JP3423657B2 - Manufacturing method of composite material - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a composite material used as a part of an aircraft or a ship, which is a composite material of fibers and resin such as FRP (fiber reinforced plastic).

[0002]

2. Description of the Related Art A method of manufacturing a composite material includes a method of using a two-dimensional prepreg (abbreviation of pre-impregnated), a method of using a two-dimensional woven fabric, and a method of using a three-dimensional woven fabric. . In the method using the two-dimensional prepreg, 2
An appropriate shape is formed by cutting and stacking the three-dimensional prepreg and hardening it. In the method using a two-dimensional woven fabric, the two-dimensional woven fabric is cut and stacked, and the resin is impregnated and cured. A method of using a three-dimensional woven fabric is described in Japanese Patent Publication No. 29304/1995.
A three-dimensional woven fabric is woven, which is impregnated with a resin and cured.

[0003]

According to the conventional method for producing a two-dimensional composite material using a two-dimensional prepreg or a two-dimensional fabric, the cured composite material exhibits high strength in the direction parallel to the fibers. The strength in the direction perpendicular to the plane (thickness direction) is lower than the strength in the in-plane fiber direction. Particularly in the case of a two-dimensional prepreg in which fibers are aligned in one direction, it is difficult to form a complicated shape. The two-dimensional woven fabric can be formed into a more complicated shape than the two-dimensional prepreg, but has a lower strength than the two-dimensional prepreg in which fibers are aligned in one direction. The three-dimensional woven fabric has high strength because it is reinforced with fibers also in the plate thickness direction, but since it is necessary to weave each part into a predetermined shape, the cost is generally high, and the manufacturing cost of the composite material is increased. Will end up.

Further, in the process of manufacturing the composite material,
In order to impregnate a dry fiber of a two-dimensional woven fabric or a three-dimensional woven fabric with a resin, a large-scale facility such as pressure-feeding the resin to the dry fiber disposed in a mold is required. Complicates the manufacturing process and raises the manufacturing cost.

An object of the present invention is to provide a low-cost, general-purpose method for producing a composite material, and a method for producing a composite material by simply impregnating dry fibers with a resin.

[0006]

According to the present invention, in a molding jig, a woven member which is either a two-dimensional woven fabric or a three-dimensional woven fabric and another member different from the woven fabric member are arranged side by side. The step of sealing, the step of injecting a thermosetting resin into the molding jig to impregnate the woven member with the resin, and the heating of the molding jig to cure the resin to cure the woven member and other members. And a step of integrating them, which is a method for producing a composite material.

According to the present invention, a prepreg formed by, for example, a fabric member which is one of a two-dimensional woven fabric and a three-dimensional woven fabric of dry fiber and a fiber impregnated with a resin and semi-cured in a molding jig. And other members different from the above-mentioned woven member. In this state, the inside of the molding jig is hermetically sealed, and the gap between the fibers of the fabric member in the internal space is empty. Since the resin is injected into the molding jig in this state, the fabric member is impregnated with the resin. Since the impregnated resin comes into contact with another member, the woven member and the other member can be integrated by curing the resin.

As described above, since the plurality of members arranged in the molding jig includes the woven member which is one of the two-dimensional woven fabric and the three-dimensional woven fabric of dry fiber, the woven member is impregnated with the woven member. With the resin that is cured by curing, a composite material in which the respective members are integrated can be manufactured. For example, for a part having a complicated shape, a two-dimensional woven fabric that easily forms a complicated shape, for a part requiring high strength is a three-dimensional woven fabric, and for a part having a planar shape requiring high strength in the plane. By applying the two-dimensional prepreg, it is possible to manufacture an integrally molded part that takes advantage of the features of the two-dimensional woven fabric, the three-dimensional woven fabric, and the two-dimensional prepreg at low cost.

Further, according to the present invention, a woven member which is either a two-dimensional woven fabric or a three-dimensional woven fabric and another member different from the woven fabric member are arranged on a molding jig, and these members are arranged in a flexible bag. And a thermosetting resin is injected into the bag so that the fabric member is impregnated with the resin, and the molding jig is heated and pressed in the autoclave to cure the resin so that the fabric member and other A method of manufacturing a composite material, comprising the step of integrating members.

According to the present invention, for example, a prepreg obtained by impregnating a fiber with a resin and semi-curing it on a molding jig, which is either a two-dimensional woven fabric or a three-dimensional woven fabric of dry fiber. Other members different from the woven member, such as the above, are arranged and covered with a flexible bag. With the bag covered with the molding jig, the gap between the fibers of the fabric member in the space inside the bag becomes empty. Since the resin is injected into the bag in this state, the fabric member is impregnated with the resin. Since the impregnated resin comes into contact with another member, the woven member and the other member can be integrated by curing the resin.

