JP2019209520A - Method of manufacturing composite material structure and manufacturing fixture for composite material structure - Google Patents

Abstract

To provide means to reduce a fixture cost, lessen workload, and enable molding a surface shape of a composite material fixture with high accuracy, in manufacturing a panel form composite material fixture having a concave surface.SOLUTION: A method of manufacturing a composite material structure of this invention, by disposing in an overlapping manner plural sheet-like laminate bodies each including a laminated prepreg on a convex surface of a first plate curved in an arc-shape viewed from one direction perpendicular to a sheet thickness direction; and disposing a second plate that is curved in an arc-shaped viewed from the one direction and has lower rigidity than the first plate on an opposite surface relative to a first plate side of the laminate bodies while matching directions of the first plate and the convex surface, includes: a first step of forming a laminate unit having a laminate structure including the first plate, the laminate bodies, and the second plate; and a second step, after the first step, of molding and curing the laminate bodies into a predetermined shape in a state in which the laminate unit is held from a second plate side by a base table.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a composite material structure manufacturing method and a composite material structure manufacturing jig.

  For example, as disclosed in Patent Document 1, a laminated body in which a plurality of prepregs are laminated on a convex outer surface of a mandrel (male type), and a molding die is placed on this laminated body. A method for producing a panel-like composite material structure having a concavely curved surface (hereinafter also referred to simply as a concave surface) when viewed from one direction by curing a laminate with a mandrel and a molding die (Hereinafter referred to as a mandrel method) is known.

  Further, as disclosed in, for example, Patent Document 2, a laminated body is placed on a concave inner surface of a female shape, and a thin plate is placed on the laminated body, with a female shape and a plate. A method of manufacturing a panel-shaped composite material structure having a concave surface (hereinafter, referred to as a female mold method) by curing a laminated body while forming is known. Examples of the composite material structure include an aircraft fuselage.

Japanese Patent No. 5576650 JP2013-18286A

  The mandrel method has an advantage that the concave surface of the composite material structure can be formed with high accuracy by the mandrel. This is preferable in that when a composite material structure is applied to an aircraft fuselage, shim adjustment is not required when various parts are attached to the concave surface corresponding to the inner surface of the fuselage. However, dedicated mandrels may be required for different types of composite material structures. For example, in a plurality of derivative machine bodies having different lengths, the rigidity required for each part is different, so that the mandrel shape is different because the thickness of the body skin is different while the outer diameter is constant for each model. Therefore, a dedicated mandrel is required for each model. For this reason, when the production rate is high, a plurality of expensive mandrels are required, which causes an increase in jig cost.

In addition, the female type construction method can produce multiple types of composite material structures with the longest single female type when the outer diameter is constant between models even if it is a derivative machine such as an aircraft fuselage. In comparison, a mandrel having a dedicated shape is unnecessary, and there is an advantage that the jig cost can be reduced. However, since it is difficult to form the concave surface of the composite material structure (the fuselage inner surface in an aircraft) with high accuracy, there is a problem that shim adjustment is required when various parts are attached to the concave surface.
These problems become prominent when the composite material structure to be manufactured is relatively large, such as an aircraft fuselage.

  The present invention has been made in view of this problem, and in the case of manufacturing a panel-like composite material structure having a concave surface, the jig cost is reduced and the work load is reduced, and the composite material structure is reduced. The object is to enable the surface shape to be molded with high accuracy.

  A manufacturing method of a composite material structure according to an aspect of the present invention includes a sheet-like structure including a plurality of prepregs stacked on a convex surface of a first plate that is curved in an arc shape when viewed from one direction perpendicular to the plate thickness direction. The second laminated body is arranged on the surface opposite to the first plate side of the laminated body, is curved in an arc shape when viewed from the one direction, and has a lower rigidity than the first plate. A first step of forming a laminated unit having a laminated structure including the first plate, the laminated body, and the second plate by arranging the plates so as to overlap with the first plate while aligning the direction of the convex surface; After the first step, there is a second step of forming and curing the laminated body in a predetermined shape in a state where the laminated unit is supported by the base stand from the second plate side.

  According to the above method, in the second step, the laminate can be cured so as to have a highly accurate concave surface by the convex surface of the first plate having higher rigidity than the second plate. Further, in the second step, the laminated unit can be supported by the base table from the laminated body side of the second plate, so that the laminated body can be supported while being sandwiched between the first plate and the base table. Therefore, the laminate can be stably cured while favorably preventing the thickness of the laminate from varying. Therefore, it is possible to manufacture a panel-shaped composite material structure in which the concave surface is formed with high accuracy.

  For example, the shape of the first plate and the second plate can be adjusted by bending at least one of the first plate and the second plate. Therefore, a plurality of types of composite material structures can be manufactured by the pair of first plate and second plate.

