold is one preferred method. For example, an additional portion mold having a cavity capable of molding the additional portion 12 is used, and the second fiber-reinforced composite material is placed in the cavity, followed by heating and, if necessary, pressure application.

[0031] In process P33, the base portion 11 and the additional portion 12, which have been fabricated separately, are placed in the third molding die 51. Process P34 is the same as process P24 described above. In process P34, a heat treatment is performed to heat the consolidation mold 5 with the additional portion 12 overlapping the inner periphery 112 of the base portion 11. In process P34, pressure may be applied as necessary. Since the additional portion 12 has already been molded, in process P34, the base portion 11 and the additional portion 12 are integrated and the annular prepregs 2 are welded together.

[0032] [Details of First Process] The first process for forming the base portion 11 uses an annular prepreg 2 formed from a first fiber-reinforced composite material including a thermoplastic resin 21 as a first resin and continuous reinforcing fibers 22. Examples of the thermoplastic resin 21 include polyetheretherketone (PEEK), polyaryletherketone (PAEK), polyetherketoneketone (PEKK), polyetherimide (PEI), polyamide (PA), polyacetal (POM), polyphenylenesulfide (PPS), and a thermoplastic epoxy resin. For example, carbon fiber, aramid fiber, glass fiber, ceramic fiber, metal fiber, or organic fiber can be used as the continuous fiber 22. Carbon fiber is preferable as the continuous fiber 22 because it is lightweight and has high strength.

[0033] The second resin and reinforcing fibers constituting the second fiber-reinforced composite material used in the second treatment described below may be made of the same material as the thermoplastic resin 21 and the same fibers as the continuous fibers 22. At least one of the first resin and the second resin may contain a thermoplastic resin. At least one of the first resin and the second resin may contain a thermosetting resin.

[0034] The base portion 11 is formed of a prepreg laminate 20 in which a plurality of annular prepregs 2 are laminated. Fig. 5 shows an example in which the continuous fibers 22 are oriented at a fiber direction of 45°. It is desirable that the fiber directions of adjacent annular prepregs 2 differ from each other. Figs. 9A to 9C are diagrams showing variations in forming the prepreg laminate 20.

[0035] 9A shows an example of forming a prepreg laminate 20 by combining a first annular prepreg 2A having a fiber direction of +45° and a second annular prepreg 2B having a fiber direction of 0°. FIG. 9B shows an example of forming a prepreg laminate 20 by combining a first annular prepreg 2A having a fiber direction of +45°, a second annular prepreg 2B having a fiber direction of 0°, and a third annular prepreg 2C having a fiber direction of 90°. FIG. 9C shows an example of forming a prepreg laminate 20 by combining a first annular prepreg 2A having a fiber direction of +45°, a second annular prepreg 2B having a fiber direction of 0°, a third annular prepreg 2C having a fiber direction of 90°, and a fourth annular prepreg 2D having a fiber direction of -45°. In this way, by multi-layering multiple types of annular prepregs 2 having different fiber directions in a plane, a base portion 11 having quasi-isotropy can be formed. The fiber direction shown in Fig. 9 is an example, and the fiber directions of the multiple types of annular prepregs 2 may be other than the fiber directions shown in Fig. 9. The prepreg laminate 20 may be formed by multi-layering five or more types of annular prepregs 2 having different fiber directions.

[0036] In the first process, as described above, the prepreg laminate 20 is heated and pressurized using the base portion mold 3 to produce the shaped base portion 11. As the heating temperature in the first process, an example of a temperature based on the melting point Th [°C] of the thermoplastic resin 21 was given in the explanation of process P13. The heating temperature when forming the base portion 11 can be appropriately selected from the range of 200°C or higher and 400°C or lower. The pressure for shaping the base portion 11 can be appropriately selected from the range of 0.1 MPa or higher and 7.0 MPa or lower. The above heating temperature range and pressure range can also be applied to the heating and pressurization in the second process described below.

[0037] [Details of the Second Process] The additional portion 12 formed in the second process or the third process includes a second fiber-reinforced composite material containing reinforcing fibers and a second resin. Specific examples of the reinforcing fibers included in the second fiber-reinforced composite material are the same as the material used for the continuous fibers 22. Specific examples of the second resin included in the additional portion 12 are the same as the material used for the thermoplastic resin 21. The following first to fifth examples are shown as specific examples of the second fiber-reinforced composite material. First Example: A solid composite material having at least one fiber and a second resin. Second Example: A fibrous composite material having at least one continuous fiber and at least one fibrous second resin. Third Example: A linear composite material having at least one fiber and a second resin. Fourth Example: A powdery composite material consisting of a plurality of particles having a fiber and a second resin. Fifth Example: A composite material formed by mixing two or more of the composite materials of the first to fourth examples.