As described above, since the plurality of members arranged in the bag on the molding jig include the woven member which is one of the two-dimensional woven fabric and the three-dimensional woven fabric of dry fiber, the woven member With the resin that is impregnated into and cured, it is possible to manufacture a composite material in which each member is integrated. For example, for a part having a complicated shape, a two-dimensional woven fabric that easily forms a complicated shape, for a part requiring high strength is a three-dimensional woven fabric, and for a part having a planar shape requiring high strength in the plane. By applying the two-dimensional prepreg, it is possible to manufacture an integrally molded part that takes advantage of the features of the two-dimensional woven fabric, the three-dimensional woven fabric, and the two-dimensional prepreg at low cost.

[0012]

[0013]

[0014]

According to the present invention, a woven member, which is either a two-dimensional woven fabric or a three-dimensional woven fabric, and another member different from the woven fabric member are arranged on a molding jig, and these are arranged in a flexible bag. A step of impregnating the fabric member with a thermosetting resin, and a process of curing the resin by heating and pressurizing the molding jig in the autoclave to integrate the fabric member and other members. A method of manufacturing a composite material including: in the step of impregnating a fabric member with the resin, a recess is provided in advance at a position covered by the bag of the molding jig, and the inside of the bag is removed while the resin is stored in the recess. When the bag is pressed, the bag is pressed into the recess, and the resin stored in the recess is extruded to impregnate the fabric member with the bag.

According to the present invention, a prepreg obtained by impregnating a fiber with a resin and semi-curing the woven member, which is one of a two-dimensional woven fabric and a three-dimensional woven fabric, for example, on a molding jig. Other members different from the woven member, such as the above, are arranged and covered with a flexible bag. In this state, the bag is evacuated. The bag is attracted inward by deaeration, is brought into close contact with each member, and presses the resin in the recess formed in the molding jig. The resin pressed by the bag is extruded through the depression and impregnates the fabric member. At this time, the impregnated resin comes into contact with the other member, so that the woven member and the other member can be integrated by heating and pressing in the autoclave to cure the resin.

As described above, since the fabric member is impregnated with the resin by the simple method of forming the depression in the molding jig and storing the resin in the depression, a large-scale facility for pumping the resin is not required. Therefore, the manufacturing process of the composite material can be greatly simplified, and the manufacturing cost can be reduced.

Further, according to the present invention, a step of storing a thermosetting resin on a molding jig, a step of floating a plate having a through hole on the resin, and a woven fabric which is one of a two-dimensional woven fabric and a three-dimensional woven fabric A member and a step of arranging another member different from this woven member on a plate, a step of covering a plurality of members with a flexible bag, and degassing the inside of the bag to transfer the resin from the through hole to the woven member. A method for producing a composite material, which comprises a step of impregnating and a step of curing a resin by heating and pressurizing a molding jig in an autoclave to integrate a woven member and other members.

According to the present invention, by degassing the inside of the bag, the plate-shaped woven member and other members are pressed downward, and the plate is further pressed toward the resin to be sunk into the resin and penetrated. The fabric member can be impregnated with resin through the holes. At this time, the impregnated resin comes into contact with the other member, so that the woven member and the other member can be integrated by heating and pressing in the autoclave to cure the resin. In this way, since the fabric member is impregnated with the resin by a simple method, large-scale equipment for pumping the resin is not required, and the manufacturing process of the composite material can be greatly simplified, and the manufacturing cost can be reduced. can do.

Further, the present invention is characterized in that the other member includes a prepreg obtained by impregnating fibers with a resin and semi-curing the resin.

According to the present invention, since the prepreg, which is a relatively general-purpose material, is used, a more general-purpose composite material manufacturing method can be realized.

Further, the present invention is characterized in that the other member includes a precure member obtained by impregnating fibers with a resin and curing the resin.

According to the present invention, since the pre-cure member in which the resin is completely cured is used, the resources to be the product can be utilized alone, and the general-purpose composite material manufacturing method can be realized to reduce the manufacturing cost. It can be reduced.

[0024]

1 is a sectional view showing a first embodiment of the present invention. The molding jig 12a includes a base portion 31 and a lid portion 32, and a recess 31a is formed on the surface of the base portion 31. A plurality of two-dimensional fabrics 4 are provided in the recess 31a.
The two-dimensional and three-dimensional fabrics 43 are placed side by side, the base portion 31 is covered with the lid portion 32, and the lid portions 32 are fixed with bolts or the like. When the lid portion 32 is fixed to the base portion 31, the internal space 36 formed between the lower surface of the lid portion 32 and the recess 31a of the base portion 31 is sealed. The internal space 36 has a shape corresponding to a composite material to be a product, and holds the shapes of the two-dimensional woven fabric 42 and the three-dimensional woven fabric 43 placed in the internal space 36.