  In addition, since the laminate is cured while being formed by the first plate and the second plate, it is not necessary to separately prepare a dedicated base stand or plate every time different types of composite material structures are manufactured. Moreover, since the composite material structure can be manufactured using the first plate and the second plate that are relatively light in weight, handling by the operator can be improved. Therefore, it is possible to reduce the jig cost and the work burden when manufacturing the composite material structure.

  The base may have a support surface that supports the stacked unit by contacting the stacked unit from the second plate side while maintaining the convex surface of the first plate in a predetermined shape. Thereby, since a lamination | stacking unit can be favorably supported by the support surface of a base stand, the composite material structure in which the concave surface was formed with high precision can be manufactured.

  In the second step, the laminated unit is covered with a bag film in an airtight manner independently of the base table, and then the laminated unit is supported by the base table using a high-temperature and high-pressure gas. The laminate may be cured while heating and pressing from both sides in the thickness direction.

  According to the above method, the laminate is brought into close contact with the first plate and the second plate using the bag film and the high-temperature high-pressure gas while reducing the jig cost and the work load. A composite material structure in which concave surfaces are formed with high accuracy can be manufactured by applying pressure from both sides in the thickness direction and curing.

  The maximum plate thickness of the first plate may be thicker than the maximum plate thickness of the second plate. Thereby, the rigidity of the first plate can be made higher than the rigidity of the second plate.

  In the first step, the first plate is disposed so that the upper surface is the convex surface and the lower surface is a concave surface, and the first plate is moved from the lower surface side while maintaining the convex surface of the first plate in a predetermined shape. A first sub-step supported by a support member; a second sub-step in which the stacked body is disposed on the upper surface of the first plate after the first sub-step; and a second sub-step after the second sub-step. In a state where one plate is supported by the support member, a third sub-step for vertically inverting the first plate and the laminated body together with the support member may be included.

  According to the above method, in the first sub-step, the convex surface of the first plate is maintained in a predetermined shape by the support member, and in the second sub-step, the stacked body is overlaid on the upper surface of the first plate in an appropriate shape. Can be placed. Further, in the third sub-step, with the first plate supported by the support member, the first plate and the laminated body are turned upside down together with the support member, thereby maintaining the shape of the first plate and the laminated body. The third sub-step can be smoothly shifted to the second step.

  A jig according to an aspect of the present invention is a jig for manufacturing a composite material structure for forming and curing a sheet-like laminate including a plurality of laminated prepregs in a predetermined shape, and in the thickness direction A first plate that is curved in an arc shape when viewed from one direction perpendicular to the surface and is disposed so that the laminate is stacked on a convex surface, and has a lower rigidity than the first plate, and an arc shape when viewed from the one direction. A second plate that is curved and overlapped on the surface of the laminate opposite to the first plate while aligning the first plate and the convex surface, the first plate, and the laminate And a base table that supports a laminated unit having a laminated structure including the second plate from the second plate side.

  According to the said structure, a laminated body can be hardened so that it may have a highly accurate concave surface using the convex surface of a 1st plate whose rigidity is higher than a 2nd plate. In addition, by supporting the laminated unit from the laminated body side of the second plate by the base stand, the laminated body can be supported while being sandwiched between the first plate and the base stand, thus preventing the thickness of the laminated body from varying. The laminate can be cured. Therefore, a composite material structure in which the concave surface is formed with high accuracy can be manufactured.

  For example, the shape of the first plate and the second plate can be adjusted by bending at least one of the first plate and the second plate. Therefore, a plurality of types of composite material structures can be manufactured by the pair of first plate and second plate. Further, since the laminate can be formed by the first plate and the second plate, it is not necessary to prepare a dedicated base stand or plate every time different types of composite material structures are manufactured. Moreover, since the composite material structure can be manufactured using the first plate and the second plate that are relatively light in weight, handling by the operator can be improved. Therefore, it is possible to reduce the jig cost and the work burden when manufacturing the composite material structure.

  The base may have a support surface that supports the stacked unit by contacting the stacked unit from the second plate side while keeping the convex surface of the first plate in a predetermined shape.

  As described above, the laminated unit is supported by the support surface of the base base from the second plate side while keeping the convex surface of the first plate in a predetermined shape, thereby reducing the jig cost and the work load while reducing the concave surface. A composite material structure formed with high precision can be manufactured.

  The first plate is supported from the concave side while keeping the convex surface of the first plate in a predetermined shape, and the first plate is disposed so as to be able to be reversed in the thickness direction while supporting the first plate. A support member may be further provided.

  According to the above configuration, since the convex surface of the first plate can be maintained in a predetermined shape by the support member, the first stack is held by the support member while maintaining the stack disposed on the first plate in a predetermined shape. The laminated body can be arranged so as to be satisfactorily overlapped with the second plate by being inverted together with the plate in the thickness direction of the first plate.

