JP2003011231A - Method for manufacturing composite panel - Google Patents
Method for manufacturing composite panelInfo
- Publication number
- JP2003011231A JP2003011231A JP2001202371A JP2001202371A JP2003011231A JP 2003011231 A JP2003011231 A JP 2003011231A JP 2001202371 A JP2001202371 A JP 2001202371A JP 2001202371 A JP2001202371 A JP 2001202371A JP 2003011231 A JP2003011231 A JP 2003011231A
- Authority
- JP
- Japan
- Prior art keywords
- reinforcing member
- thermosetting resin
- composite material
- dry preform
- resin film
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000002131 composite material Substances 0.000 title claims abstract description 73
- 238000000034 method Methods 0.000 title claims abstract description 35
- 238000004519 manufacturing process Methods 0.000 title claims description 66
- 239000011347 resin Substances 0.000 claims abstract description 96
- 229920005989 resin Polymers 0.000 claims abstract description 96
- 229920001187 thermosetting polymer Polymers 0.000 claims abstract description 95
- 230000003014 reinforcing effect Effects 0.000 claims abstract description 87
- 239000000853 adhesive Substances 0.000 claims description 22
- 238000010438 heat treatment Methods 0.000 claims description 22
- 230000001070 adhesive effect Effects 0.000 claims description 21
- 238000010030 laminating Methods 0.000 claims description 16
- 239000000463 material Substances 0.000 claims description 8
- 239000000805 composite resin Substances 0.000 claims description 4
- 239000013067 intermediate product Substances 0.000 claims description 4
- 239000012778 molding material Substances 0.000 claims description 4
- 238000007789 sealing Methods 0.000 claims description 4
- 238000007599 discharging Methods 0.000 claims description 3
- 230000002093 peripheral effect Effects 0.000 claims 1
- 239000004634 thermosetting polymer Substances 0.000 abstract 1
- 238000000465 moulding Methods 0.000 description 14
- 239000012783 reinforcing fiber Substances 0.000 description 12
- 238000006243 chemical reaction Methods 0.000 description 9
- 239000000835 fiber Substances 0.000 description 7
- 239000007789 gas Substances 0.000 description 6
- 238000003860 storage Methods 0.000 description 6
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 5
- 238000005470 impregnation Methods 0.000 description 5
- 229910052710 silicon Inorganic materials 0.000 description 5
- 239000010703 silicon Substances 0.000 description 5
- 230000000694 effects Effects 0.000 description 4
- 239000004744 fabric Substances 0.000 description 4
- 238000007796 conventional method Methods 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 239000003822 epoxy resin Substances 0.000 description 3
- 229920000647 polyepoxide Polymers 0.000 description 3
- 230000002787 reinforcement Effects 0.000 description 3
- 239000004677 Nylon Substances 0.000 description 2
- 238000006073 displacement reaction Methods 0.000 description 2
- 229920001971 elastomer Polymers 0.000 description 2
- 239000003365 glass fiber Substances 0.000 description 2
- 238000003475 lamination Methods 0.000 description 2
- 230000007774 longterm Effects 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 229920001778 nylon Polymers 0.000 description 2
- 239000005011 phenolic resin Substances 0.000 description 2
- 229920000728 polyester Polymers 0.000 description 2
- 239000000047 product Substances 0.000 description 2
- 238000005057 refrigeration Methods 0.000 description 2
- 239000011800 void material Substances 0.000 description 2
- XQUPVDVFXZDTLT-UHFFFAOYSA-N 1-[4-[[4-(2,5-dioxopyrrol-1-yl)phenyl]methyl]phenyl]pyrrole-2,5-dione Chemical compound O=C1C=CC(=O)N1C(C=C1)=CC=C1CC1=CC=C(N2C(C=CC2=O)=O)C=C1 XQUPVDVFXZDTLT-UHFFFAOYSA-N 0.000 description 1
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004642 Polyimide Substances 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 229920006231 aramid fiber Polymers 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 229920003020 cross-linked polyethylene Polymers 0.000 description 1
- 239000004703 cross-linked polyethylene Substances 0.000 description 1
- 230000003111 delayed effect Effects 0.000 description 1
- MSKQYWJTFPOQAV-UHFFFAOYSA-N fluoroethene;prop-1-ene Chemical group CC=C.FC=C MSKQYWJTFPOQAV-UHFFFAOYSA-N 0.000 description 1
- 238000009940 knitting Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 1
- 239000004745 nonwoven fabric Substances 0.000 description 1
- 229920003192 poly(bis maleimide) Polymers 0.000 description 1
- -1 polyethylene Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920001721 polyimide Polymers 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 238000010008 shearing Methods 0.000 description 1
- 229920002379 silicone rubber Polymers 0.000 description 1
- 239000004945 silicone rubber Substances 0.000 description 1
- 239000003351 stiffener Substances 0.000 description 1
- 238000001721 transfer moulding Methods 0.000 description 1
- 238000009941 weaving Methods 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
Classifications
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T50/00—Aeronautics or air transport
- Y02T50/40—Weight reduction
Landscapes
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Moulding By Coating Moulds (AREA)
- Lining Or Joining Of Plastics Or The Like (AREA)
Abstract
(57)【要約】
【課題】 航空機の外板のように補強部材を有する複合
材パネルを、ＲＦＩ法を使用して一体的に成形する方法
を提供する。
【解決手段】 熱硬化性樹脂フィルム２１の上にドライ
プリフォーム２２およびあらかじめ成形された補強部材
３０を順次配置して真空バッグフィルム７０によって被
覆し、この真空バッグフィルム７０の内部を真空状態に
してドライプリフォーム２２に熱硬化性樹脂フィルム２
１および補強部材３０を密着させると同時に加熱する。
これによって熱硬化性樹脂フィルム２１の熱硬化性樹脂
をドライプリフォーム２２に含浸・硬化させて板状体２
０を成形すると同時に、板状体２０表面への補強部材３
０の固定を行って複合材パネル１０を得る。
[PROBLEMS] To provide a method for integrally forming a composite panel having a reinforcing member such as an outer panel of an aircraft by using an RFI method. SOLUTION: A dry preform 22 and a preformed reinforcing member 30 are sequentially arranged on a thermosetting resin film 21 and covered with a vacuum bag film 70, and the inside of the vacuum bag film 70 is evacuated to dry the film. Thermoset resin film 2 on reform 22
1 and the reinforcing member 30 are brought into close contact with each other and heated.
As a result, the dry preform 22 is impregnated and cured with the thermosetting resin of the thermosetting resin film 21 to form the plate-like body 2.
At the same time as forming 0, the reinforcing member 3 on the surface of the plate-like body 20
The composite panel 10 is obtained by fixing 0.
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、複合材パネルの製
造方法に関し、特に、繊維強化樹脂製の複合材料によっ
て構成され、航空機翼の外板などに好適に使用される複
合材パネルを製造する方法に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a composite material panel, and more particularly to manufacturing a composite material panel which is composed of a composite material made of fiber reinforced resin and which is suitable for use as an outer panel of an aircraft wing. Regarding the method.
【０００２】[0002]
【従来の技術】現在、繊維強化樹脂製の複合材料が、各
種産業分野で使用されている。特に、航空宇宙分野にお
いては、航空機や宇宙航行機などの構造設計に軽量化お
よび高強度化が要求されるため、近年では、航空機の主
翼（または尾翼）の外板などに用いられる複合材パネル
（以下、「補強パネル」という）が、この繊維強化樹脂
製の複合材料によって製造されることが多くなってい
る。2. Description of the Related Art Currently, a composite material made of fiber reinforced resin is used in various industrial fields. Particularly in the aerospace field, structural design of aircrafts and spacecrafts is required to be lightweight and have high strength. Therefore, in recent years, composite material panels used for outer panels of main wings (or tail wings) of aircraft. (Hereinafter, referred to as "reinforcing panel") is often manufactured by the composite material made of the fiber reinforced resin.
【０００３】前記したような補強パネルは、外板と、こ
れに一体的に取り付けられたストリンガやスティフナな
どの補強部材とを備えるものである。外板に補強部材を
取り付けるための従来の手法としては、（１）外板と補
強部材とを別々に成形した後、外板の表面の適所に配置
した補強部材をリベット打ちなどによって固定する手
法、（２）プリプレグ積層法またはＲＴＭ（Resin Tran
sfer Molding）法によって成形して１次硬化させた補強
部材を、外板成形用のプリプレグに硬化と同時に接着さ
せる手法、などが挙げられる。The reinforcing panel as described above includes an outer plate and a reinforcing member such as a stringer or a stiffener integrally attached to the outer plate. As a conventional method for attaching the reinforcing member to the outer plate, (1) a method in which the outer plate and the reinforcing member are separately molded, and then the reinforcing member arranged at a proper position on the surface of the outer plate is fixed by riveting or the like. , (2) Prepreg lamination method or RTM (Resin Tran
sfer Molding) method and a primary hardening method is used to bond the reinforcing member to the prepreg for molding the outer plate simultaneously with hardening.