[0038] When the solid composite material of the first example is used as the second fiber-reinforced composite material, in the second process, a plurality of solid composite materials are placed on the base portion 11 set in the third molding die 51 of the consolidation mold 5. Specifically, in step P22 of FIG. 7 , a plurality of solid composite materials as the additional portion material 120 are placed along the circumferential direction of the base portion 11 on the inner periphery 112 of the base portion 11. In other words, in step P22 of FIG. 7 , the solid composite materials are placed in a ring shape on the inner periphery 112. This placement can be performed by various methods, including manually placing the solid composite material by an operator, using a placement jig such as a formwork, using a device that dispenses or extrudes the composite material, or using a robot that automatically places the composite material. After the solid composite material is placed, the fourth molding die 52 is fitted into the third molding die 51, and the additional portion 12 is integrated with the base portion 11 by heating and pressurizing in step P24.

[0039] In the third process of separately fabricating the additional portion 12, in step P32 of Fig. 8, a plurality of the solid composite materials are placed in the cavity of the additional portion mold so as to be aligned along a direction corresponding to the circumferential direction of the base portion 11. In other words, a plurality of solid composite materials are placed in the additional portion mold so as to match the annular shape of the inner peripheral portion 112. The placement method can be the same as the method for placing the solid composite material in the inner peripheral portion 112. After the solid composite material is placed, the additional portion 12 is formed by applying heat and pressure using the additional portion mold.

[0040] FIG. 10 is a diagram showing a specific example of a second fiber-reinforced composite material. In FIG. 10, pellets 61, chops 62, perforated preforms 63, and filaments 66 are exemplified as the second fiber-reinforced composite material. In addition, flakes, crushed pieces, and grains can also be used as the second fiber-reinforced composite material. Flakes and crushed pieces can be obtained by processing a sheet, substrate, or waste material containing reinforcing fibers and the second resin, such as by cutting or crushing. Using waste material contributes to resource recycling. Using waste material can further reduce manufacturing costs. Grains can be produced by crushing or grinding a base material such as pellets 61, chops 62, flakes, or crushed pieces using a grinder such as a mill. As the second fiber-reinforced composite material, only one type of composite material from among pellets 61, chops 62, perforated preforms 63, filaments 66, flakes, crushed pieces, and grains may be used, or any combination of two or more types of composite materials may be used.

[0041] The pellets 61 and chops 62 are examples of the first example solid composite material. The pellets 61 contain, for example, carbon fiber and thermoplastic resin. The pellets 61 have a cylindrical shape. The pellets 61 can be produced by feeding raw materials containing carbon fiber and thermoplastic resin into an extruder, continuously extruding a long body with a circular cross section, and cutting the long body after cooling. The axial length of the pellets 61 is selected, for example, from a range of 1 mm to 30 mm. The radial length of the pellets 61 is selected, for example, from a range of 1 mm to 30 mm. The chops 62 are components obtained by cutting a base sheet, in which carbon fibers aligned in a predetermined fiber direction are impregnated with a thermoplastic resin, into strips. The chops 62 may also be used in the form of a chopped sheet, in which the chops 62 are randomly arranged and welded together.

[0042] In the second process step P22, a plurality of pellets 61 or a plurality of chops 62 are arranged in a ring shape on the base portion 11 set in the consolidation mold 5. In the third process step P32, a plurality of pellets 61 or a plurality of chops 62 are arranged in a ring shape in the cavity of the mold for the additional portion.

[0043] When arranging the plurality of pellets 61 or the plurality of chops 62 in an annular shape, at least some of the plurality of pellets 61 or at least some of the plurality of chops 62 may be arranged without restricting their orientation relative to the base portion 11. In other words, the plurality of pellets 61 or the plurality of chops 62 may be arranged relative to the base portion 11 in a state in which their orientation is random. When the plurality of pellets 61 or the plurality of chops 62 are arranged in a state in which their orientation is random, the orientation of the reinforcing fibers contained in each of the plurality of pellets 61 or the plurality of chops 62 is not uniform but random. When the plurality of pellets 61 or the plurality of chops 62 are in a state in which the orientation of the reinforcing fibers contained in each of the plurality of pellets 61 or the plurality of chops 62 is not uniform but random, the isotropy of the linear expansion coefficient of the additional portion 12 can be improved by melting and integrating the plurality of pellets 61 or the plurality of chops 62 by heat treatment. The improved isotropy suppresses thermal stress generated between the base portion 11 and the additional portion 12 during molding. Suppressing the thermal stress generated during molding suppresses deformation of the window frame 1, resulting in stable quality. There are no limitations on the arrangement of the multiple pellets 61 or the multiple chops 62. The multiple pellets 61 or the multiple chops 62 may be arranged relative to the base portion 11 with the direction of the reinforcing fibers contained in each pellet 61 or chops 62 aligned.

[0044] When using the fibrous composite material of the second example, in the second process, the fibrous composite material is placed on the base portion 11 set in the third molding die 51 of the consolidation mold 5. Specifically, in step P22 of FIG. 7 , the fibrous composite material as the additional portion material 120 is placed on the inner periphery 112 of the base portion 11 along the circumferential direction of the base portion 11. In other words, in step P22 of FIG. 7 , the fibrous composite material is placed in an annular shape on the inner periphery 112. In the case of the third process, in step P32 of FIG. 8 , the fibrous composite material is placed in the cavity of the additional portion mold along a direction corresponding to the circumferential direction of the base portion 11. In other words, the fibrous composite material is placed in the additional portion mold so as to match the annular shape of the inner periphery 112.

