Patent Publication Number: US-2023150175-A1

Title: Forming device and forming method

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of priority to Japanese Patent Application Number 2021-184792 filed on Nov. 12, 2021. The entire contents of the above-identified application are hereby incorporated by reference. 
     BACKGROUND 
     1. Technical Field 
     The present disclosure relates to a forming device and a forming method for forming a laminated body of a plurality of laminated sheet materials containing reinforced fibers. 
     2. Description of Related Art 
     Structural members of aircrafts or the like have various sectional shapes, and as a method for manufacturing such a structural member, there is a known method of pressing a laminated body of a plurality of laminated sheet materials containing reinforced fibers against a forming die and forming the laminated body to obtain an intended shape (for example, see Japanese Patent No. 5278790). 
     Japanese Patent No. 5278790 discloses arranging a laminated body in a forming die and applying a pressure thereto by a bladder to form the laminated body along the forming die. 
     When a laminated body is formed along a forming die, a wrinkle may occur in a particular portion such as a region having a large change in the shape of the forming die. Such a wrinkle is likely to occur particularly when the forming die has a curved surface shape having a curvature in the longitudinal direction and also has a curved portion including a concave shape or a convex shape in the width direction orthogonal to the longitudinal direction. 
     When a pressure is applied by a bladder as disclosed in Japanese Patent No. 5278790, however, a region that is preferentially formed or a timing that the forming takes place is already determined in accordance with the positional relationship between the bladder and the forming die. It is therefore difficult to suitably adjust a region to preferentially perform forming, a timing to perform forming, or the like, such as by pressing a region where a wrinkle is likely to occur against a forming die prior to pressing other regions. 
     BRIEF SUMMARY 
     The present disclosure has been made in view of such circumstances and intends to provide a forming device and a forming method that can suppress a problem of a wrinkle occurring in a laminated body when forming the laminated body along a forming die. 
     A forming device for forming a laminated body of a plurality of laminated sheet materials containing reinforced fibers according to one aspect of the present disclosure includes a first forming die having a curved surface that extends in a longitudinal direction and includes at least any one of a concave shape and a convex shape with respect to a width direction; a second forming die configured to form the laminated body along a surface shape of the first forming die by pressing the laminated body against the first forming die; a pushing force generating mechanism configured to generate pushing force for pressing the second forming die against the first forming die; and a control unit configured to control the pushing force generating mechanism, wherein the second forming die has a plurality of forming members aligned in the longitudinal direction, wherein the pushing force generating mechanism has a plurality of pushing force generating units connected to the plurality of forming members and configured to generate pushing force for pressing the forming members against the first forming die, and wherein the control unit controls the plurality of pushing force generating units so as to press a pair of the forming members arranged adjacent in the longitudinal direction against the first forming die at different timings from each other. 
     A forming method for forming a laminated body of a plurality of laminated sheet materials containing reinforced fibers according to one aspect of the present disclosure includes a fixing step of fixing one end of the laminated body to a first forming die having a curved surface that extends in a longitudinal direction and includes at least any one of a concave shape and a convex shape with respect to a width direction; and a forming step of forming the laminated body along a surface shape of the first forming die by pressing a second forming die having a plurality of forming members aligned in the longitudinal direction against the first forming die, wherein the forming step presses a pair of the forming members arranged adjacent in the longitudinal direction against the first forming die at different timings from each other. 
     According to the present disclosure, it is possible to provide a forming device and a forming method that can suppress a problem of a wrinkle occurring in a laminated body when forming the laminated body along a forming die. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         FIG.  1    is a perspective view illustrating a lower die and a laminated body according to a first embodiment of the present disclosure and illustrates a state before the laminated body is formed. 
         FIG.  2    is a perspective view illustrating the lower die and the laminated body according to the first embodiment of the present disclosure and illustrates a state after the laminated body has been formed. 
         FIG.  3    is a sectional view illustrating a forming device according to the first embodiment of the present disclosure and illustrates a state before an upper die starts motion toward the lower die. 
         FIG.  4    is a right side view of the forming device illustrated in  FIG.  3    and illustrates a state before the upper die starts motion toward the lower die. 