A resin injection pipe 34 for connecting the internal space 36 and the resin pot 33 is provided in the base portion 31, and a liquid thermosetting resin is stored in the resin pot 33. By sending nitrogen gas into the resin pot 33, the inside of the resin pot 33 is pressurized and the liquid thermosetting resin is sent toward the internal space 36.
The pressurization inside the resin pot 33 may be performed by mechanical operation of a piston or the like. The resin sent to the internal space 36 is the two-dimensional fabric 42 arranged in the internal space 36.
And impregnate the three-dimensional fabric 43. On the other hand, a resin discharge pipe 35 is provided in the lid portion 32, and the air and excess resin existing in the internal space 36 are discharged from the internal space 36 to the outside.

Further, the molding jig 12a is provided with a heater for heating the resin, and after the two-dimensional fabric 42 and the three-dimensional fabric 43 are impregnated with the resin, the molding jig 12a.
The resin is heated and cured via a. by this,
The two-dimensional woven fabric 42 and the three-dimensional woven fabric 43 are integrated to complete the composite material.

2A is a plan view showing the two-dimensional fabric 42 of FIG. 1, FIG. 2B is a sectional view thereof, and FIG. 3 is a perspective view showing the three-dimensional fabric 43 of FIG. is there. The two-dimensional woven fabric 42 shown in FIG. 2 is a woven fabric in which long fibers are woven in two-dimensionally orthogonal X and Y directions, and is generally called cloth. Three-dimensional fabric 53 shown in FIG.
Is a woven fabric in which long fibers are woven in a plane formed in the X and Y directions orthogonal to each other and in a Z direction orthogonal to the plane.

Although the two-dimensional woven fabric 42 and the three-dimensional woven fabric 53 of dry fibers are used as a plurality of members in FIG. 1, in the first embodiment, instead of either the two-dimensional woven fabric or the three-dimensional woven fabric. Other members such as a prepreg or a precure member may be used.

FIG. 4 is a sectional view showing a second embodiment of the present invention. The molding jig 12b of FIG. 4 is the molding jig 1 of FIG.
It is composed only of a base portion corresponding to the base portion 31 of 2a. A stack of the three-dimensional fabric 43 and a plurality of prepregs 52 is placed side by side on the molding jig 12b. The prepreg 52 is formed by impregnating the two-dimensional fabric 42 having the structure shown in FIG. The three-dimensional fabric 43 and the prepreg 52 are attached to the silicon mandrel 24.
A flexible bag 2 covered from above and further from above
Covered by 5. The peripheral edge of the bag 25 and the upper surface of the molding jig 12b are brought into close contact with each other by a seal 57, and the inside of the bag 25 is sealed.

The molding jig 12b is provided with a resin injection pipe 55 connected to the resin pot 11, and the molding jig 12 is connected from the resin pot 11 via the resin injection pipe 55.
The resin is sent to b, and the three-dimensional fabric 43 is impregnated with the resin.
At this time, the injection pressure of the resin is lower than the internal pressure of the autoclave. The pressurization inside the resin pot 11 may be performed by mechanical operation of a piston or the like.

The molding jig 12b has a resin discharge pipe 5
6 is also provided, and air and excess resin existing in the three-dimensional fabric 43 are discharged. The molding jig 12b after the resin is injected is heated and pressurized in the autoclave 58. As a result, the resin impregnated in the three-dimensional fabric 43 is cured to integrate the three-dimensional fabric 43 and the prepreg 52.

In the second embodiment, a plurality of two-dimensional fabrics may be stacked instead of the three-dimensional fabric 43.
As the prepreg 52, a plurality of fibers bundled in parallel in one direction and impregnated with a resin to be semi-cured may be used, or a three-dimensional woven fabric impregnated with a resin and semi-cured may be used. May be. Further, instead of the prepreg 52, a precure obtained by completely curing a resin impregnated in fibers may be used. Furthermore, silicon mandrel 24
It is also possible to use a method in which the three-dimensional fabric 43 and the prepreg 52 are directly covered with the bag 25.