【０００４】前記（１）の手法においては、外板および
補強部材をオートクレーブ成形によって別々に成形する
のが一般的であった。すなわち、未硬化状態の熱硬化性
樹脂を所定の強化繊維の束に含浸させたプリプレグを所
定の形状の治具の上に配置し、要すればプリプレグの上
に所定のプレッシャープレートを載置した後、このプリ
プレグ層（およびプレッシャープレート）の上にバッグ
フィルムを被せ、このバッグフィルムの内部の空気を排
出して真空圧を負荷した後に、オートクレーブ内で加圧
・加熱して硬化させて、所望の外板や補強部材を成形し
ていた。また、成形した外板に補強部材を固定するため
には、前記したようにリベット打ちなどの煩雑な作業を
要した。In the above method (1), it is general that the outer plate and the reinforcing member are separately molded by autoclave molding. That is, a prepreg obtained by impregnating a predetermined reinforcing fiber bundle with an uncured thermosetting resin is placed on a jig having a predetermined shape, and if necessary, a predetermined pressure plate is placed on the prepreg. After that, a bag film is covered on the prepreg layer (and the pressure plate), air inside the bag film is exhausted and a vacuum pressure is applied, and then it is pressed and heated in an autoclave to be cured, and the desired The outer plate and the reinforcing member were molded. Further, in order to fix the reinforcing member to the molded outer plate, complicated work such as riveting is required as described above.
【０００５】また、前記（２）の手法においては、プリ
プレグ積層法またはＲＴＭ法によって成形し１次硬化さ
せた補強部材を、接着剤を介して外板成形用のプリプレ
グ上に配置し、オートクレーブを使用して加圧・加熱し
て、これら外板成形用のプリプレグと補強部材とを接着
させると同時に、プリプレグを硬化させる必要があっ
た。In the method (2), the reinforcing member molded by the prepreg laminating method or the RTM method and primarily cured is arranged on the prepreg for molding the outer plate through the adhesive, and the autoclave is formed. It was necessary to use and pressurize and heat the prepreg for molding the outer plate and the reinforcing member, and at the same time, to cure the prepreg.
【０００６】[0006]
【発明が解決しようとする課題】しかし、プリプレグお
よびオートクレーブを使用して補強パネルを製造する従
来の手法には、以下のような問題があった。However, the conventional method of manufacturing a reinforcing panel using a prepreg and an autoclave has the following problems.
【０００７】すなわち、前記した（１）および（２）の
手法で外板を成形する際には、板状のプリプレグを複数
枚積層する作業を要するが、一般的にプリプレグは粘着
性が高いため、一度プリプレグ同士を積層すると、再度
剥がしてその位置を微調整するのが困難であった。ま
た、オートクレーブを使用してプリプレグを硬化させて
仕上がった成形品（外板または補強部材）の内部には、
熱硬化性樹脂の硬化反応の際に発生する気泡が残存して
空隙が形成され、この空隙が成形品の強度を低下させる
ことがあった。That is, when molding the outer plate by the above-mentioned methods (1) and (2), it is necessary to stack a plurality of plate-shaped prepregs, but generally the prepreg has high adhesiveness. Once the prepregs were laminated, it was difficult to peel them off again and finely adjust the position. In addition, inside the molded product (outer plate or reinforcing member) finished by curing the prepreg using an autoclave,
Bubbles generated during the curing reaction of the thermosetting resin may remain to form voids, which may reduce the strength of the molded product.
【０００８】また、プリプレグは、未硬化状態の熱硬化
性樹脂を所定の強化繊維の束に含浸させたものである
が、この未硬化状態の熱硬化性樹脂の硬化反応の進行を
防ぐため、プリプレグを低温の環境で保管する必要があ
る。このため、プリプレグ保管のために別途冷蔵設備を
設置する必要があった。また、プリプレグを低温の環境
で保管した場合でも、保管中に徐々に硬化反応が進行す
るために保管期間が限られ、保管期間が経過した場合に
は、プリプレグを構成する熱硬化性樹脂と強化繊維とを
ともに廃棄しなければならず、製造上のコストが嵩んで
いた。The prepreg is obtained by impregnating a predetermined bundle of reinforcing fibers with an uncured thermosetting resin. To prevent the curing reaction of the uncured thermosetting resin, The prepreg should be stored in a low temperature environment. Therefore, it was necessary to install a separate refrigeration facility for storing the prepreg. Even when the prepreg is stored in a low temperature environment, the storage reaction is limited because the curing reaction gradually progresses during storage, and when the storage period elapses, it is reinforced with the thermosetting resin that constitutes the prepreg. Since the fiber and the fiber must be discarded together, the manufacturing cost is high.
【０００９】さらに、前記した（１）および（２）の手
法で外板を成形する際には、プリプレグ硬化のためにオ
ートクレーブを使用する必要があり、特に、前記した
（１）の手法で外板と補強部材とを別々にオートクレー
ブ成形によって成形する場合には、オートクレーブを複
数回作動させる必要がある。このオートクレーブの作動
にはきわめて大きな電力を要するため、補強パネルを製
造する際の製造コストは、きわめて大きいものとなって
いた。Further, when molding the outer plate by the above-mentioned methods (1) and (2), it is necessary to use an autoclave for curing the prepreg, and in particular, the outside of the method (1) is used. When the plate and the reinforcing member are separately molded by autoclave molding, it is necessary to operate the autoclave multiple times. Since the operation of this autoclave requires an extremely large amount of electric power, the manufacturing cost for manufacturing the reinforcing panel has been extremely high.
【００１０】さらにまた、例えば大型航空機の主翼用補
強パネルのようなきわめて大型の補強パネルを製造する
際には、きわめて大型のオートクレーブを築造する必要
があるが、このような大型のオートクレーブを築造する
場所の確保が困難であることやコスト上の問題などによ
って、実用化が遅延していた。Furthermore, when manufacturing an extremely large reinforcing panel such as a reinforcing panel for a main wing of a large aircraft, it is necessary to construct an extremely large autoclave, which is constructed. Practical application was delayed because it was difficult to secure a place and there was a cost problem.
【００１１】本発明は、前記したようなプリプレグおよ
びオートクレーブを使用して補強パネルを製造する際の
問題を一挙に解決するものである。すなわち、本発明の
課題は、製造上の労力を格段に低減することができ、か
つ、製造上のコストを格段に削減することができる複合
材パネルの製造方法を提供することである。The present invention is to solve all the problems at the time of manufacturing a reinforcing panel using the prepreg and the autoclave as described above. That is, an object of the present invention is to provide a method for manufacturing a composite material panel, which can significantly reduce the manufacturing labor and the manufacturing cost.
【００１２】[0012]
【課題を解決するための手段】以上の課題を解決するた
めに、請求項１記載の発明は、例えば図１から図３に示
すように、繊維強化樹脂複合材製の板状体と、前記板状
体を補強する繊維強化樹脂複合材製の補強部材とを有す
る複合材パネルの製造方法において、前記補強部材をあ
らかじめ成形する補強部材成形工程と、下型治具の上に
熱硬化性樹脂フィルムおよびドライプリフォームを積層
する板状体成形材料積層工程と、前記ドライプリフォー
ムの上に熱硬化性の接着剤を介して前記補強部材を配置
する補強部材配置工程と、前記補強部材の上から真空バ
ッグフィルムを被せて、前記補強部材と前記熱硬化性樹
脂フィルムと前記ドライプリフォームとを密封する密封
工程と、前記真空バッグフィルムで密封した部分から空
気を排出する排気工程と、前記真空バッグフィルムで密
封して空気を排出した部分を加熱する加熱工程とを備え
ることを特徴とする。In order to solve the above problems, the invention according to claim 1 is, for example, as shown in FIGS. 1 to 3, a plate-shaped body made of a fiber-reinforced resin composite material, and In a method of manufacturing a composite material panel having a reinforcing member made of a fiber-reinforced resin composite material for reinforcing a plate-shaped body, a reinforcing member forming step of previously forming the reinforcing member, and a thermosetting resin on the lower die jig. A plate-shaped molding material laminating step of laminating a film and a dry preform, a reinforcing member arranging step of arranging the reinforcing member on the dry preform via a thermosetting adhesive, and a vacuum from above the reinforcing member. A sealing step of covering the bag member with the reinforcing member, the thermosetting resin film and the dry preform, and exhausting air from the portion sealed with the vacuum bag film. And extent, characterized in that it comprises a heating step and sealed with the vacuum bag film to heat moiety discharging air.