[0045] The fibrous composite material of the second example may include one continuous fiber and one fibrous second resin. The fibrous composite material of the second example may include one continuous fiber and multiple fibrous second resins. The fibrous composite material of the second example may include multiple continuous fibers and one fibrous second resin. The fibrous composite material of the second example may include multiple continuous fibers and multiple fibrous second resins. The perforated preform 63 is an example of the fibrous composite material of the second example. The perforated preform 63 is a composite of multiple continuous fibers 64 and multiple fibrous resins 65. The continuous fiber 64 is, for example, carbon fiber. The fibrous resin 65 is, for example, thermoplastic resin fiber.

[0046] In step P22 of the second process, the perforated preform 63 is arranged in an annular shape on the base portion 11 set in the consolidation mold 5. In step P32 of the third process, the perforated preform 63 is arranged in an annular shape in the cavity of the mold for the additional portion. When arranging the perforated preform 63, the perforated preform 63 may be arranged in an annular shape with the fiber direction of the perforated preform 63 aligned along the circumferential direction of the base portion 11. When arranging the perforated preform 63, the perforated preform 63 may be arranged in an annular shape with the fiber direction of the perforated preform 63 and the circumferential direction of the base portion 11 set in a different direction. When arranging the perforated preform 63, cut pieces of the perforated preform 63 may be arranged in an annular shape along the circumferential direction of the base portion 11.

[0047] When the linear composite material of the third example is used, in the second process, a predetermined number of linear composite materials are placed on the base portion 11 set in the third molding die 51 of the consolidation mold 5. Specifically, in step P22 of Fig. 7, linear composite material as the additional portion material 120 is placed on the inner periphery 112 of the base portion 11 along the circumferential direction of the base portion 11. In the case of the third process, in step P32 of Fig. 8, linear composite material is placed in the cavity of the additional portion mold (not shown) along the direction corresponding to the circumferential direction of the base portion 11.

[0048] The filament 66 is an example of a linear composite material of the third example. The filament 66 is a linear body composed of a fiber serving as a core material and a resin coating the core material. The core material includes a single fiber or an aggregate of multiple fibers. The resin coating the core material includes, for example, a thermoplastic resin. In the second process step P22, one or multiple filaments 66 are annularly arranged on the base portion 11 set in the consolidation mold 5. In the third process step P32, the filament 66 is annularly arranged in the cavity of the additional portion mold. When arranging the filament 66, the longitudinal direction of the filament 66 may be aligned along the circumferential direction of the base portion 11, or the longitudinal direction of the filament 66 may be aligned in a different direction from the circumferential direction of the base portion 11. When arranging the filament 66, the filament 66 may be cut to a predetermined length and then annularly arranged along the circumferential direction of the base portion 11.

[0049] When the powdered composite material of the fourth example is used, in the second process, the powdered composite material is placed on the base portion 11 set in the third molding die 51 of the consolidation mold 5. Specifically, in step P22 of Fig. 7, the powdered composite material as the additional portion material 120 is scattered on the inner periphery 112 of the base portion 11, for example, so as to be arranged in a ring shape along the circumferential direction of the base portion 11. In the case of the third process, in step P32 of Fig. 8, the powdered composite material is placed in the cavity of the additional portion mold (not shown) along the direction corresponding to the circumferential direction of the base portion 11.

[0050] The powdered composite material includes particles containing fibers and the second resin. The particles may be obtained by pulverizing two or more types of base materials. The powdered composite material may not include particles containing fibers and the second resin, but may include particles consisting only of fibers and particles of resin that does not contain fibers. In other words, powder particles that are a mixture of particles consisting only of fibers and particles of resin that does not contain fibers may be used as the additional portion material 120.

[0051] In the fifth example, a mixed composite material is used that includes two or more of the composite materials of the first to fourth examples. Examples of the mixed composite material include a mixed composite material of pellets 61 or chopped pieces 62 and a powdered composite material, and a mixed composite material of perforated preforms 63 and a powdered composite material.

[0052] [Regarding the Order of Processing] Variations in the execution order of the first process and the second process, and variations in the execution order of the first process, the third process, and the fourth process will be described. Examples of the execution order include the following first to third execution orders. In the first execution order, the second process is executed after the first process is completed. In the second execution order, the first and second processes are executed substantially simultaneously. In the third execution order, the first and third processes are executed in no particular order, and then the fourth process is executed.

[0053] FIG. 11 is a flowchart showing a second embodiment of a method for manufacturing a window frame 1, corresponding to the first execution sequence. First, in step S11, a required number of first fiber-reinforced composite sheets are stacked and placed in the base portion mold 3. The first fiber-reinforced composite is, for example, the annular prepreg 2 shown in FIG. 5. Step S11 can be performed using the techniques of steps P11 and P12 illustrated in FIG. 6. In step S11, a prepreg laminate 20 is placed in the first molding die 31. Next, in step S12, the base portion mold 3 is heated and pressurized to form a shaped base portion 11. Step S12 can be performed using the technique of step P13 in FIG. 6. In step S12, a second molding die 32 is fitted into the first molding die 31 in which the prepreg laminate 20 has been set, and heating and pressurization are performed.