  According to each aspect of the present invention, when manufacturing a composite material structure, the jig cost can be reduced and the work load can be reduced, and the surface shape of the composite material structure can be formed with high accuracy.

It is a fragmentary figure of the aircraft fuselage comprised by the composite material structure concerning an embodiment. It is a perspective view of the jig for manufacture used when manufacturing the composite material structure of FIG. It is a flowchart of the manufacturing method of the composite material structure which concerns on embodiment. (A)-(D) are the figures for demonstrating each step of FIG. It is a figure for demonstrating the hardening step by the conventional female type | mold construction method.

  Hereinafter, embodiments will be described with reference to the drawings.

(Embodiment)
[Composite material structure]
FIG. 1 is a partial view of an aircraft fuselage constituted by a composite material structure 20 (hereinafter referred to as a structure 20) according to an embodiment. The structure 20 has a panel shape, and as an example, is a skin panel constituting an aircraft fuselage. The structure 20 is a curved plate that is curved in an arc shape and extends in the same direction when viewed from the longitudinal direction (one direction to be described later) of the aircraft fuselage.

  As will be described later, the structure 20 is manufactured from a composite material obtained by curing a sheet-like laminate 15 including a plurality of laminated prepregs. The prepreg includes a fiber sheet and a resin impregnated in the fiber sheet. The structure 20 has an FPR structure. This FRP structure is made of carbon fiber reinforced plastic (CFRP) in this embodiment, but may be made of other fiber reinforced plastic.

  In an aircraft, as an example, the four structures 20 are combined side by side in the circumferential direction of the fuselage. The concave surface 20b, which is a concave surface when viewed from the longitudinal direction of the aircraft fuselage, serves as the inner peripheral surface of the fuselage. A plurality of stringers (hat-type stringers) 20c (see FIG. 4D) extending in the same direction are formed on the concave surface 20b so as to be separated from each other in the circumferential direction of the body. The convex surface 20a, which is a convex surface as viewed from the longitudinal direction of the aircraft fuselage, is formed smoothly.

  An aircraft fuselage is required to have a plurality of components (structural components such as a frame and a floor beam constituting the fuselage structure) accurately attached to predetermined positions on the inner peripheral surface. Therefore, the concave surface 20b of the structure 20 is required to be formed with high accuracy. The structure 20 is manufactured using the manufacturing jig 1 described below, so that the concave surface 20b is formed with high accuracy.

[Manufacturing jig]
FIG. 2 is a perspective view of the manufacturing jig 1 used when manufacturing the structure 20 of FIG. FIG. 2 shows a state in which the frame member 6 is arranged with the distal end side of the arm portion 6b (the contact side of the arm portion 6b with the first plate 2) facing downward. In addition, for convenience of explanation, the stacked body 15 disposed between the first plate 2 and the second plate 3 is indicated by a virtual line (two-dot chain line).

  The manufacturing jig 1 is a jig for manufacturing a structure 20 by molding and curing a sheet-like laminate 15 (manufacturing intermediate of the structure 20) including a plurality of stacked prepregs into a predetermined shape. is there.

  As shown in FIG. 2, the manufacturing jig 1 includes a first plate 2, a second plate 3, a support member 4, and a base base 5. The first plate 2 and the second plate 3 are arranged so as to sandwich the laminate 15 in the thickness direction. Thereby, when the structure 20 is manufactured, the laminated unit 16 having a laminated structure including the first plate 2, the laminated body 15, and the second plate 3 is formed. The laminated unit 16 is plate-like as a whole, and is subjected to high-temperature and high-pressure (autoclave) processing in the autoclave while being supported by the base 5.

  The first plate 2 and the second plate 3 are curved plates that are curved in an arc shape and extend in one direction when viewed from one (X) direction perpendicular to the plate thickness direction (hereinafter simply referred to as one direction). is there. A concave portion 2c is formed on the convex surface 2a, which is a convex surface when viewed from one direction of the first plate 2. The recess 2c is formed so as to be recessed in the thickness direction of the first plate 2 and extending in one direction. The recessed portion 2 c is used as a mold portion for forming the stringer 20 c of the structure 20.

  The 1st plate 2 and the 2nd plate 3 of this embodiment consist of the same material. As an example, the first plate 2 and the second plate 3 have an FRP structure. This FRP structure is made of carbon fiber reinforced plastic (CFRP) in this embodiment, but may be made of other fiber reinforced plastic. When the structure 20 is a part of an aircraft fuselage, the first plate 2 and the second plate 3 are ideally materials having the same thermal expansion as the structural material of the aircraft fuselage.