【００１３】請求項１記載の発明によれば、熱硬化性樹
脂フィルムとドライプリフォームとあらかじめ成形した
補強部材とから複合材パネルを製造するため、複合材パ
ネルの製造にプリプレグを使用する必要がなく、プリプ
レグを使用することによって生じていた従来の製造上の
問題を一挙に解決することができる。According to the first aspect of the present invention, since the composite material panel is manufactured from the thermosetting resin film, the dry preform and the preformed reinforcing member, it is not necessary to use a prepreg for manufacturing the composite material panel. It is possible to solve all of the conventional manufacturing problems that have been caused by using the prepreg.
【００１４】すなわち、強化繊維製のドライプリフォー
ムを熱硬化性樹脂フィルムの上に配置した場合に、これ
らドライプリフォームおよび熱硬化性樹脂フィルムの粘
着力が弱く、かつ、このドライプリフォームを複数枚積
層した場合にも層間が密着することがないので、積層作
業がきわめて容易となる。また、一度積層してからも、
ドライプリフォームの配置方向を自在に変更することが
できる。この結果、複合材パネルの製造が容易となる。
また、プリプレグを硬化させた場合のように内部に空隙
が形成されることがなく、製造された複合材パネルの品
質が低下することもない。That is, when a dry preform made of reinforcing fibers is placed on a thermosetting resin film, the dry preform and the thermosetting resin film have weak adhesion and a plurality of dry preforms are laminated. Also in this case, the layers do not come into close contact with each other, so that the laminating work becomes extremely easy. Also, even after stacking once,
The arrangement direction of the dry preform can be freely changed. As a result, the manufacture of the composite panel is facilitated.
Further, unlike the case where the prepreg is cured, voids are not formed inside, and the quality of the manufactured composite material panel is not deteriorated.
【００１５】さらに、冷凍保管が必要になるのは熱硬化
性樹脂フィルムのみで、強化繊維製のドライプリフォー
ムは常温で保管することができるため、熱硬化性樹脂フ
ィルムと強化繊維製のドライプリフォームとを分離して
保管することができる。従って、長期間にわたる保管に
よって熱硬化性樹脂フィルムが劣化した場合でも、熱硬
化性樹脂フィルムのみを廃棄するだけですみ、プリプレ
グ廃棄の際のように熱硬化性樹脂と強化繊維とをともに
廃棄する必要がない。この結果、複合材パネル製造上の
コストを削減することもできる。Further, only the thermosetting resin film needs to be stored in a frozen state, and the dry preform made of the reinforcing fiber can be stored at room temperature, so that the thermosetting resin film and the dry preform made of the reinforcing fiber can be stored. Can be stored separately. Therefore, even if the thermosetting resin film deteriorates due to long-term storage, only the thermosetting resin film needs to be discarded, and both the thermosetting resin and the reinforcing fiber are discarded as in the case of prepreg disposal. No need. As a result, the cost for manufacturing the composite material panel can be reduced.
【００１６】また、請求項１記載の発明によれば、熱硬
化性樹脂フィルムとドライプリフォームとから板状体の
成形を行い、かつ、あらかじめ成形した補強部材を複合
材パネルの構成要素として使用しているため、熱硬化性
樹脂フィルムの熱硬化性樹脂をドライプリフォームに含
浸させるだけの圧力があればよく、排気工程の真空引き
による加圧のみで充分成形可能である。従って、複合材
パネル製造の際にオートクレーブを使用する必要がな
い。According to the first aspect of the invention, a plate-like body is formed from the thermosetting resin film and the dry preform, and the preformed reinforcing member is used as a constituent element of the composite material panel. Therefore, the pressure required to impregnate the thermosetting resin of the thermosetting resin film into the dry preform is sufficient, and sufficient molding can be performed only by pressurization by evacuation in the exhaust step. Therefore, it is not necessary to use an autoclave when manufacturing the composite panel.
【００１７】この結果、従来、オートクレーブを使用す
ることによって生じていた製造上の問題を一挙に解決す
ることができる。すなわち、オートクレーブを使用した
場合のように複合材パネルの製造コストが嵩むことがな
く、また、製造する複合材パネルが大型である場合に
も、これに適応させた大型のオートクレーブを築造する
必要がない。As a result, it is possible to solve the manufacturing problems that have conventionally been caused by using an autoclave. That is, the manufacturing cost of the composite material panel does not increase unlike the case where the autoclave is used, and even when the composite material panel to be manufactured is large, it is necessary to build a large autoclave adapted to this. Absent.
【００１８】また、請求項１記載の発明によれば、熱硬
化性樹脂フィルムおよびドライプリフォームから構成さ
れる板状体の成形と、この板状体表面への補強部材の固
定を同時に行うことができる。このため、複合材パネル
製造時において、板状体に補強部材を固定する際に従来
必要であったリベット打ちなどの煩雑な作業を省くこと
ができ、複合材パネルの製造上の労力を格段に低減させ
ることができる。Further, according to the first aspect of the present invention, it is possible to simultaneously form the plate-like body composed of the thermosetting resin film and the dry preform and fix the reinforcing member on the surface of the plate-like body. it can. Therefore, when manufacturing the composite material panel, it is possible to omit the complicated work such as riveting which is conventionally required when fixing the reinforcing member to the plate-like body, and the labor for manufacturing the composite material panel is remarkably increased. Can be reduced.
【００１９】請求項２記載の発明は、請求項１記載の複
合材パネルの製造方法において、前記補強部材は、熱硬
化性樹脂を１次硬化させた中間製品であり、前記加熱工
程において、前記補強部材を本硬化させることを特徴と
する。According to a second aspect of the present invention, in the method for producing a composite material panel according to the first aspect, the reinforcing member is an intermediate product obtained by primary curing a thermosetting resin, and in the heating step, It is characterized in that the reinforcing member is fully cured.
【００２０】請求項２記載の発明によれば、請求項１記
載の発明と同様の作用効果を奏することに加え、補強部
材が、熱硬化性樹脂を１次硬化させた中間製品であり、
この補強部材の本硬化を、板状体の成形とこの板状体表
面への補強部材の固定と同時に前記加熱工程において行
うため、あらかじめ本硬化させた補強部材を使用する必
要がない。この結果、補強部材を本硬化させる手間（労
力）を省くことができ、全体として、製造時間の短縮
と、一層の製造上の労力の低減および製造上のコストの
削減をもたらすことができる。According to the second aspect of the present invention, in addition to the same effects as the first aspect of the invention, the reinforcing member is an intermediate product obtained by primary curing a thermosetting resin,
Since the main curing of the reinforcing member is performed in the heating step simultaneously with the molding of the plate and the fixing of the reinforcing member on the surface of the plate, it is not necessary to use the reinforcing member that has been main cured in advance. As a result, the labor (labor) for the main curing of the reinforcing member can be omitted, and as a whole, the manufacturing time can be shortened, and the manufacturing labor and the manufacturing cost can be further reduced.
【００２１】請求項３記載の発明は、請求項１または２
記載の複合材パネルの製造方法において、例えば図３に
示すように、前記板状体成形材料積層工程では、下型治
具の上に前記熱硬化性樹脂フィルムを積層した後、前記
熱硬化性樹脂フィルムの上に前記ドライプリフォームを
積層し、積層した前記熱硬化性樹脂フィルムおよび前記
ドライプリフォームの周囲の側面に近接させて側面治具
を配置し、前記側面治具と前記ドライプリフォームと前
記補強部材との上に空気通路を形成することを特徴とす
る。The invention according to claim 3 is the invention according to claim 1 or 2.
In the method for producing a composite material panel described above, for example, as shown in FIG. 3, in the plate-shaped body molding material laminating step, after laminating the thermosetting resin film on a lower die jig, the thermosetting resin is laminated. The dry preform is laminated on a resin film, and a side jig is arranged close to the laminated thermosetting resin film and the side surface around the dry preform, and the side jig, the dry preform, and the reinforcement are arranged. An air passage is formed above the member.