         FIG.  5    is a block diagram illustrating a control configuration of the forming device according to the first embodiment of the present disclosure. 
         FIG.  6    is a flowchart illustrating a composite material molding method using the forming device. 
         FIG.  7    is a flowchart of a second forming step illustrated in  FIG.  6   . 
         FIG.  8    is a sectional view illustrating the forming device in a lamination step of  FIG.  6   . 
         FIG.  9    is a partial enlarged view of portion B of  FIG.  8   . 
         FIG.  10    is a sectional view illustrating the forming device in the second forming step of  FIG.  6    and illustrates a state where the upper die is moving toward the lower die. 
         FIG.  11    is a right side view of the forming device illustrated in  FIG.  10    and illustrates a state where the upper die is moving toward the lower die. 
         FIG.  12    is a sectional view illustrating the forming device in the second forming step of  FIG.  6    and illustrates a state where the upper die has completed the motion toward the lower die and stops. 
         FIG.  13    is a right side view of the forming device illustrated in  FIG.  11    and illustrates a state where the upper die has completed the motion toward the lower die. 
         FIG.  14    is a sectional view illustrating a forming device according to a second embodiment of the present disclosure and illustrates a state before the upper die starts motion toward the lower die. 
         FIG.  15    is a sectional view illustrating the forming device according to the second embodiment of the present disclosure and illustrates a state where the upper die is moving toward the lower die. 
         FIG.  16    is a sectional view illustrating the forming device according to the second embodiment of the present disclosure and illustrates a state where the upper die has completed the motion toward the lower die. 
     
    
    
     DETAILED DESCRIPTION 
     First Embodiment 
     A forming device  100  according to the first embodiment of the present disclosure and a forming method using the same will be described below with reference to the drawings.  FIG.  1    is a perspective view illustrating a lower die  10  and a laminated body  200  according to the present embodiment and illustrates a state before the laminated body  200  is formed.  FIG.  2    is a perspective view illustrating the lower die  10  and the laminated body  200  according to the present embodiment and illustrates a state after the laminated body  200  has been formed. 
     The forming device  100  of the present embodiment is a device that forms the laminated body  200 , which is a plurality of laminated sheet materials, along the surface shapes of the lower die (first forming die)  10  and an upper die (second forming die)  20 . As illustrated in  FIG.  1   , the laminated body  200  before formed is a planarly laminated multilayered sheet-like composite materials. 
     In the present embodiment, as the laminated body  200 , a planarly shaped laminated body of a plurality of laminated reinforced fiber sheets (dry sheets) containing no matrix resin is used. When reinforced fiber sheets containing no matrix resin are used, a resin transfer molding (RTM) method is used in which the laminated body  200  formed along the surface shapes of the lower die  10  and the upper die  20  is arranged in a molding die (not illustrated) and a resin material is injected inside the molding die to impregnate the reinforced fibers therewith and mold the same. The reinforced fiber contained in the reinforced fiber sheet may be, for example, carbon fiber, glass fiber, aramid fiber, or the like. 
     Although, as described above, a plurality of sheet-like reinforced fiber sheets containing no matrix resin are used as the laminated body  200  in the present embodiment, another manner may be possible. For example, a plurality of laminated reinforced fiber sheets containing a matrix resin may be used as the laminated body  200 . 
     As the matrix resin contained in the reinforced fiber sheets, either a thermosetting resin material or a thermoplastic resin material can be used. The thermosetting matrix resin is, for example, an epoxy resin, an unsaturated polyester, a vinyl ester, a phenol, a cyanate ester, a polyimide, or the like. 
     Examples of the thermoplastic matrix resin include polyetheretherketone (PEEK), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), nylon 6 (PA6), nylon 66 (PA66), polyphenylene sulfide (PPS), polyetherimide (PEI), polyetherketoneketone (PEKK), and the like. 