  Since the first plate 2 and the second plate 3 have a relatively lightweight FRP structure, the burden on the operator when handling the first plate 2 and the second plate 3 is reduced, and conveyance for transportation is performed. Cars and peripherals are relatively inexpensive. Further, by configuring the first plate 2 and the second plate 3 with the same material, the physical properties of the first plate 2 and the second plate 3 are made uniform, and the physical properties of both surfaces of the structure 20 are easily made uniform. Can do. The first plate 2 and the second plate 3 may be made of different materials.

  The second plate 3 is less rigid than the first plate 2. The second plate 3 is curved in an arc shape when viewed from one direction, and the direction of the first plate 2 and the convex surfaces 2a and 3a on the surface opposite to the first plate 2 side of the laminate 15 (here as an example) X, Y, and Z directions are aligned and aligned.

  The maximum plate thickness dimension of the first plate 2 is thicker than the maximum plate thickness dimension of the second plate 3. As a result, the first plate 2 is suppressed from being bent or distorted more than the second plate 3. Therefore, in the laminated body 15, when the resin viscosity of a prepreg falls during autoclave hardening, it follows the surface (concave surface 15b) on the 1st plate 2 side where rigidity is higher than the surface (convex surface 15a) on the 2nd plate 3 side. The shape is determined and molded with high accuracy.

  As an example, the plate thickness dimensions of the first plate 2 and the second plate 3 are uniform. Although the plates 2 and 3 have a certain degree of rigidity, they have a property of bending slightly when an external force of a certain level or more is applied in the thickness direction. A plurality of types of structures 20 having different shapes can be manufactured by bending the plates 2 and 3 into a desired shape. Therefore, when manufacturing a plurality of types of structures 20, the number of replacements of the plates 2 and 3 in accordance with the types of the structures 20 can be reduced, so that the jig cost of the structure 20 can be reduced, and It is possible to reduce the work burden on the operator for replacement.

  The support member 4 is disposed so as to support the first plate 2 from the concave surface 2b side while keeping the convex surface 2a in a predetermined shape and to be able to reverse the first plate 2 in the thickness direction while supporting the first plate 2. ing.

  In the present embodiment, the support member 4 is suspended in the vertical (z) direction by the wire W while supporting the first plate 2 from below, and the suspension direction of the support member 4 is reversed, so that the first The plate 2 is inverted in the plate thickness direction.

  Specifically, the support member 4 includes a frame member 6 and a plurality of holding members 7 fixed to the frame member 6. The frame member 6 has a main body portion 6a and a plurality of arm portions 6b. The main body 6a is composed of a combination of a plurality of long members. Suspended portions 6 c for suspending the support member 4 with wires W are provided at a plurality of positions of the main body 6 a.

  The arm portion 6b protrudes from one surface of the main body portion 6a. The tip of the arm portion 6b is in contact with the concave surface 2b of the first plate 2. Thereby, the 1st plate 2 is supported from the concave surface 2b side by the some arm part 6b.

  The arm portion 6b has a plurality of connecting members 6d connected in the longitudinal direction. The connection angle θ between the adjacent connecting members 6d when viewed from the side of the arm 6b and the maximum length of the arm 6b can be adjusted within a certain range.

  In the present embodiment, when viewed from a specific direction (X direction in FIG. 2), the arm portion 6b is disposed at a position corresponding to the center position of the main body portion 6a and both sides thereof, and positions corresponding to the both sides of the main body portion 6a. The connecting members 6d adjacent to each other in the arm portions 6b are connected so that the tips of the arm portions 6b bend toward the outside of the main body portion 6a.

  The support member 4 supports the first plate 2 so that the specific direction matches one direction. By adjusting at least one of the connection angle θ and the maximum length of the arm portion 6b, the support member 4 supports the first plate 2 by the plurality of arm portions 6b while keeping the convex surface 2a in a predetermined shape. .

  In the present embodiment, the connecting member 6d has a bolt hole. The adjacent connecting members 6d in each arm portion 6b are connected by screwing the bolts B into the respective bolt holes. The plurality of connecting members 6d in the arm portion 6b are connected by screwing the bolt holes and the bolts B in a state where the connecting angle θ between the adjacent connecting members 6d is set to a predetermined angle.

  The holding member 7 is attached to the arm portion 6b of the frame member 6, and holds the first plate 2 from the concave surface 2b side. The holding member 7 is a vacuum chuck as an example. The holding member 7 includes a cylinder, an actuator having an operating shaft that can be moved out and withdrawn from the cylinder, and a suction cup 7a attached to the tip of the operating shaft of the actuator. The holding member 7 holds the first plate 2 by adsorbing the suction cup 7a to the concave surface 2b of the first plate 2 in a state where the operating shaft is set to a predetermined protruding length.