【００２２】請求項３記載の発明によれば、請求項１ま
たは２記載の発明と同様の作用効果を奏することに加
え、熱硬化性樹脂の含浸・硬化反応によって発生するガ
スや、接着剤界面（すなわち、ドライプリフォームと接
着剤との間、および、補強部材と接着剤との間）に存在
する空気を、外部に効果的に排出させることができる。
この結果、より高品質な複合材パネルを製造することが
できる。According to the invention of claim 3, in addition to the same effect as the invention of claim 1 or 2, the gas generated by the impregnation / curing reaction of the thermosetting resin and the adhesive interface Air existing between the dry preform and the adhesive and between the reinforcing member and the adhesive can be effectively discharged to the outside.
As a result, a higher quality composite material panel can be manufactured.
【００２３】[0023]
【発明の実施の形態】以下、本発明の実施の形態を、図
面に基づいて詳細に説明する。BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below in detail with reference to the drawings.
【００２４】[第１の実施の形態]本実施の形態に係る複
合材パネル１０は、航空機の翼外板などに使用されるも
のであり、図１に示すように、外板２０と、これに一体
的に固定された補強部材３０とを備える。複合材パネル
１０の外板２０は、後述するように熱硬化性樹脂フィル
ム２１とドライプリフォーム２２とから成形される。ま
た、補強部材３０は、図１から明らかなように、長さ方
向に対して直角に切断した際の断面形状がＴ字型を呈す
る長尺の部材（ストリンガ）である。[First Embodiment] A composite material panel 10 according to the present embodiment is used for an aircraft wing skin or the like, and as shown in FIG. And a reinforcing member 30 integrally fixed to. The outer plate 20 of the composite material panel 10 is formed from a thermosetting resin film 21 and a dry preform 22 as described later. Further, as is apparent from FIG. 1, the reinforcing member 30 is a long member (stringer) having a T-shaped cross-sectional shape when cut at right angles to the length direction.
【００２５】熱硬化性樹脂フィルム２１は、ドライプリ
フォーム２２とともに複合材パネル１０の外板２０を形
成するものである。熱硬化性樹脂フィルム２１の材料と
なる熱硬化性樹脂の種類としては、エポキシ樹脂、フェ
ノール樹脂、架橋ポリエチレン、ビスマレイミド、ポリ
イミドなどを挙げることができ、中でも、エポキシ樹脂
が好適である。熱硬化性樹脂フィルム２１およびドライ
プリフォーム２２の厚さは、製造する複合材パネル１０
の外板２０のサイズに応じて適宜決めることができる。The thermosetting resin film 21 forms the outer plate 20 of the composite material panel 10 together with the dry preform 22. Examples of the thermosetting resin used as the material of the thermosetting resin film 21 include epoxy resin, phenol resin, cross-linked polyethylene, bismaleimide, and polyimide. Among them, epoxy resin is preferable. The thickness of the thermosetting resin film 21 and the dry preform 22 are the same as those of the composite material panel 10 to be manufactured.
It can be appropriately determined according to the size of the outer plate 20.
【００２６】ドライプリフォーム２２は、前記した熱硬
化性樹脂フィルム２１とともに複合材パネル１０の外板
２０を形成するものである。なお、本発明において「ド
ライプリフォーム」とは、各種強化繊維によって構成さ
れる可撓性の乾燥した薄板状体を意味し、この薄板状体
が複数枚積層されている積層体も含むものとする。ドラ
イプリフォーム２２を構成する強化繊維の種類として
は、ガラス繊維、カーボン繊維、アラミド繊維、アルミ
ナ繊維などを挙げることができる。The dry preform 22 forms the outer plate 20 of the composite material panel 10 together with the above-mentioned thermosetting resin film 21. In the present invention, the “dry preform” means a flexible and dried thin plate-like body composed of various reinforcing fibers, and includes a laminated body in which a plurality of the thin plate-like bodies are laminated. Examples of the type of reinforcing fiber forming the dry preform 22 include glass fiber, carbon fiber, aramid fiber, and alumina fiber.
【００２７】ドライプリフォーム２２の構成態様として
は、例えば、前記強化繊維を織り、編み、または撚り合
わせることによって織物状、編物状、マット状、フェル
ト状に構成した態様とすることができる。また、ドライ
プリフォーム２２の厚さは、製造する複合材パネル１０
の外板２０のサイズや、前記熱硬化性樹脂フィルム２１
の厚さに応じて適宜決めることができる。The dry preform 22 can be configured, for example, by weaving, knitting, or twisting the reinforcing fibers into a woven, knit, mat, or felt shape. The thickness of the dry preform 22 is the same as the composite material panel 10 to be manufactured.
The size of the outer plate 20 and the thermosetting resin film 21
Can be appropriately determined according to the thickness of the.
【００２８】補強部材３０は、前記した熱硬化性樹脂フ
ィルム２１およびドライプリフォーム２２によって成形
される外板２０の上に一体的に固定されて外板２０を補
強するものであり、せん断荷重、ねじり荷重または曲げ
荷重に対して複合材パネル１０に高い強度を発揮させ
る。この補強部材３０は、熱硬化性樹脂を材料としてプ
リプレグ積層法またはＲＴＭ法によって成形して１次硬
化または本硬化させたものであり、本実施の形態では、
前記したように長さ方向に対して直角に切断した際の断
面形状がＴ字型とされている。The reinforcing member 30 is integrally fixed on the outer plate 20 formed by the thermosetting resin film 21 and the dry preform 22 to reinforce the outer plate 20, and shearing load and torsion are applied. The composite material panel 10 exhibits high strength against a load or a bending load. The reinforcing member 30 is made of thermosetting resin as a material and is molded by the prepreg laminating method or the RTM method and primary-cured or main-cured. In the present embodiment,
As described above, the cross-sectional shape when cut at a right angle to the length direction is T-shaped.
【００２９】次に、第１の実施の形態に係る複合材パネ
ル１０の製造方法について、図２および図３を用いて説
明する。Next, a method of manufacturing the composite material panel 10 according to the first embodiment will be described with reference to FIGS. 2 and 3.
【００３０】まず、所定の場所に下型治具４０を設置す
る。この下型治具４０の表面形状は、成形する複合材パ
ネル１０の外板２０の表面形状と同一とされ、その表面
の上に、前記熱硬化性樹脂フィルム２１を配置するもの
である。この下型治具４０は、後述する排気工程による
真空圧によっても変形しない剛性と、後述する加熱工程
に耐え得る耐熱性とを備える必要があるが、このような
特性を有するものであれば、その構造や材料に制限はな
い。First, the lower die jig 40 is installed at a predetermined place. The surface shape of the lower jig 40 is the same as the surface shape of the outer plate 20 of the composite material panel 10 to be molded, and the thermosetting resin film 21 is arranged on the surface. The lower jig 40 needs to have rigidity that is not deformed by a vacuum pressure in an exhaust process described below and heat resistance that can endure a heating process described below. However, as long as it has such characteristics, There are no restrictions on its structure or material.
【００３１】次いで、前記下型治具４０の表面の上に、
熱硬化性樹脂フィルム２１を配置する。この際、熱硬化
性樹脂フィルム２１と下型治具４０の表面との間に剥離
剤を介在させておくと、成形後に、下型治具４０から複
合材パネル１０を容易に分離させることができるので、
好ましい。Next, on the surface of the lower die jig 40,
The thermosetting resin film 21 is arranged. At this time, if a release agent is interposed between the thermosetting resin film 21 and the surface of the lower die jig 40, the composite material panel 10 can be easily separated from the lower die jig 40 after molding. Because you can
preferable.
【００３２】次いで、熱硬化性樹脂フィルム２１の上
に、ドライプリフォーム２２を配置する（板状体成形材
料配置工程、図２参照）。このドライプリフォーム２２
を、強化繊維製の薄板状体を複数枚積層して構成する場
合には、前記薄板状体の強化繊維の配向を種々異ならせ
て積層すると、あらゆる方向からの荷重に対して高い強
度を発揮する外板２０を成形することができる。また、
ドライプリフォーム２２は熱硬化性樹脂が含浸されてい
ないので相互に接着することがなく、また、熱硬化性樹
脂フィルム２１の粘着力も弱いので、積層作業が格段に
容易となる。Next, the dry preform 22 is placed on the thermosetting resin film 21 (plate-like molding material placing step, see FIG. 2). This dry preform 22
, When laminating a plurality of reinforcing fiber thin plate-shaped bodies, by stacking with different orientations of the reinforcing fibers of the thin plate-shaped body, high strength against load from any direction is demonstrated. The outer plate 20 can be molded. Also,
Since the dry preforms 22 are not impregnated with a thermosetting resin, they do not adhere to each other, and the adhesive force of the thermosetting resin film 21 is weak, so that the laminating work is significantly facilitated.