[0054] After the first process including steps S11 and S12 is performed, the second process is performed. In the second process, in step S13, the base portion 11 and the second fiber-reinforced composite material prepared in the first process are placed in the consolidation mold 5. Step S13 can be performed by the method of steps P21 and P22 illustrated in FIG. 7. In step S13, the base portion 11 and the additional portion material 120 are placed in the third molding die 51 of the consolidation mold 5. Next, in step S14, the base portion 11 and the additional portion 12 are integrally molded by heating and pressurizing the consolidation mold 5. Step S14 can be performed in steps P23 and P24 of FIG. 7. In step S14, a fourth molding die 52 is fitted into the third molding die 51 in which the base portion 11 and the additional portion material 120 have been set, and heating and pressurization are performed.

[0055] FIG. 12 is a flowchart illustrating a third embodiment of a method for manufacturing a window frame 1, corresponding to the second execution procedure. In the second execution procedure, pre-processing for the first and second processes is performed, and then the first and second processes are simultaneously performed. First, in step S21, a required number of first fiber-reinforced composite sheets are stacked and placed in the consolidation mold 5, not in the base portion mold 3. In step S21, for example, a prepreg laminate 20 is placed in the consolidation mold 5. Next, in step S22, an additional portion material 120 serving as a second fiber-reinforced composite is placed on the unmolded prepreg laminate 20 set in the consolidation mold 5. Next, in step S23, the consolidation mold 5 is heated and pressurized to produce a shaped base portion 11, and the base portion 11 and the additional portion 12 are integrally molded. In FIG. 12, step S22 is executed after step S21, but step S21 may be executed after step S22 is executed, or step S21 and step S22 may be executed in parallel.

[0056] 13 is a cross-sectional view showing processes P41 and P42 corresponding to steps S21 to S23 of the third embodiment. To simultaneously perform the first and second processes, the consolidation mold 5 includes a third molding die 51 including a fifth molding die 511 and a sixth molding die 512, and a fourth molding die 52 including a seventh molding die 521, an eighth molding die 522, and a ninth molding die 523. The sixth molding die 512 and the eighth molding die 522 are used to form the outer periphery and the stepped portion, and are arranged to overlap with the base portion 11 sandwiched therebetween. In the first direction X1, the sixth molding die 512 can be moved separately from the fifth molding die 511. In the first direction X1, the eighth molding die 522 can be moved separately from the seventh molding die 521 and the ninth molding die 523. For example, the positions of the seventh molding die 521 and the ninth molding die 523 are fixed, and the fifth molding die 511, the sixth molding die 512, and the eighth molding die 522 move relative to the seventh molding die 521 and the ninth molding die 523. The seventh molding die 521 and the ninth molding die 523 are fixed to, for example, a fixed portion of a press device. The fifth molding die 511, the sixth molding die 512, and the eighth molding die 522 are fixed to, for example, a movable portion of the press device. The seventh molding die 521 has a wall portion that defines the inner peripheral edge of the annular prepreg 2. The ninth molding die 523 has a wall portion that defines the outer peripheral edge of the annular prepreg 2.

[0057] In process P41, which corresponds to steps S21 and S22, the additional portion material 120 and the prepreg laminate 20, which is formed by laminating annular prepregs 2, are placed between the third molding die 51 and the fourth molding die 52. The sixth molding die 512 is positioned offset upward relative to the fifth molding die 511. The eighth molding die 522 is positioned offset upward relative to the seventh molding die 521. In process P41, the prepreg laminate 20 has not yet been shaped or interlayer welded. In process P41, first, the additional portion material 120 is placed in the cavity formed by the seventh molding die 521 and the eighth molding die 522. Next, in process P41, the prepreg laminate 20 is placed so that it partially overlaps the additional portion material 120. Next, in process P41, the fifth molding die 511 and the sixth molding die 512 are positioned so that they overlap the prepreg laminate 20.

[0058] In process P42, which corresponds to step S23, the prepreg laminate 20 and the additional portion material 120 are heated through the consolidation mold 5. A general heating device can be used for heating the consolidation mold 5. A general heating method can be used for heating the consolidation mold 5. The heating temperature is a temperature at which the layers of the prepreg laminate 20 fuse together. Furthermore, in process P42, the sixth molding die 512 and the eighth molding die 522 are lowered to apply a shaping force to the prepreg laminate 20. The seventh molding die 521 has a mold surface that shapes the inclined surface SL. The sixth molding die 512 has a mold surface that shapes the stepped portion 113 of the base portion 11. The sixth molding die 512 and the seventh molding die 521 are positioned overlapping in the first direction X1, sandwiching the stepped portion 113, in the region where the stepped portion 113 is to be formed. The eighth molding die 522 and the sixth molding die 512 sandwich the portion of the prepreg laminate 20 that corresponds to the outer periphery 111 .