FIG. 5 is a plan view showing a third embodiment of the present invention, and FIGS. 6 (a) and 6 (b) are sectional views showing a step of impregnating dry fibers with a resin. The molding jig 12e of FIG. 5, like the molding jig 12b of FIG. 4, is composed of only a base portion corresponding to the base portion 31 of the molding jig 12a of FIG. On this molding jig 12e, the three-dimensional fabric 4
A stack of three and a plurality of prepregs 52 is placed side by side. The prepreg 52 is formed by impregnating a two-dimensional fabric with a resin and semi-curing the resin. The three-dimensional fabric 43 and the prepreg 52 are covered with a flexible bag 53. The peripheral edge of the bag 53 and the upper surface of the molding jig 12e are in close contact with each other by the seal 57.

On the upper surface of the molding jig 12e, a recess 71 is provided in advance in a region between the three-dimensional fabric 43 and the seal 57, and resin is stored in the recess 71 before covering with the bag 53. Thereby, the bag 53 covers the mouth of the recess 71 together with the three-dimensional fabric 43 and the prepreg 52. By degassing the inside of the bag 53 in this state, the bag 53 is pulled inward, and is brought into close contact with the three-dimensional fabric 43 and the prepreg 52, and presses the resin in the recess 71. The resin pressed by the bag 53 is extruded from the depression 71 and impregnates the three-dimensional fabric 43. At this time, the impregnated resin contacts the prepreg 52.

After degassing the inside of the bag 53, the molding jig 1
2e is heated and pressurized in the autoclave 58. As a result, the resin impregnated in the three-dimensional fabric 43 is cured to integrate the three-dimensional fabric 43 and the prepreg 52.

5 and 6, the three-dimensional fabric 43 and the prepreg 52 are used as a plurality of members, but in the third embodiment, the two-dimensional fabric is used instead of the three-dimensional fabric 43. Alternatively, instead of the prepreg 52, a precure member in which fibers are impregnated with a resin and completely cured may be used. Also, although multiple members are used,
The composite material may be manufactured by using the two-dimensional or three-dimensional fabric of dry fiber alone.

FIG. 7 is a sectional view showing a fourth embodiment of the present invention. The locator 60 is placed on the molding jig 12f, a resin is put in a portion surrounded by the locator 60, a single hole or a perforated plate 61 is placed on the resin, and the three-dimensional fabric 43 and the prepreg 52 are arranged on the perforated plate 61. . The entire upper part is covered with a bag 53, the periphery of which is sealed by a seal 57, and one end of which is provided with a metal fitting for vacuuming. In the step of impregnating the resin, the inside covered with the bag 53 is evacuated using a vacuum pump or the like, and the resin permeates the three-dimensional fabric 43.

After degassing the inside of the bag 53, the molding jig 1
2f is heated and pressurized in the autoclave 58. As a result, the resin impregnated in the three-dimensional fabric 43 is cured to integrate the three-dimensional fabric 43 and the prepreg 52.

In the fourth embodiment of FIG. 7 as well, 3
A two-dimensional fabric may be used instead of the three-dimensional fabric 43,
Instead of the prepreg 52, a precure member in which fibers are impregnated with a resin and completely cured may be used. Further, although a plurality of members are used, the composite material may be manufactured by using the two-dimensional woven fabric or the three-dimensional woven fabric of dry fiber alone.

Further, as the fibers of the first to fourth embodiments, inorganic glass, carbon, boron, alumina, potassium titanate, silica or the like, or organic aramid, vinylon, acrylic or the like is used, and as the resin. As the thermosetting unsaturated polyester, epoxy, phenol, silicone, acrylic, or the like is used.

[0041]

As described above, according to the present invention, a molding jig containing a woven member which is either one of a two-dimensional woven fabric and a three-dimensional woven fabric of dry fiber and another member is hermetically sealed to form a woven fabric member. By impregnating the resin with a resin and curing the resin, a composite material in which the respective members are integrated can be manufactured. In addition, for parts with complex shapes, two-dimensional fabrics that are easy to form complex shapes are used. For parts that require high strength, three-dimensional fabrics are used. Is a two-dimensional fabric by applying a two-dimensional prepreg,
It is possible to manufacture an integrally molded part that makes use of the characteristics of the three-dimensional fabric and the two-dimensional prepreg at low cost.

On the molding jig, a woven member made of either a two-dimensional woven fabric or a three-dimensional woven fabric of dry fibers and another member are arranged side by side and covered with a flexible bag, and the woven member is made of resin. Similarly, by impregnating and curing
It is possible to manufacture a composite material in which each member is integrated. In addition, a part having a complicated shape is a two-dimensional woven fabric that easily forms a complicated shape, a part requiring a high strength is a three-dimensional woven fabric, and a part having a planar shape requiring a high in-plane strength. Similarly, by applying a two-dimensional prepreg, it is possible to manufacture an integrally molded part that makes the best use of the characteristics of the two-dimensional woven fabric, the three-dimensional woven fabric, and the two-dimensional prepreg at low cost.