【００３３】次いで、ドライプリフォーム２２の上に、
接着剤２３を介して、前記した補強部材３０を配置する
（補強部材配置工程、図２参照）。接着剤２３は、後述
する加熱工程で硬化させることができて高強度な、エポ
キシ樹脂系、フェノール樹脂系などの熱硬化性樹脂製の
接着剤とする。また、接着剤２３の態様は、フィルム
状、液状、粉末状などとすることができるが、取り扱い
易く、品質の安定したフィルム状の態様とするのが好ま
しく、本実施の形態においてもフィルム状の接着剤２３
を採用している。Then, on the dry preform 22,
The above-mentioned reinforcing member 30 is arranged via the adhesive 23 (reinforcing member arranging step, see FIG. 2). The adhesive 23 is an adhesive made of a thermosetting resin such as an epoxy resin type or a phenol resin type, which can be cured in a heating step described later and has high strength. The adhesive 23 may be in the form of a film, a liquid, a powder, or the like, but it is preferable that the adhesive 23 be a film in which the handling is easy and the quality is stable. Adhesive 23
Has been adopted.
【００３４】次いで、図２に示すように、ドライプリフ
ォーム２２の上にプレッシャープレート５０を配置し
て、後述する排気工程の際にドライプリフォーム２２に
均等な圧力を加えることができるようにする。このプレ
ッシャープレート５０は、被覆工程の際における補強部
材３０の位置のずれを防止するという機能も果たし、金
属やゴムによって調製することができる。Next, as shown in FIG. 2, a pressure plate 50 is arranged on the dry preform 22 so that a uniform pressure can be applied to the dry preform 22 during the exhausting step described later. The pressure plate 50 also has a function of preventing the displacement of the position of the reinforcing member 30 during the covering step, and can be prepared from metal or rubber.
【００３５】また、熱硬化性樹脂フィルム２１とドライ
プリフォーム２２とプレッシャープレート５０との積層
体の周囲にダム６０を配置して、後述する加熱工程によ
って熱硬化性樹脂フィルム２１の熱硬化性樹脂をドライ
プリフォーム２２へと含浸させる際に、熱硬化性樹脂が
外部へ流出しないようにする。このダム６０も、プレッ
シャープレート５０と同様に金属やゴムによって調製す
ることができる。Further, a dam 60 is arranged around the laminate of the thermosetting resin film 21, the dry preform 22 and the pressure plate 50, and the thermosetting resin of the thermosetting resin film 21 is removed by a heating process described later. When impregnating the dry preform 22, the thermosetting resin is prevented from flowing out. Like the pressure plate 50, the dam 60 can be made of metal or rubber.
【００３６】次いで、下型治具４０の上に配置した熱硬
化性樹脂フィルム２１、ドライプリフォーム２２、プレ
ッシャープレート５０および補強部材３０を、真空バッ
グフィルム７０によって被覆して密封する（密封工程、
図２参照）。すなわち、真空バッグフィルム７０と下型
治具４０との間にこれら熱硬化性樹脂フィルム２１、ド
ライプリフォーム２２、プレッシャープレート５０およ
び補強部材３０を挟み込むようにする。Next, the thermosetting resin film 21, the dry preform 22, the pressure plate 50 and the reinforcing member 30 placed on the lower die jig 40 are covered with a vacuum bag film 70 and sealed (sealing step,
See FIG. 2). That is, the thermosetting resin film 21, the dry preform 22, the pressure plate 50, and the reinforcing member 30 are sandwiched between the vacuum bag film 70 and the lower die jig 40.
【００３７】真空バッグフィルム７０は、後述する排気
工程の際にプレッシャープレート５０や補強部材３０に
密着して加圧することができるように、高い気密性を有
しかつ柔軟性に優れたものとし、シリコンゴムで調製し
たものが好適である。The vacuum bag film 70 has high airtightness and excellent flexibility so that the vacuum bag film 70 can be in close contact with the pressure plate 50 and the reinforcing member 30 to be pressed during the exhausting process described later, Those prepared with silicone rubber are preferred.
【００３８】次いで、真空バッグフィルム７０の内部か
ら空気を排出して、真空バッグフィルム７０と下型治具
４０との間に挟み込んだ熱硬化性樹脂フィルム２１、ド
ライプリフォーム２２および補強部材７０に真空圧を加
えることによって、ドライプリフォーム２２に熱硬化性
樹脂フィルム２１および補強部材３０を密着させる（排
気工程）。Next, air is discharged from the inside of the vacuum bag film 70, and a vacuum is applied to the thermosetting resin film 21, the dry preform 22 and the reinforcing member 70 sandwiched between the vacuum bag film 70 and the lower jig 40. By applying pressure, the thermosetting resin film 21 and the reinforcing member 30 are brought into close contact with the dry preform 22 (exhaust step).
【００３９】この排気工程における排気の手法として
は、例えば、真空バッグフィルム７０に排気孔を設けて
おき、この排気孔とバキューム装置とを排気管によって
接続し、バキューム装置によって真空バッグフィルム７
０の内部の空気を排出する手法など、従来の手法を採用
することができる。As an evacuation method in this evacuation step, for example, an evacuation hole is provided in the vacuum bag film 70, the evacuation hole and a vacuum device are connected by an exhaust pipe, and the vacuum bag film 7 is connected by the vacuum device.
A conventional method such as a method of discharging the air inside 0 can be adopted.
【００４０】次いで、前記した排気工程によって真空圧
を加えた状態で、熱硬化性樹脂フィルム２１とドライプ
リフォーム２２とを加熱することによって、熱硬化性樹
脂フィルム２１の熱硬化性樹脂をドライプリフォーム２
２に含浸させ、この含浸させた熱硬化性樹脂と接着剤２
３とを硬化させる（加熱工程）。この加熱工程によっ
て、外板２０の成形と、外板２０表面への補強部材３０
の接着とを同時に行うことができる。Then, the thermosetting resin film 21 and the dry preform 22 are heated in a state where a vacuum pressure is applied by the above-described exhausting process, so that the thermosetting resin of the thermosetting resin film 21 is dried.
2 and the thermosetting resin and the adhesive 2
And 3 are cured (heating step). Through this heating step, the outer plate 20 is formed and the reinforcing member 30 is formed on the surface of the outer plate 20.
Can be simultaneously adhered.
【００４１】加熱は、下型治具４０に内蔵された加熱装
置やオーブンなどを使用して施すことができる。この際
の加熱温度および加熱時間は、熱硬化性樹脂の種類や熱
硬化性樹脂フィルム２１の厚さ、ドライプリフォーム２
２の積層数などに応じて適宜決めることができる。The heating can be performed by using a heating device or an oven built in the lower die jig 40. The heating temperature and heating time at this time are as follows: the type of thermosetting resin, the thickness of the thermosetting resin film 21, the dry preform 2
It can be appropriately determined according to the number of laminated layers of two or the like.
【００４２】なお、ドライプリフォーム２２の上に配置
される補強部材３０を、例えば、ＣＹＣＯＭ ８７５Ｒ
ＴＭ（商品名：Cytec Fiberite Inc.製）などの特定の
熱硬化性樹脂を使用してＲＴＭ法によって成形して１次
硬化させた中間製品とした場合には、前記した加熱工程
において、熱硬化性樹脂フィルム２１の熱硬化性樹脂の
ドライプリフォーム２２への含浸・硬化による外板２０
の成形と、前記熱硬化性樹脂製の接着剤２３の硬化によ
る外板２０表面への補強部材３０の固定と同時に、この
補強部材３０の本硬化を行うことができる。この結果、
複合材パネル１０の製造時間の短縮とともに、一層の製
造上の労力の低減および製造コストの削減をもたらすこ
とができる。また、補強部材３０の成形の際にもオート
クレーブを使用しなくてすむ。The reinforcing member 30 disposed on the dry preform 22 is, for example, CYCOM 875R.