[0059] In process P42, first, the fifth molding die 511 presses the prepreg laminate 20 between it and the seventh molding die 521 to fix the prepreg laminate 20. Next, while the third molding die 51 and the fourth molding die 52 are heated, the fifth molding die 511, the seventh molding die 521, and the ninth molding die 523 are kept stationary, and the sixth molding die 512 and the eighth molding die 522 are lowered to shift the prepreg laminate 20 toward the wall of the seventh molding die 521, which defines the inner peripheral edge of the annular prepreg 2. At this stage, a gap is formed between the wall of the ninth molding die 523, which defines the outer peripheral edge of the annular prepreg 2, and the prepreg laminate 20, and softened resin and fibers flow into this gap. By cooling after heating and pressurization by the third molding die 51 and the fourth molding die 52, the shaped base portion 11 and the additional portion 12 integrated with the base portion 11 are simultaneously formed. In the manufacturing method of the window frame 1 of the third embodiment, the first and second processes are performed substantially simultaneously, so that the window frame can be manufactured in an even shorter time. Of the base portion 11 formed in process P42, the outermost peripheral portion adjacent to the wall portion of the ninth molding die 523 is regarded as an excess and is cut off in the secondary processing.

[0060] 14 is a flowchart illustrating a fourth embodiment of the method for manufacturing the window frame 1, corresponding to the third execution procedure. In the third execution procedure, the second process includes a third process for separately forming the additional portion 12 and a fourth process for integrating the base portion 11 and the additional portion 12. In the third execution procedure, the first process and the third process are performed in any order. In the third execution procedure, the third process may be performed after the first process is completed, or at least a portion of the first process and at least a portion of the third process may be performed simultaneously, or the first process may be performed after the third process is completed.

[0061] First, in step S31, a required number of first fiber-reinforced composite sheets are stacked and placed in the base portion mold 3. In step S31, for example, a prepreg laminate 20 is placed in the first molding die 31. Next, in step S32, the base portion mold 3 is heated and pressurized to form a shaped base portion 11. Steps S31 and S32 are the same as steps S11 and S12 shown in Figure 11. Steps S31 and S32 correspond to the first process.

[0062] Next, in step S33, an additional portion material 120 as a second fiber-reinforced composite material is placed in the cavity of the additional portion mold in an annular shape. Next, in step S34, the additional portion mold is heated and pressurized to produce the additional portion 12. Steps S33 and S34 correspond to the third process. As described above, the third process may be performed in any order relative to the first process.

[0063] Next, in step S35, the base portion 11 and the additional portion 12, which have been separately manufactured, are placed one on top of the other in the third molding die 51 of the consolidation mold 5. Next, in step S36, the consolidation mold 5 is heated and pressurized to integrate the base portion 11 and the additional portion 12. Steps S35 and S36 correspond to the fourth process. Steps S35 and S36 can be performed by a method similar to steps P33 and P34 shown in FIG. 8 .

[0064] 7 and process P34 in Fig. 8 show an example in which a consolidation mold 5 including a non-split third molding mold 51 and a non-split fourth molding mold 52 is used. At least one of the third molding mold 51 or the fourth molding mold 52 may include a split mold. A mechanism for supporting the split mold with a biasing member such as a coil spring may be attached to the split mold.

[0065] FIG. 15 is a cross-sectional view showing manufacturing steps P51 to P54 of a window frame 1N using a consolidation mold 5A according to a modified example. The consolidation mold 5A includes a tenth mold 55 and an eleventh mold 56 arranged opposite each other. The tenth mold 55 corresponds to the third mold 51 of the consolidation mold 5 described above, and the eleventh mold 56 corresponds to the fourth mold 52 of the consolidation mold 5. The eleventh mold 56 is a split mold including a twelfth mold 561 and a thirteenth mold 562. The thirteenth mold 562 is connected to the twelfth mold 561 by a plurality of first springs 71. Each of the plurality of first springs 71 includes a coil spring. When no load is applied, i.e., when the first springs 71 are at their free length, the thirteenth mold 562 protrudes downward from the twelfth mold 561.

[0066] In process P51, the base portion 11 is set in the tenth molding die 55. The tenth molding die 55 has a cavity Ca capable of accommodating not only the base portion 11 but also the additional portion material 120 that is the constituent material of the additional portion 12. The thirteenth molding die 562 faces the portion of the base portion 11 that corresponds to the outer periphery 111.

[0067] In process P52, the eleventh molding die 56 is lowered. As the eleventh molding die 56 is lowered, the thirteenth molding die 562 comes into contact with the outer periphery 111, and the first spring 71 is compressed. That is, the thirteenth molding die 562 presses down on the outer periphery 111 with a biasing force. Furthermore, in process P52, the additional portion material 120 is poured into the cavity Ca of the tenth molding die 55, onto a portion corresponding to the inner periphery 112 of the base portion 11 set in the tenth molding die 55. When the additional portion material 120 is poured, the vertical wall on the side of the thirteenth molding die 562 restricts the placement range of the additional portion material 120 within the cavity Ca.