  Here, the first plate 2 is held by the holding member 7 while the first plate 2 is supported by the plurality of arm portions 6b in which the connection angle θ between the adjacent connection members 6d is set to a predetermined angle. The 1 plate 2 can be held by the holding member 7 while keeping the convex surface 2a in a predetermined shape. The holding member 7 is not limited to a vacuum chuck, and any member that can hold the first plate 2 may be used.

  The base 5 supports the laminated unit 16 from the second plate 3 side. The base 5 supports the laminated unit 16 while preventing deformation due to gravity. The base 5 has a support surface 5a. The support surface 5a supports the laminated unit 16 from the second plate 3 side while keeping the convex surface 2a of the first plate 2 in a predetermined shape.

  As shown in FIG. 2, the base table 5 has, for example, a rectangular parallelepiped shape in which the X direction is the width direction, the Y direction is the length direction, and the Z direction is the height direction. When viewed from a direction perpendicular to one side surface (here, the X direction), the upper surface of the base base 5 is curved in an arc shape that protrudes downward. The upper surface of the base 5 corresponds to the support surface 5a.

  The support surface 5 a has a shape corresponding to the shape of the convex surface 20 a of the structure 20. Although the support surface 5a is formed smoothly as an example, for example, minute unevenness may be formed. The base 5 and the plates 2 and 3 are combined so that the perpendicular direction matches one direction.

  On the side surface of the base table 5, a plurality of hanging portions 5 b are provided for suspending the base table 5 when the base table 5 is disposed in the autoclave. The base 5 is made of aluminum as an example. In the present embodiment, the laminated body 15 is mainly formed by the first plate 2 and the second plate 3 and does not come into contact with the base table 5, so the support surface 5 a of the base table 5 is not formed with high accuracy. May be. For this reason, a relatively inexpensive material having appropriate rigidity can be used as the material for the base 5. Moreover, the production cost of the base stand 5 is kept relatively low.

  The base 5 may have a structure including, for example, a plate material having a support surface 5a and a support frame that supports the plate material from a surface opposite to the support surface 5a. Further, the shapes and sizes of the plates 2 and 3 and the base 5 are appropriately set according to the shape and size of the structure 20. In FIG. 2, the plates 2 and 3 and the base table 5 are set such that the X-direction dimension is smaller than the Y-direction dimension. For example, the X-direction dimension is set to a larger value than the Y-direction dimension. May be.

[Production method of composite material structure]
FIG. 3 is a flowchart of the method for manufacturing the structure 20 according to the embodiment. 4A to 4D are diagrams for explaining each step in FIG. 3. As shown in FIG. 3, the manufacturing method has a first step S1 and a second step S2.

  In the first step S1, the laminated body 15 is placed on the convex surface 2a of the first plate 2, and the second plate 3 is placed on the surface of the laminated body 15 opposite to the first plate 2 side. The stacked unit 16 is formed by overlapping the plate 2 and the convex surfaces 2a and 3a while aligning the directions. The first step S1 includes a first sub-step SS1, a second sub-step SS2, a third sub-step SS3, and a fourth sub-step SS4.

  In the second step S2, after the first step S1, the laminated body 15 is molded and cured into a predetermined shape while the laminated unit 16 is supported by the base 5 from the second plate 3 side. Hereinafter, each step S1 and S2 will be described with reference to FIG.

  First, the operator arranges the first plate 2 so that the upper surface is a convex surface 2a and the lower surface is a concave surface 2b, and the first plate 2 is supported from the lower surface side while keeping the convex surface 2a of the first plate 2 in a predetermined shape. 4 (first sub-step SS1 in FIG. 3). Further, after the first sub-step SS1, the operator arranges the stacked body 15 on the upper surface of the first plate 2 (second sub-step SS2 in FIG. 3).

  Specifically, the operator places the support member 4 so that the distal end side of the arm portion 6b faces upward. The connection angle θ between the adjacent connection members 6 d in the arm portion 6 b is set according to the shape of the structure 20. After the setting, the operator causes the arm portion 6b of the support member 4 to support the first plate 2 from the concave surface 2b side. Thereby, the first sub-step SS1 is performed (FIG. 4A). Further, the operator arranges the stacked body 15 so as to overlap the convex surface 2 a of the first plate 2. The operator configures the laminate 15 by laminating (laying up) a plurality of sheet-like prepregs. As an example, the laminate 15 includes a stringer ply 12, a sheet-like filler 13, and a sheet-like skin ply 14. The stringer ply 12, the filler 13, and the skin ply 14 are made of prepreg.

  The operator arranges the stringer ply 12 at a position corresponding to the depression 2 c of the first plate 2 and arranges the filler 13 between the adjacent stringer plies 12. In addition, a long jig (bladder) 17 for forming the stringer 20c is overlapped with the stringer ply 12 at a position corresponding to the recess 2c of the stringer ply 12. Then, the skin ply 14 is stacked on the stringer ply 12, the filler 13, and the jig 17 (FIG. 4A). Each time these members are placed on the first plate 2, they are covered with a bag film and vacuum sucked to compact and adhere to each other, whereby the second sub-step SS <b> 2 is performed.