When a specific thermosetting resin such as TM (trade name: manufactured by Cytec Fiberite Inc.) is used to form an intermediate product that is molded and primary cured by the RTM method, the thermosetting is performed in the heating step described above. Plate 20 by impregnating and curing a dry preform 22 of a thermosetting resin of a flexible resin film 21
The main curing of the reinforcing member 30 can be performed at the same time as the molding and fixing of the reinforcing member 30 to the surface of the outer plate 20 by the curing of the adhesive 23 made of the thermosetting resin. As a result,
The manufacturing time of the composite material panel 10 can be shortened, and the manufacturing labor and the manufacturing cost can be further reduced. Further, it is not necessary to use an autoclave when molding the reinforcing member 30.
【００４３】以上の手順によって、熱硬化性樹脂フィル
ム２１とドライプリフォーム２２とによる外板２０の成
形と、この外板２０表面への補強部材３０の固定とを同
時に行って複合材パネル１０を製造することができる
が、さらに、ドライプリフォーム２２およびプレッシャ
ープレート５０近傍部分に配置される詳細部品につい
て、図３を用いて説明する。図３に示すように、ドライ
プリフォーム２２とプレッシャープレート５０との間に
は、排気孔を有するシリコンシート８０がピール層８
１、８２を介して配置されており、さらに、真空バッグ
フィルム７０の内側にはブリーザ９０が配置されてい
る。By the above procedure, the molding of the outer plate 20 with the thermosetting resin film 21 and the dry preform 22 and the fixing of the reinforcing member 30 to the surface of the outer plate 20 are simultaneously performed to manufacture the composite material panel 10. However, detailed components arranged in the vicinity of the dry preform 22 and the pressure plate 50 will be described with reference to FIG. As shown in FIG. 3, between the dry preform 22 and the pressure plate 50, a silicon sheet 80 having an exhaust hole is provided in the peel layer 8.
1, and a breather 90 is arranged inside the vacuum bag film 70.
【００４４】シリコンシート８０は、加熱工程によって
溶融した熱硬化性樹脂フィルム２１の熱硬化性樹脂が流
出するのを防ぐという機能を果たす。また、ピール層８
１、８２は、前記した排気工程および加熱工程を行った
際にプレッシャープレート５０がドライプリフォーム２
２に密着して成形作業後に剥離し難くなるのを防止する
とともに、熱硬化性樹脂の含浸・硬化反応によって発生
するガスや、接着剤界面に存在する空気を、外部に効果
的に排出させるという機能を果たすものである。The silicon sheet 80 has a function of preventing the thermosetting resin of the thermosetting resin film 21 melted in the heating step from flowing out. Also, the peel layer 8
In Nos. 1 and 82, the pressure plate 50 is the dry preform 2 when the exhaust process and the heating process described above are performed.
It is said that it adheres to 2 and prevents it from peeling off easily after the molding work, and effectively discharges the gas generated by the impregnation / curing reaction of the thermosetting resin and the air present at the adhesive interface to the outside. It fulfills its function.
【００４５】ドライプリフォーム２２とシリコンシート
８０との間の第１ピール層８１は、例えば、排気孔を有
するＦＥＰ（フルオロエチレンプロピレン）フィルム、
ナイロン製織物、ポリエチレン製織物などで構成するこ
とができる。また、シリコンシート８０とプレッシャー
プレート５０との間の第２ピール層８２は、ナイロン製
織物またはポリエステル製織物で構成することができ
る。第１ピール層８１がＦＥＰフィルムである場合に排
気孔を設けるのは、前記したように、熱硬化性樹脂の含
浸・硬化反応によって発生するガスや、接着剤界面に存
在する空気を外部に効果的に排出するためである。The first peel layer 81 between the dry preform 22 and the silicon sheet 80 is, for example, an FEP (fluoroethylene propylene) film having exhaust holes,
It can be made of nylon fabric, polyethylene fabric, or the like. In addition, the second peel layer 82 between the silicon sheet 80 and the pressure plate 50 may be made of nylon fabric or polyester fabric. When the first peel layer 81 is the FEP film, the exhaust hole is provided so that the gas generated by the impregnation / curing reaction of the thermosetting resin and the air existing at the adhesive interface are externally effective. This is for the purpose of effective discharge.
【００４６】また、ブリーザ９０は、前記した排気工程
および加熱工程を行った際に熱硬化性樹脂の含浸・硬化
反応によって発生するガスや、接着剤界面から排出され
た空気を、真空バッグフィルム７０の排気孔近傍へと誘
導して、これらガスや空気を真空バッグフィルム７０の
外部に効果的に排出するように機能するものである。ブ
リーザ９０は、ガラス繊維製織物やポリエステル製不織
布などによって調製することができる。Further, the breather 90 removes the gas generated by the impregnation / curing reaction of the thermosetting resin during the exhausting step and the heating step and the air discharged from the adhesive interface, in the vacuum bag film 70. It functions to effectively discharge these gases and air to the outside of the vacuum bag film 70 by guiding them to the vicinity of the exhaust hole. The breather 90 can be prepared from a glass fiber woven fabric, a polyester non-woven fabric, or the like.
【００４７】本実施の形態に係る複合材パネル１０の製
造方法によれば、熱硬化性樹脂フィルム２１とドライプ
リフォーム２２とから外板２０を成形し、かつ、あらか
じめ成形した補強部材３０を使用して複合材パネル１０
を製造しているため、製造の際にプリプレグを使用する
必要がなく、プリプレグを使用することによって生じて
いた従来の製造上の問題を一挙に解決することができ
る。According to the method of manufacturing the composite material panel 10 according to the present embodiment, the outer plate 20 is molded from the thermosetting resin film 21 and the dry preform 22, and the preformed reinforcing member 30 is used. Composite panel 10
Since it is manufactured, it is not necessary to use a prepreg at the time of manufacturing, and it is possible to solve the problems in the conventional manufacturing caused by using the prepreg all at once.
【００４８】すなわち、積層時にドライプリフォーム２
２が熱硬化性樹脂フィルム２１に粘着することがなく、
かつ、ドライプリフォーム２２を複数枚積層した場合に
も層間が密着することがないので、積層作業がきわめて
容易となる。また、積層後も、ドライプリフォーム２２
の配置方向を自在に変更することができる。この結果、
複合材パネル１０の製造が格段に容易となる。さらに、
ドライプリフォーム２２には粘着性がないため、層間か
ら空気が排出され易い。さらにまた、プリプレグを硬化
させた場合のように内部に空隙が形成されることがな
く、高品質の複合材パネル１０を得ることができる。That is, the dry preform 2 is used for stacking.
2 does not adhere to the thermosetting resin film 21,
Moreover, even when a plurality of dry preforms 22 are laminated, the layers do not adhere to each other, so that the laminating operation becomes extremely easy. In addition, even after lamination, the dry preform 22
The arrangement direction of can be freely changed. As a result,
The manufacture of the composite material panel 10 is much easier. further,
Since the dry preform 22 does not have adhesiveness, air is easily discharged from the layers. Furthermore, unlike the case where the prepreg is cured, no void is formed inside, and a high quality composite material panel 10 can be obtained.
【００４９】また、本実施の形態に係る製造方法で使用
されるドライプリフォーム２２は常温で保管することが
できるため、プリプレグのように低温の環境で保管する
必要がなく、熱硬化性樹脂フィルム保管用の冷凍設備だ
けで足りる。また、長期間にわたる保管によって熱硬化
性樹脂フィルム２１が劣化した場合でも、熱硬化性樹脂
フィルム２１のみを廃棄するだけですみ、従来のプリプ
レグ廃棄の際のように熱硬化性樹脂と強化繊維とをとも
に廃棄する必要がない。この結果、複合材パネル１０の
製造上のコストを削減することができる。Further, since the dry preform 22 used in the manufacturing method according to the present embodiment can be stored at room temperature, it is not necessary to store it in a low temperature environment like prepreg, and the thermosetting resin film can be stored. Only the refrigeration equipment for use is enough. Further, even if the thermosetting resin film 21 deteriorates due to storage for a long period of time, only the thermosetting resin film 21 needs to be discarded, and the thermosetting resin and the reinforced fiber can be removed as in the conventional prepreg disposal. There is no need to dispose of As a result, the manufacturing cost of the composite material panel 10 can be reduced.
【００５０】また、本実施の形態に係る複合材パネル１
０の製造方法によれば、下型治具４０に熱硬化性樹脂フ
ィルム２１とドライプリフォーム２２とを順次積層して
外板２０を成形し、かつ、あらかじめ成形した補強部材
３０を使用して真空引きして加熱することによって複合
材パネル１０を製造しているので、製造の際にオートク
レーブを使用する必要がなく、オートクレーブを使用す
ることによって生じていた従来の製造上の問題を一挙に
解決することができる。Further, the composite material panel 1 according to the present embodiment.