[0068] In process P53, the eleventh molding die 56 applies a press load to the laminate of the base portion 11 and the additional portion material 120 under heating. The twelfth molding die 561 presses down on the additional portion material 120 to form the additional portion 12. The thirteenth molding die 562 continues to press down on the outer periphery 111. The first spring 71 is compressed, and the thirteenth molding die 562 is pressed down by the twelfth molding die 561. Even if the additional portion material 120 expands due to heating, the vertical wall of the thirteenth molding die 562 prevents it from entering the outer periphery 111. Through the above processes P51 to P53, a window frame 1 can be manufactured in which an additional portion 12A whose surface is parallel to the inner periphery 112 and has a rectangular cross section is integrated with the base portion 11.

[0069] Process P54 shows the window frame 1N being removed from the consolidation mold 5A. The window frame 1N is formed by integrating an additional portion 12A having a triangular cross section with a base portion 11. When the window frame 1 is removed from the tenth molding mold 55, the window frame 1 is demolded from the tenth molding mold 55 by an ejector pin that can protrude from above the tenth molding mold 55.

[0070] As long as the laminate can be pressed in the order of steps P52 and P53, the mold structure of the consolidation mold 5A may be changed, and for example, the first spring 71 may be omitted. The shape of the additional portion 12A is determined by the shapes of the twelfth molding mold 561 and the thirteenth molding mold 562 that contact the additional portion 12A. The shapes of the twelfth molding mold 561 and the thirteenth molding mold 562 that contact the additional portion 12A are not limited to this modified example, and for example, the twelfth molding mold 561 may have a molding surface similar to the molding surface 52A of the fourth molding mold 52.

[0071] 16 is a cross-sectional view showing an example of manufacturing steps P61 to P64 of a window frame 1M using a consolidation mold 5B according to another modified example. The consolidation mold 5B includes a fourteenth molding die 57 and a seventeenth molding die 58 arranged opposite each other. The fourteenth molding die 57 corresponds to the fourth molding die 52 of the consolidation mold 5 described above, and the seventeenth molding die 58 corresponds to the third molding die 51. The fourteenth molding die 57 is a split mold including a fifteenth molding die 571 and a sixteenth molding die 572.

[0072] The fifteenth molding die 571 has a through hole 573 through which the sixteenth molding die 572 can be inserted. The through hole 573 passes through a portion of the fifteenth molding die 571 in the vertical direction. The fifteenth molding die 571 is supported on a base plate 574 by a plurality of second springs 72. Each of the plurality of second springs 72 includes a coil spring. The sixteenth molding die 572 is inserted into the through hole 573 while fixed to the base plate 574. The sixteenth molding die 572 has a cavity Ca with a V-shaped cross section on the surface facing the seventeenth molding die 58, capable of accommodating the additional portion material 120. When no load is applied to the fifteenth molding die 571, i.e., when the second springs 72 are at their free length, the upper surface of the cavity Ca of the sixteenth molding die 572 is positioned in the through hole 573. A shim spacer 73 is provided on the base plate 574 to regulate the height to which the fifteenth molding die 571 can be lowered.

[0073] The shim spacer 73, for example, surrounds the end of the second spring 72 on the base plate 574 side. The shim spacer 73 has, for example, a cylindrical shape. A guide member 74 that guides the fifteenth molding die 571 in the up-down direction is provided upright on the base plate 574. The guide member 74 includes, for example, a rod extending in the up-down direction. The guide member 74 is formed in the fifteenth molding die 571 and is inserted into an insertion hole 75 that has a shape complementary to the guide member 74. The guide member 74 is located, for example, in a position surrounded by the second spring 72. The arrangement of the shim spacer 73, the guide member 74, and the second spring 72 is not limited to this modified example.

[0074] In process P61, the additional portion material 120 is filled into the cavity Ca of the sixteenth molding die 572. Even if the additional portion material 120 is filled to a height exceeding the top opening of the cavity Ca, it does not leak out because the cavity Ca is surrounded by the inner wall surface of the through-hole 573. In process P62, the base portion 11 is set in the fourteenth molding die 57. The sixteenth molding die 572 faces the portion of the base portion 11 that corresponds to the inner periphery 112.

[0075] In process P63, the seventeenth molding die 58 is lowered under heating, and a press load is applied to the base portion 11. As the seventeenth molding die 58 descends, the seventeenth molding die 58 comes into contact with the base portion 11 and presses the fifteenth molding die 571 down against the biasing force of the second spring 72. As the seventeenth molding die 58 descends, the second spring 72 is compressed. The lower surface of the fifteenth molding die 571 abuts against the shim spacer 73, and the height position of the fifteenth molding die 571 is determined. When the portion corresponding to the inner periphery 112 is pressed down by the seventeenth molding die 58, the upper surface of the additional portion material 120 is indirectly pressed down, and molding pressure is also applied to the additional portion material 120 placed in the cavity Ca.

[0076] Process P64 shows the window frame 1M removed from the consolidation mold 5B. The window frame 1M has an additional portion 12B with a triangular cross section integrated with the base portion 11. The additional portion 12 can be any shape as long as it accurately and properly receives the peripheral edge 15a of the window panel 15. Therefore, the additional portion 12 may be the additional portion 12B with a triangular cross section, or, as in the example of Figure 15, the additional portion 12 may be the additional portion 12A with a rectangular cross section. A window frame 1M with an additional portion 12B with a triangular cross section can easily be made lighter. A rectangular cross-sectional additional portion 12A can evenly bear the press load applied to the additional portion material 120, making it easier to improve molding quality.