  After the second sub-step SS2, the operator flips the first plate 2 and the laminated body 15 together with the support member 4 with the first plate 2 supported by the support member 4 (third sub-step SS3 in FIG. 3). ).

  Specifically, the operator connects the wire W to the suspended portion 6 c of the support member 4 and holds the first plate 2 by the holding member 7. In this state, the support member 4 is turned upside down from the state of FIG. 4A by the wire W, so that the first plate 2 and the laminated body 15 are turned upside down together with the support member 4 (FIG. 4B). Thereby, the third sub-step SS3 is performed.

  The operator places the second plate 3 on the support surface 5 a of the base 5. After the third sub-step SS3, the operator arranges the first plate 2 and the stacked body 15 so as to overlap the second plate 3 (fourth sub-step SS4 in FIG. 3).

  Specifically, the operator places the second plate 3 on the support surface 5a of the base 5 so that the concave surface 3b is on the upper side. The operator also adjusts the relative position in the horizontal direction of the support member 4 and the base 5 so that the first plate 2, the stacked body 15, and the second plate 3 are stacked at appropriate positions. After this adjustment, the operator moves the support member 4 downward and arranges the first plate 2 and the stacked body 15 so as to overlap the second plate 3 on the base table 5. Thereby, the fourth sub-step SS4 is performed. Thus, the first step S1 is completed.

  Subsequently, as the second step S2, after the first step S1, the operator forms and cures the laminated body 15 into a predetermined shape with the laminated unit 16 supported by the base 5 from the second plate 3 side.

  In the second step S <b> 2 of the present embodiment, the operator covers the laminated unit 16 airtightly with the bag film 18 independently of the base table 5, and then supports the laminated unit 16 with the base table 5. The laminate 15 is cured while heating 16 and pressing from both sides in the thickness direction.

  Specifically, after the fourth sub-step SS4, the operator seals the internal space V1 between the first plate 2 and the second plate 3 with the bag film 18, and vacuums (bags) the internal space V1. Further, the support member 4 is removed from the first plate 2 and the stacked unit 16 is supported by the base 5.

  In this state, the operator connects the wire W to the suspended portion 5 b of the base table 5, lifts the base table 5 with the wire W, and places the laminated unit 16 in the autoclave together with the base table 5. Thereafter, the operator forms and cures the laminate 15 into a predetermined shape by subjecting the laminate 15 to high-temperature and high-pressure treatment in the autoclave (FIG. 4C).

  Here, in this embodiment, vacuuming using the bag film 18 is performed between the first plate 2 and the second plate 3, and not between the plates 2 and 3 and the support surface 5 a. In other words, the space between the convex surface 3a of the second plate 3 and the support surface 5a of the base 5 is not airtight. Accordingly, the high-temperature and high-pressure gas in the autoclave enters between the convex surface 3 a of the second plate 3 and the support surface 5 a of the base 5.

  As a result, as shown in FIG. 4C, the stacked body 15 is pressed from both sides in the thickness direction while being sandwiched between the first plate 2 and the second plate 3. The laminated body 15 is pressed against the convex surface 2a of the first plate 2 having high rigidity, thereby forming a body skin with an accurate inner surface shape. In the case where a variation in the plate thickness peculiar to the composite material after curing occurs, the laminate 15 is thermally cured while the variation is generated on the second plate 3 side having low rigidity.

  By performing the above second step S2, the laminate 15 is molded and cured to obtain the structure 20 (FIG. 4D). The first plate 2, the second plate 3, and the base table 5 used for manufacturing the structure 20 can be used repeatedly. The structure 20 may be subjected to trimming such as drilling for inserting a rivet while being supported from the concave surface 20b side by a dedicated support member.

  Here, FIG. 5 is a diagram for explaining a curing step by a conventional female mold method. When performing the curing step, as an example, the operator arranges a sheet-like laminate 115 including a plurality of laminated prepregs on a support surface 105a of a base base 105 that is a female type in advance. Further, the plate 103 is placed on the stacked body 115 so that the upper surface of the stacked body 115 is covered with a plurality of plates (curl plates) 103.

  Next, the operator seals the internal space V2 between the plate 103 and the support surface 105a with the bag film 118 and vacuums it. Thereafter, the laminate 115 is subjected to a high-temperature and high-pressure treatment in an autoclave to perform a curing step.

  In this curing step, the surface of the laminate 115 opposite to the plate 103 (hereinafter referred to as a convex surface 115a) is in close contact with the support surface 105a of the female base base 105 having high rigidity. For this reason, the convex surface 115a is shape | molded with high precision by the support surface 105a.