According to the manufacturing method of No. 0, the thermosetting resin film 21 and the dry preform 22 are sequentially laminated on the lower die jig 40 to form the outer plate 20, and a vacuum is produced by using the preformed reinforcing member 30. Since the composite material panel 10 is manufactured by pulling and heating, it is not necessary to use an autoclave at the time of manufacturing, and the conventional manufacturing problems caused by using the autoclave are solved at once. be able to.
【００５１】すなわち、下型治具４０に加熱装置を内蔵
したりすることによってオートクレーブを使用せずに加
熱することができ、オートクレーブを使用した場合のよ
うに複合材パネルの製造コストが嵩むことがなく、ま
た、製造する複合材パネルが大型である場合にも、これ
に対応させた大型のオートクレーブを築造する必要がな
い。That is, by incorporating a heating device in the lower die 40, heating can be performed without using an autoclave, and the manufacturing cost of the composite material panel is increased unlike the case where an autoclave is used. In addition, even when the composite material panel to be manufactured is large, there is no need to build a large autoclave corresponding to this.
【００５２】また、本実施の形態に係る複合材パネル１
０の製造方法によれば、熱硬化性樹脂フィルム２１およ
びドライプリフォーム２２から構成される外板２０の成
形と、この外板２０への補強部材３０の固定とを同時に
行うことができる。このため、複合材パネル１０製造時
において、外板２０に補強部材３０を固定する際に従来
必要であったリベット打ちなどの煩雑な作業を省くこと
ができ、製造上の労力を格段に低減させることができ
る。Further, the composite material panel 1 according to the present embodiment.
According to the manufacturing method of No. 0, the outer plate 20 including the thermosetting resin film 21 and the dry preform 22 can be molded and the reinforcing member 30 can be fixed to the outer plate 20 at the same time. For this reason, when manufacturing the composite material panel 10, it is possible to omit the complicated work such as riveting which is conventionally required when fixing the reinforcing member 30 to the outer plate 20, and the manufacturing labor is significantly reduced. be able to.
【００５３】また、本実施の形態に係る複合材パネル１
０の製造方法によれば、補強部材３０を接着剤２３を介
してドライプリフォーム２２の上に配置し、かつ、この
補強部材３０の側部にプレッシャープレート５０を配置
するため、ドライプリフォーム２２の上に補強部材３０
を容易かつ正確に仮固定することができ、かつ、その位
置のずれを防止することができる。Further, the composite material panel 1 according to the present embodiment.
According to the manufacturing method of No. 0, since the reinforcing member 30 is arranged on the dry preform 22 via the adhesive 23 and the pressure plate 50 is arranged on the side portion of the reinforcing member 30, the dry preform 22 is formed. To the reinforcing member 30
Can be temporarily fixed easily and accurately, and the displacement of the position can be prevented.
【００５４】[第２の実施の形態]次に、第２の実施の形
態について説明する。本実施の形態では、第１の実施の
形態に係る製造方法とほぼ同一工程を経て複合材パネル
を製造する方法を説明する。本実施の形態では、第１の
実施の形態で使用したプレッシャープレート５０を用い
ずに、ブリーザ９０と第２ピール層８２との間に多孔性
フィルタ５０’を配置している（図４参照）。[Second Embodiment] Next, a second embodiment will be described. In the present embodiment, a method for manufacturing a composite material panel will be described, which includes substantially the same steps as the manufacturing method according to the first embodiment. In this embodiment, the porous filter 50 ′ is arranged between the breather 90 and the second peel layer 82 without using the pressure plate 50 used in the first embodiment (see FIG. 4). .
【００５５】多孔性フィルタ５０’を採用することによ
り、真空バッグフィルム７０を直接的にシリコンシート
８０に密着させて真空圧を加えることができる。また、
多孔性フィルタ５０’によって、溶融した熱硬化性樹脂
フィルム２１の熱硬化性樹脂がブリーザ９０側に流出す
るのを防ぐことができる。By using the porous filter 50 ', the vacuum bag film 70 can be directly adhered to the silicon sheet 80 to apply a vacuum pressure. Also,
The porous filter 50 ′ can prevent the melted thermosetting resin of the thermosetting resin film 21 from flowing out to the breather 90 side.
【００５６】以上の実施の形態に係る複合材パネルを構
成する補強部材は、長さ方向に対して直角に切断した際
の断面形状がＴ字型を呈するものを示したが、これに限
定されるものではない。例えば、前記断面形状がＩ字型
を呈する補強部材３０’（図５参照）や、前記断面形状
がハット型（すなわち上方に突出した矩形状の凸部とこ
の両端部に連接する左右への延在部とからなる形状）を
呈する補強部材３０”（図６参照）などを使用して複合
材パネルを構成することができる。The reinforcing member constituting the composite material panel according to the above-described embodiment has a T-shaped cross section when cut at a right angle to the length direction, but is not limited thereto. Not something. For example, the reinforcing member 30 ′ having the I-shaped cross section (see FIG. 5) or the hat shaped cross section (that is, a rectangular convex portion projecting upward and extending to the left and right connected to both ends thereof). The composite panel can be constructed by using a reinforcing member 30 ″ (see FIG. 6) having a shape including the existing portion).
【００５７】[0057]
【発明の効果】請求項１記載の発明によれば、ドライプ
リフォームが熱硬化性樹脂フィルムに粘着することがな
く、かつ、このドライプリフォームを複数枚積層した場
合にも相互に粘着することがないので、積層作業がきわ
めて容易となり、積層後も、ドライプリフォームの配置
方向を自在に変更することができる。この結果、複合材
パネルの製造が容易となる。また、プリプレグを硬化さ
せた場合のように内部に空隙が形成されることがなく、
高品質の複合材パネルを製造することができる。According to the invention of claim 1, the dry preform does not adhere to the thermosetting resin film, and even when a plurality of dry preforms are laminated, they do not adhere to each other. Therefore, the stacking work becomes extremely easy, and the arrangement direction of the dry preform can be freely changed even after stacking. As a result, the manufacture of the composite panel is facilitated. In addition, unlike the case where the prepreg is cured, no void is formed inside,
High quality composite panels can be manufactured.
【００５８】また、請求項１記載の発明によれば、ドラ
イプリフォームを常温で保管することができるため、プ
リプレグのように低温の環境で保管する必要がなく、熱
硬化性樹脂フィルム保管用の冷蔵設備を設置するだけで
足りる。また、長期間にわたる保管によって熱硬化性樹
脂フィルムが劣化した場合でも、熱硬化性樹脂フィルム
のみを廃棄するだけですみ、プリプレグ廃棄の際のよう
に熱硬化性樹脂と強化繊維とをともに廃棄する必要がな
い。この結果、複合材パネルの製造上のコストを削減す
ることができる。According to the first aspect of the present invention, since the dry preform can be stored at room temperature, it is not necessary to store it in a low temperature environment like a prepreg, and it is refrigerated for storing a thermosetting resin film. All you need to do is install the equipment. Moreover, even if the thermosetting resin film deteriorates due to long-term storage, only the thermosetting resin film needs to be discarded, and both the thermosetting resin and the reinforcing fiber are discarded as in the case of prepreg disposal. No need. As a result, the manufacturing cost of the composite material panel can be reduced.
【００５９】さらに、請求項１記載の発明によれば、オ
ートクレーブを使用した場合のように複合材パネルの製
造コストが嵩むことがなく、また、製造する複合材パネ
ルが大型である場合にも、これに適応させた大型のオー
トクレーブを設置する必要がない。Further, according to the invention of claim 1, the manufacturing cost of the composite material panel does not increase unlike the case where the autoclave is used, and when the composite material panel to be manufactured is large, There is no need to install a large autoclave adapted to this.
【００６０】さらにまた、請求項１記載の発明によれ
ば、熱硬化性樹脂フィルムおよびドライプリフォームか
ら構成される板状体の成形と、この板状体への補強部材
の固定を同時に行うことができる。このため、複合材パ
ネル製造時において、板状体に補強部材を固定する際に
従来必要であったリベット打ちなどの煩雑な作業を省く
ことができ、複合材パネルの製造上の労力を格段に低減
させることができる。Furthermore, according to the first aspect of the present invention, it is possible to simultaneously form the plate-shaped body composed of the thermosetting resin film and the dry preform and fix the reinforcing member to the plate-shaped body. it can. Therefore, when manufacturing the composite material panel, it is possible to omit the complicated work such as riveting which is conventionally required when fixing the reinforcing member to the plate-like body, and the labor for manufacturing the composite material panel is remarkably increased. Can be reduced.