[0077] The specific embodiments described above include disclosures having the following configurations.

[0078] A method for manufacturing a window frame according to a first aspect of the present disclosure includes stacking a plurality of sheets of a first fiber-reinforced composite material, the first fiber-reinforced composite material including a plurality of continuous fibers and a first resin impregnated into the plurality of continuous fibers, and performing a first process including heating to form an annular base portion extending in a circumferential direction, and performing a second process including placing a substantially annular additional portion formed of a second fiber-reinforced composite material including reinforcing fibers and a second resin and extending along the circumferential direction on the base portion and heating the additional portion, thereby integrating the base portion and the additional portion.

[0079] In the first aspect of the manufacturing method, the substantially annular additional portion is disposed on the base portion, and the base portion and the additional portion are integrated by performing a second process including heating. The first aspect of the manufacturing method allows for greater freedom in design of the additional portion than when the additional portion is manufactured by injection molding.

[0080] The second aspect of the method for manufacturing a window frame is the same as the first aspect, except that the second process includes a third process for forming the additional portion and a fourth process for overlapping the additional portion on the base portion and heating it.

[0081] According to the manufacturing method of the second aspect, the additional portion is formed separately in the third process, and the additional portion and the base portion are integrated in the fourth process, thereby increasing the degree of freedom in performing the second process.

[0082] A third aspect of the manufacturing method for a window frame is the same as the first aspect, except that the second fiber-reinforced composite material includes a solid composite material having at least one fiber and the second resin, and in the second process, the additional portion is placed on the base portion by arranging multiple pieces of the solid composite material along the circumferential direction on the base portion.

[0083] A fourth aspect of the manufacturing method for a window frame is the same as the second aspect, except that the second fiber-reinforced composite material includes a solid composite material having at least one fiber and the second resin, and in the third process, the additional portion is formed by arranging multiple pieces of the solid composite material along a direction corresponding to the circumferential direction.

[0084] According to the manufacturing methods of the third and fourth aspects, the annular additional portion can be disposed on the base portion by a simple method of disposing a plurality of solid composite materials on the base portion.

[0085] A fifth aspect of the method for manufacturing a window frame is the same as the first aspect, except that the second fiber-reinforced composite material includes a fibrous composite material having at least one continuous fiber and at least one fibrous second resin, and in the second process, the additional portion is positioned on the base portion by arranging the fibrous composite material on the base portion along the circumferential direction.

[0086] A sixth aspect of the method for manufacturing a window frame is the same as the second aspect, except that the second fiber-reinforced composite material includes a fibrous composite material having at least one continuous fiber and at least one fibrous second resin, and in the third process, the additional portion is formed by arranging the fibrous composite material along a direction corresponding to the circumferential direction.

[0087] According to the manufacturing methods of the fifth and sixth aspects, the annular additional portion can be disposed on the base portion by a simple method of disposing a plurality of fibrous composite materials on the base portion.

[0088] A seventh aspect of the method for manufacturing a window frame is a method for manufacturing a window frame according to any one of the first to sixth aspects, wherein the second fiber-reinforced composite material includes at least one of pellets, chopped pieces, perforated preforms, filaments, flakes, grains, and broken pieces.

[0089] According to the manufacturing method of the seventh aspect, the constituent members of the second fiber reinforced composite material can be diversified.

[0090] The window frame manufacturing method of the eighth aspect is the manufacturing method of the first to seventh aspects, wherein at least one of the first treatment and the second treatment, or at least one of the first treatment, the third treatment and the fourth treatment includes pressure application.

[0091] According to the eighth aspect of the manufacturing method, by applying pressure in addition to heating, it is possible to form the base portion and integrate the base portion and the additional portion reliably in a short time.

[0092] A ninth aspect of the method for manufacturing a window frame is the same as any of the first to eighth aspects, in which the additional portion is formed in a continuous ring shape.

[0093] According to the manufacturing method of the ninth aspect, the additional portion is connected in a ring shape, so that strength can be easily ensured.

[0094] The window frame manufacturing method of the tenth aspect is the manufacturing method of the first to ninth aspects, in which the second process is performed after the first process is completed, or the second process is performed substantially simultaneously with the first process.

[0095] According to the manufacturing method of the tenth aspect, the degree of freedom in performing the first process and the second process can be increased.

[0096] A method for manufacturing a window frame according to an eleventh aspect is the same as any one of the first to tenth aspects, in which the first resin and the second resin each include a thermoplastic resin.

[0097] According to the manufacturing method of the eleventh aspect, the base portion and the additional portion can be easily formed by heating and then cooling.

[0098] A twelfth aspect of the method for manufacturing a window frame is a method for manufacturing a window frame according to any one of the first to eleventh aspects, wherein the continuous fibers contained in the first fiber-reinforced composite material and the reinforcing fibers contained in the second fiber-reinforced composite material contain carbon fibers.