  However, the surface of the laminate 115 on the plate 103 side (hereinafter referred to as a concave surface 115 b) is in contact with the plate 103 having a lower rigidity than the base table 105. In this method, the high-temperature and high-pressure gas in the autoclave cannot enter between the support surface 105 a of the base table 105 and the convex surface 115 a of the laminate 115. For this reason, in the laminated body 115, the board | plate thickness dispersion | variation after hardening comes out on the surface side of the concave surface 115b, and falls rather than the precision of the convex surface 115a.

  Thus, when the structure obtained by hardening the laminated body 115 is used as a skin panel of an aircraft fuselage because the shape accuracy of the concave surface 115b is lowered, components are accurately attached to the inner peripheral surface of the skin panel. Enormous shim adjustment is required, and the work load is greatly increased.

  On the other hand, according to the present embodiment, as described above, in the second step S2, the convex surface 2a of the first plate 2 having higher rigidity than the second plate 3 is provided with the highly accurate concave surface 15b. The laminate 15 can be cured. In the second step S <b> 2, the laminated unit 16 can be supported by being sandwiched between the first plate 2 and the base 5 by supporting the laminated unit 16 from the laminated body 15 side of the second plate 3 by the base 5. Therefore, the accuracy of the inner surface shape of the laminate 15 can be improved, and the laminate 15 can be cured stably. Therefore, the panel-like structure 20 in which the concave surface 20b is formed with high accuracy can be manufactured.

  Thereby, for example, when the structure 20 is used as a skin panel of an aircraft fuselage, the structure 20 is manufactured so that the concave surface 20b becomes the inner peripheral surface of the skin panel, so that a component is placed on the inner peripheral surface of the skin panel. Shim adjustment at the time of installation becomes unnecessary. Therefore, an increase in work load can be prevented, and the structure 20 can be favorably used as a skin panel.

  Further, for example, the shape of the first plate 2 and the second plate 3 can be adjusted by bending at least one of the first plate 2 and the second plate 3. Therefore, a plurality of types of structures 20 can be manufactured by the pair of first plate 2 and second plate 3.

  Further, since the laminate 15 is cured while being molded by the first plate 2 and the second plate 3, a dedicated base 5 and plates 2 and 3 are separately prepared every time different types of structures 20 are manufactured. There is no need to do.

  Moreover, since the structure 20 can be manufactured using the relatively light plates 2 and 3, handling by an operator can be improved. Therefore, it is possible to reduce the production cost and work load when manufacturing the structure 20.

  The base 5 has a support surface 5a that supports the laminated unit 16 by contacting the laminated unit 16 from the second plate 3 side while keeping the convex surface 2a of the first plate 2 in a predetermined shape. Therefore, since the lamination | stacking unit 16 can be favorably supported by the support surface 5a of the base stand 5, the structure 20 in which the concave surface 20b was formed with high precision can be manufactured.

  In the second step S2, the laminated unit 16 is airtightly covered with the bag film 18 independently of the base table 5, and then the laminated unit 16 is supported by the base table 5 using a high-temperature and high-pressure gas. The laminate 15 is cured while heating the unit 16 and applying pressure from both sides in the thickness direction. Therefore, the laminate 15 is brought into close contact with the first plate 2 and the second plate 3 using the bag film 18 and the high-temperature and high-pressure gas while reducing the production cost and the work load. The structure 20 in which the concave surface 20b is formed with high accuracy can be manufactured by applying pressure from both sides in the thickness direction and curing.

  Further, since the maximum plate thickness dimension of the first plate 2 is thicker than the maximum plate thickness dimension of the second plate 3, the rigidity of the first plate 2 can be made higher than the rigidity of the second plate 3.

  The first step S1 includes a first sub-step SS1, a second sub-step SS2, and a third sub-step SS3. Therefore, in the first sub-step SS1, the laminated body 15 is appropriately formed on the upper surface of the first plate 2 in the second sub-step SS2 while the convex surface 2a of the first plate 2 is kept in a predetermined shape by the support member 4. Can be placed in layers. Further, in the third sub-step SS3, the first plate 2 and the laminated body are turned upside down with the supporting member 4 while the first plate 2 is supported by the supporting member 4. 15 can be smoothly transferred from the third sub-step to the second step while maintaining the shape of 15.

  The base 5 has a support surface 5a that supports the laminated unit 16 by contacting the laminated unit 16 from the second plate 3 side while keeping the convex surface 2a of the first plate 2 in a predetermined shape. Therefore, while maintaining the convex surface 2a of the first plate 2 in a predetermined shape, the laminated unit 16 is supported by the support surface 5a of the base 5 from the second plate 3 side, thereby reducing the production cost and the work load. The structure 20 in which the concave surface 20b is formed with high accuracy can be manufactured.