【００６１】請求項２記載の発明によれば、請求項１記
載の発明の効果を奏するのは勿論のこと、補強部材を本
硬化させる手間（労力）を省くことができ、全体とし
て、複合材パネルの製造時間の短縮と、一層の製造上の
労力の低減および製造上のコストの削減をもたらすこと
ができる。According to the invention described in claim 2, not only the effect of the invention described in claim 1 can be obtained, but also the labor (labor) for the main curing of the reinforcing member can be omitted, and the composite material as a whole. The manufacturing time of the panel can be shortened, and the manufacturing labor and the manufacturing cost can be further reduced.
【００６２】請求項３記載の発明によれば、請求項１ま
たは２記載の発明の効果を奏するのは勿論のこと、熱硬
化性樹脂の含浸・硬化反応によって発生するガスや、接
着剤界面に存在する空気を、より効果的に外部に排出さ
せることができる。この結果、より高品質な複合材パネ
ルを製造することができる。According to the invention of claim 3, not only the effect of the invention of claim 1 or 2 can be obtained, but also the gas generated by the impregnation / curing reaction of the thermosetting resin or the interface of the adhesive agent The existing air can be discharged to the outside more effectively. As a result, a higher quality composite material panel can be manufactured.
【図１】本発明の実施の形態に係る複合材パネルの製造
方法によって製造された複合材パネルの一例を示す斜視
図である。FIG. 1 is a perspective view showing an example of a composite material panel manufactured by a method for manufacturing a composite material panel according to an embodiment of the present invention.
【図２】図１に示した複合材パネルの製造方法を説明す
るための説明図である。FIG. 2 is an explanatory diagram for explaining a method of manufacturing the composite material panel shown in FIG.
【図３】図２のIII部分の拡大図である。FIG. 3 is an enlarged view of a portion III in FIG.
【図４】本発明の第２の実施の形態に係る複合材パネル
の製造方法を説明するための説明図である。FIG. 4 is an explanatory diagram for explaining the method for manufacturing the composite material panel according to the second embodiment of the present invention.
【図５】本発明に係る複合材パネルの製造方法におい
て、補強部材の断面形状がＩ字型である場合を示す説明
図である。FIG. 5 is an explanatory diagram showing a case where the reinforcing member has an I-shaped cross section in the method for manufacturing a composite material panel according to the present invention.
【図６】本発明に係る複合材パネルの製造方法におい
て、補強部材の断面形状がハット型である場合を示す説
明図である。FIG. 6 is an explanatory view showing a case where the reinforcing member has a hat-shaped cross-sectional shape in the method for manufacturing a composite material panel according to the present invention.
【図７】本発明の実施の形態に係る複合材パネルの製造
方法を示す斜視図である。FIG. 7 is a perspective view showing a method of manufacturing the composite material panel according to the embodiment of the present invention.
１０ 複合材パネル ２０ 外板 ２１ 熱硬化性樹脂フィルム ２２ ドライプリフォーム ２３ 接着剤 ３０ 補強部材（断面Ｔ字型のストリンガ） ３０’ 補強部材（断面Ｉ字型のストリンガ） ３０” 補強部材（断面ハット型のストリンガ） ４０ 下型治具 ５０ プレッシャープレート ５０’ 多孔性フィルタ ６０ ダム ７０ 真空バッグフィルム ８０ シリコンシート ８１ 第１ピール層 ８２ 第２ピール層 ９０ ブリーザ 10 composite panel 20 outer plate 21 Thermosetting resin film 22 Dry preform 23 Adhesive 30 Reinforcement member (stringer with T-shaped cross section) 30 'Reinforcing member (stringer with I-shaped cross section) 30 "Reinforcement member (string-shaped stringer) 40 Lower die 50 pressure plate 50 'porous filter 60 dam 70 vacuum bag film 80 silicone sheet 81 First peel layer 82 Second peel layer 90 Breather
───────────────────────────────────────────────────── フロントページの続き (51)Int.Cl.7 識別記号 ＦＩ テーマコート゛(参考） Ｂ２９Ｌ 31:30 Ｂ２９Ｃ 67/14 Ｕ Ｆターム(参考） 4F205 AA36 AD05 AD16 AD19 AG05 AG28 AH31 HA14 HA22 HA33 HA35 HA44 HB01 HK04 HK16 HK26 HT02 HT13 HT27 4F211 AD05 AD08 AD16 AD21 AH31 AM28 AM32 TA03 TC03 TD11 TN02 TN44 TQ07 ─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. 7 Identification code FI theme code (reference) B29L 31:30 B29C 67/14 UF term (reference) 4F205 AA36 AD05 AD16 AD19 AG05 AG28 AH31 HA14 HA22 HA33 HA35 HA44 HB01 HK04 HK16 HK26 HT02 HT13 HT27 4F211 AD05 AD08 AD16 AD21 AH31 AM28 AM32 TA03 TC03 TD11 TN02 TN44 TQ07
Claims (3)
状体を補強する繊維強化樹脂複合材製の補強部材とを有
する複合材パネルの製造方法において、 前記補強部材をあらかじめ成形する補強部材成形工程
と、 下型治具の上に熱硬化性樹脂フィルムおよびドライプリ
フォームを積層する板状体成形材料積層工程と、 前記ドライプリフォームの上に熱硬化性の接着剤を介し
て前記補強部材を配置する補強部材配置工程と、 前記補強部材の上から真空バッグフィルムを被せて、前
記補強部材と前記熱硬化性樹脂フィルムと前記ドライプ
リフォームとを密封する密封工程と、 前記真空バッグフィルムで密封した部分から空気を排出
する排気工程と、 前記真空バッグフィルムで密封して空気を排出した部分
を加熱する加熱工程とを備えることを特徴とする複合材
パネルの製造方法。1. A method of manufacturing a composite material panel, comprising: a plate-shaped body made of a fiber-reinforced resin composite material; and a reinforcing member made of a fiber-reinforced resin composite material for reinforcing the plate-shaped body. A reinforcing member forming step, a plate-shaped body forming material laminating step of laminating a thermosetting resin film and a dry preform on a lower jig, and a thermosetting adhesive on the dry preform via the thermosetting adhesive. A reinforcing member disposing step of disposing a reinforcing member; a sealing step of covering the reinforcing member with a vacuum bag film to seal the reinforcing member, the thermosetting resin film and the dry preform; and the vacuum bag film. It is characterized by comprising an exhausting step of discharging air from the part sealed by the above, and a heating step of heating the part where the air is discharged by sealing with the vacuum bag film. Method for manufacturing a composite panel to.
記載の複合材パネルの製造方法。2. The reinforcing member is an intermediate product obtained by primary curing a thermosetting resin, and the reinforcing member is fully cured in the heating step.
A method for manufacturing the composite material panel described.
後、前記熱硬化性樹脂フィルムの上に前記ドライプリフ
ォームを積層し、 積層した前記熱硬化性樹脂フィルムおよび前記ドライプ
リフォームの周囲の側面に近接させて側面治具を配置
し、 前記側面治具と前記ドライプリフォームと前記補強部材
との上に空気通路を形成することを特徴とする請求項１
または２記載の複合材パネルの製造方法。3. In the plate-shaped body molding material laminating step, after laminating the thermosetting resin film on a lower die jig, laminating the dry preform on the thermosetting resin film, laminating A side jig is disposed in close proximity to the peripheral side surfaces of the thermosetting resin film and the dry preform, and an air passage is formed on the side jig, the dry preform, and the reinforcing member. Claim 1
Alternatively, the method for manufacturing the composite material panel according to the item 2.
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|---|---|---|---|
| JP2001202371A JP4856327B2 (en) | 2001-07-03 | 2001-07-03 | Method for manufacturing composite panel |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2001202371A JP4856327B2 (en) | 2001-07-03 | 2001-07-03 | Method for manufacturing composite panel |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JP2003011231A true JP2003011231A (en) | 2003-01-15 |
| JP4856327B2 JP4856327B2 (en) | 2012-01-18 |
Family
ID=19039187
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP2001202371A Expired - Fee Related JP4856327B2 (en) | 2001-07-03 | 2001-07-03 | Method for manufacturing composite panel |
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| Country | Link |
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| JP (1) | JP4856327B2 (en) |
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