[0099] According to the manufacturing method of the twelfth aspect, the first and second fiber-reinforced composite materials can be reinforced with carbon fiber, which has the advantages of being lightweight and high strength.

[0100] A thirteenth aspect of the method for manufacturing a window frame is a method for manufacturing a window frame according to any one of the first to twelfth aspects, wherein the second fiber-reinforced composite material includes a plurality of pellets or a plurality of chops, and at least a portion of the plurality of pellets or at least a portion of the plurality of chops are arranged without any restriction on their orientation relative to the base portion.

[0101] According to the manufacturing method of the thirteenth aspect, a plurality of pellets or a plurality of chops can be arranged on the base portion 11 without aligning their orientation, which improves workability.

[0102] The manufacturing method for a window frame according to the fourteenth aspect is the same as the manufacturing methods of the first to thirteenth aspects, except that the base portion includes an inner periphery, an outer periphery, and a step portion that forms a step between the inner periphery and the outer periphery, and the additional portion is integrated with the inner periphery and the step portion.

[0103] According to the manufacturing method of the fourteenth aspect, the additional portion is integrated with the inner periphery and the step portion, thereby improving the strength of the window frame.

[0104] An aircraft window frame according to a fifteenth aspect is an aircraft window frame manufactured by the window frame manufacturing method according to any one of the first to fourteenth aspects.

[0105] According to the manufacturing method of the fifteenth aspect, window frames that can be manufactured with high strength and high quality can be used as window frames for aircraft, which can contribute to improving the production efficiency of aircraft.

Claims

1. A method for manufacturing a window frame, comprising: stacking a plurality of sheets of a first fiber-reinforced composite material comprising a plurality of continuous fibers and a first resin impregnated into the plurality of continuous fibers; performing a first process including heating to form an annular base portion extending in a circumferential direction; and performing a second process including placing on the base portion an additional portion that is formed of a second fiber-reinforced composite material comprising reinforcing fibers and a second resin and that extends along the circumferential direction, and heating the additional portion, thereby integrating the base portion and the additional portion.

2. A method for manufacturing a window frame according to claim 1, wherein the second process includes a third process for forming the additional portion, and a fourth process including heating the additional portion overlaid on the base portion.

3. A method for manufacturing a window frame as described in claim 1, wherein the second fiber-reinforced composite material includes a solid composite material having at least one fiber and the second resin, and in the second process, the additional portion is arranged on the base portion by arranging multiple pieces of the solid composite material along the circumferential direction on the base portion.

4. A method for manufacturing a window frame as described in claim 2, wherein the second fiber-reinforced composite material includes a solid composite material having at least one fiber and the second resin, and in the third process, the additional portion is formed by arranging multiple pieces of the solid composite material along a direction corresponding to the circumferential direction.

5. A method for manufacturing a window frame as described in claim 1, wherein the second fiber-reinforced composite material includes a fibrous composite material having at least one continuous fiber and at least one fibrous second resin, and in the second process, the fibrous composite material is arranged on the base portion along the circumferential direction, thereby arranging the additional portion on the base portion.

6. A method for manufacturing a window frame as described in claim 2, wherein the second fiber-reinforced composite material includes a fibrous composite material having at least one continuous fiber and at least one fibrous second resin, and in the third process, the additional portion is formed by arranging the fibrous composite material along a direction corresponding to the circumferential direction.

7. A method for manufacturing a window frame according to claim 1 or 2, wherein the second fiber reinforced composite material comprises at least one of pellets, chopped pieces, perforated preforms, filaments, flakes, grains, and broken pieces.

8. A method for manufacturing a window frame according to claim 1 or 2, wherein at least one of the first treatment and the second treatment, or at least one of the first treatment, the third treatment and the fourth treatment includes pressurization.

9. A method for manufacturing a window frame according to any one of claims 1 to 6, wherein the additional portion is formed in a continuous ring shape.

10. A method for manufacturing a window frame according to any one of claims 1 to 6, wherein the second process is carried out after the first process is completed, or the second process is carried out substantially simultaneously with the first process.

11. A method for manufacturing a window frame according to any one of claims 1 to 6, wherein the first resin and the second resin each contain a thermoplastic resin.

12. A method for manufacturing a window frame according to any one of claims 1 to 6, wherein the continuous fibers contained in the first fiber-reinforced composite material and the reinforcing fibers contained in the second fiber-reinforced composite material contain carbon fibers.

13. A method for manufacturing a window frame according to any one of claims 1 to 6, wherein the second fiber-reinforced composite material includes a plurality of pellets or a plurality of chops, and at least a portion of the plurality of pellets or at least a portion of the plurality of chops are arranged without any restriction on their orientation relative to the base portion.

14. A method for manufacturing a window frame as claimed in any one of claims 1 to 6, wherein the base portion includes an inner periphery, an outer periphery, and a step portion that forms a step between the inner periphery and the outer periphery, and the additional portion is integrated with the inner periphery and the step portion.

15. A window frame for an aircraft manufactured by the method for manufacturing a window frame according to any one of claims 1 to 6.

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