  Moreover, since the manufacturing jig 1 includes the support member 4, the convex surface 2 a of the first plate 2 can be maintained in a predetermined shape by the support member 4. For this reason, the laminated body 15 placed on the first plate 2 is kept in a predetermined shape, and the laminated body 15 is reversed together with the first plate 2 in the thickness direction of the first plate 2 by the supporting member 4 to laminate the laminated body 15. The body 15 can be placed on the second plate 3 in a favorable manner.

  In the present embodiment, an aircraft fuselage is manufactured by combining a plurality of structures 20. For this reason, compared with the case where an aircraft fuselage is manufactured in one piece in the circumferential direction, manufacturing equipment and parts for manufacturing an aircraft can be easily conveyed. Moreover, since manufacturing equipment such as an autoclave can be reduced in size, manufacturing equipment costs can be reduced. Therefore, an aircraft can be efficiently manufactured using the structure 20.

  In the above embodiment, the first plate 2 and the laminated body 15 are turned upside down, and then the second plate 3 is placed on the laminated body 15 so that the laminated unit 16 is supported by the base 5. However, after the first plate 2, the laminated body 15, and the second plate 3 are set to form the laminated unit 16, the laminated unit 16 may be turned upside down and supported by the base 5.

  The present invention is not limited to the above-described embodiment, and the configuration and method thereof can be changed, added, or deleted without departing from the spirit of the present invention.

  In the case of manufacturing a panel-shaped composite material structure having a concave surface, the present invention can reduce the jig cost and work load, and can form the surface shape of the composite material structure with high accuracy. It can be used widely and suitably in each field using a material structure.

S1 1st step S2 2nd step SS1 1st substep SS2 2nd substep SS3 3rd substep 1 Manufacturing jig 2 1st plate 2a Convex surface 2b Concave surface 3 2nd plate 4 Support member 5 Base stand 5a Support surface 15 Laminate 15a Convex surface (upper surface of laminate)
16 Laminated unit 18 Bag film 20 Composite material structure

Claims (8)

A sheet-like laminate including a plurality of laminated prepregs is arranged on the convex surface of the first plate that is curved in an arc shape when viewed from one direction perpendicular to the plate thickness direction, and the first of the laminate is provided. A second plate that is curved in an arc shape when viewed from one direction and has a lower rigidity than the first plate is placed on the surface opposite to the plate side, with the first plate and the convex surface being aligned. A first step of forming a stacked unit having a stacked structure including the first plate, the stacked body, and the second plate;
After the first step, a second step of forming and curing the laminated body into a predetermined shape with the laminated unit supported by the base from the second plate side, and a method for producing a composite material structure .   The said base stand has a support surface which contacts the said lamination | stacking unit from the said 2nd plate side, and supports the said lamination | stacking unit, keeping the said convex surface of the said 1st plate in a predetermined shape. Production method.   In the second step, the laminated unit is covered with a bag film in an airtight manner independently of the base table, and then the laminated unit is supported by the base table using a high-temperature and high-pressure gas. The manufacturing method according to claim 2, wherein the laminate is cured while heating and pressing from both sides in the thickness direction.   The manufacturing method according to claim 1, wherein a maximum plate thickness dimension of the first plate is thicker than a maximum plate thickness dimension of the second plate. The first step includes
The first plate is arranged such that the upper surface is convex and the lower surface is concave, and the first plate is supported by a support member from the lower surface side while keeping the convex surface of the first plate in a predetermined shape. 1 substep,
After the first sub-step, a second sub-step in which the stacked body is disposed on the upper surface of the first plate; and
And a third sub-step for vertically inverting the first plate and the laminated body together with the support member in a state where the first plate is supported by the support member after the second sub-step. The manufacturing method of any one of -4. A jig for manufacturing a composite material structure for molding and curing a sheet-like laminate including a plurality of laminated prepregs into a predetermined shape,
A first plate that is curved in an arc shape when viewed from one direction perpendicular to the plate thickness direction, and the laminate is disposed on the convex surface;
It is less rigid than the first plate, is curved in an arc shape when viewed from the one direction, and the first plate and the convex surface are aligned on the opposite side of the laminate from the first plate side. A second plate that is placed in a stack,
A manufacturing jig comprising: a base table that supports a laminated unit having a laminated structure including the first plate, the laminated body, and the second plate from the second plate side.   The said base stand has a support surface which contacts the said lamination unit from the said 2nd plate side with respect to the said lamination | stacking unit, and supports the said lamination | stacking unit, keeping the said convex surface of the said 1st plate in a predetermined shape. Manufacturing jig.   The first plate is supported from the concave side while keeping the convex surface of the first plate in a predetermined shape, and the first plate is disposed so as to be able to be reversed in the thickness direction while supporting the first plate. The manufacturing jig according to claim 6, further comprising a support member.

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