Further, the manufacturing process of the composite material can be greatly simplified and the manufacturing cost can be reduced by a simple method of forming a recess in the molding jig and storing the resin in the recess. it can.

Further, a plate having through holes is floated on the resin on the molding jig, and the woven member and other members are arranged on this plate,
The simple method of covering with a flexible bag and degassing the inside of the bag can greatly simplify the manufacturing process of the composite material and reduce the manufacturing cost.

By using a prepreg or a precure member as the other member, it is possible to realize a more general-purpose method for manufacturing a composite material.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing a first embodiment of the present invention.

2 (a) is a plan view showing the two-dimensional fabric 42 of FIG. 1, and FIG. 2 (b) is a sectional view thereof.

3 is a perspective view showing the three-dimensional fabric 43 of FIG. 1. FIG.

FIG. 4 is a cross-sectional view showing a second embodiment of the present invention.

FIG. 5 is a plan view showing a third embodiment of the present invention.

FIG. 6 is a cross-sectional view showing how a dry fiber is impregnated with a resin.

FIG. 7 is a sectional view showing a fourth embodiment of the present invention.

[Explanation of symbols]

11,33 resin pot 12a, 12b, 12e, 12f Molding jig 24 Silicon Mandrel 25 bags 31 Base 32 Lid 36 Internal space 42 two-dimensional fabric 43 three-dimensional fabric 52 prepreg 58 autoclave 71 hollow

─────────────────────────────────────────────────── ─── Continuation of the front page (72) Kaoru Onohara, No. 1 Kawasaki-cho, Kakamigahara-shi, Gifu Kawasaki Heavy Industries, Ltd. Gifu factory (56) Reference JP-A-5-237853 (JP, A) JP-A-5 -124118 (JP, A) JP-A-8-1690 (JP, A) JP-A-7-60770 (JP, A) JP-A-4-216923 (JP, A) JP-A-61-132310 (JP, A) (58) Fields surveyed (Int.Cl. ⁷ , DB name) B29C 39/10, 39/22-39/24 B29C 43/10-43/18 B29C 43/32-43/34

Claims (6)

(57) [Claims] 1. A process of arranging a woven member, which is one of a two-dimensional woven fabric and a three-dimensional woven fabric, and another member different from the woven fabric member in a molding jig to seal the inside, and a molding jig. Including a step of injecting a thermosetting resin into the inside to impregnate the fabric member with the resin, and a step of heating the molding jig to cure the resin and integrate the fabric member and other members. A method of manufacturing a composite material, comprising: 2. A step of arranging a woven member, which is either one of a two-dimensional woven fabric and a three-dimensional woven fabric, and another member different from the woven fabric member on a molding jig and covering them with a flexible bag. And a step of injecting a thermosetting resin into the bag to impregnate the fabric member with the resin, and curing the resin by heating and pressurizing the molding jig in the autoclave to integrate the fabric member and other members. A method for producing a composite material, comprising: 3. A step of arranging a woven member, which is one of a two-dimensional woven fabric and a three-dimensional woven fabric, and another member different from the woven fabric member on a molding jig and covering them with a flexible bag. And a step of impregnating the woven member with a thermosetting resin, and a step of curing the resin by heating and pressurizing the molding jig in the autoclave to integrate the woven member and other members. In the step of impregnating the fabric member with the resin, a recess is provided in advance at a position covered by the bag of the molding jig, and the inside of the bag is deaerated while the resin is stored in the recess. The method of manufacturing a composite material, wherein the bag is pressed into the recess by the method, and the resin stored in the recess is extruded to impregnate the fabric member. 4. A step of storing a thermosetting resin on a molding jig, a step of floating a plate having a through hole on the resin, and a woven member which is one of a two-dimensional woven fabric and a three-dimensional woven fabric, A step of arranging another member different from the woven member on a plate, a step of covering a plurality of members with a flexible bag, and a step of evacuating the inside of the bag to impregnate the woven member with resin through the through holes. And a step of heating and pressurizing a molding jig in an autoclave to cure the resin and integrate the woven material member and the other member with each other. 5. The method for producing a composite material according to claim 1, wherein the other member includes a prepreg obtained by impregnating fibers with a resin and semi-curing the resin. 6. The method for producing a composite material according to claim 1, wherein the other member includes a precure member obtained by impregnating fibers with a resin and curing the resin.