     When a thermoplastic resin is used as the matrix resin, the forming device  100  includes a heating mechanism (not illustrated) that can heat the thermoplastic resin contained in the laminated body  200  at the softening temperature or higher. By heating the thermoplastic resin at the softening temperature or higher by the heating mechanism, it is possible to form the laminated body  200  containing the thermoplastic resin along the surface shapes of the lower die  10  and the upper die  20 . 
     Details of the forming device  100  according to the present embodiment will be described with reference to the drawings.  FIG.  3    is a sectional view illustrating the forming device  100  according to the present embodiment and illustrates a state before the upper die  20  starts motion toward the lower die  10 .  FIG.  4    is a right side view of the forming device illustrated in  FIG.  3    and illustrates a state before the upper die starts motion toward the lower die.  FIG.  5    is a block diagram illustrating a control configuration of the forming device  100  of the present embodiment. As illustrated in  FIG.  3    to  FIG.  5   , the forming device  100  of the present embodiment includes the lower die  10 , the upper die  20 , an upper die (third forming die)  30 , a pushing force generating mechanism  40 , and a control unit  50 . 
     The forming device  100  illustrated in  FIG.  3    and  FIG.  4    is arranged in a three-dimensional space. The X-axis, the Y-axis, and the Z-axis illustrated in  FIG.  3    and  FIG.  4    are axes intersecting each other in the three-dimensional space. The X-axis is an axis extending parallel to an installation surface S on which the lower die  10  is installed, and the Z-axis is an axis extending in a direction orthogonal to the installation surface S on which the lower die  10  is installed. The Y-axis is an axis orthogonal to both the X-axis and the Z-axis and extending in a sheet depth direction in  FIG.  3   . 
     The lower die  10  is a block-shape die having a surface shape for forming the laminated body  200  and is made of a metal material, for example. The lower die  10  has an upper surface (first forming surface)  11 , a side surface (second forming surface)  12 , a convex surface (curved surface)  13 , a concave surface (curved surface)  14 , and a bottom surface  15  as the surface shape for forming the laminated body  200 .  FIG.  3    is a sectional view taken along the arrow A-A of  FIG.  4    and illustrates a cross section of the lower die  10  at or near the middle part in the longitudinal direction LD parallel to the Y-axis. 
     As illustrated in  FIG.  3   , the upper surface  11  of the lower die  10  is a surface extending planarly parallel to the X-axis. The side surface  12  of the lower die  10  is a surface extending planarly parallel to the Z-axis. The bottom surface  15  of the lower die  10  is a surface extending planarly in a direction intersecting the X-axis. 
     The convex surface  13  is a surface connected between the upper surface  11  and the side surface  12  and has a circular arc shape whose normal direction of the surface gradually changes so as to change from a surface parallel to the X-axis to a surface parallel to the Z-axis as a position on the convex surface  13  approaches the side surface  12  from the upper surface  11  parallel to the X-axis. The convex surface  13  is a portion including a convex shape with respect to the width direction WD parallel to the X-axis. 
     The concave surface  14  is a surface connected between the side surface  12  and the bottom surface  15  and has a circular arc shape whose normal direction of the surface gradually changes so as to change from a surface parallel to the Z-axis to a surface parallel to the X-axis as a position on the concave surface  14  approaches the bottom surface  15  from the side surface  12  parallel to the Z-axis and further change to a surface intersecting the X-axis. The concave surface  14  is a portion including a concave shape with respect to the width direction WD. 
     As illustrated in  FIG.  3   , the laminated body  200  has a first end region  200   a  and a second end region  200   b  in the width direction WD. The second end region  200   b  of the laminated body  200  is fixed to the lower die  10 . The second end region  200   b  of the laminated body  200  is fixed to a predetermined position of the upper surface  11  of the lower die  10 . 
     The shape of the lower die  10  illustrated in  FIG.  3    may be another shape. For example, the upper surface  11  may be a surface extending in a direction different from the X-axis or may be a non-planar surface. Further, the side surface  12  may be a surface extending in a direction different from the Z-axis. Further, the convex surface  13  may have any convex shape different from a circular arc shape. Further, the concave surface  14  may have any concave shape different from a circular arc shape. Further, the bottom surface  15  may be a surface extending in a direction parallel to the X-axis or a direction inclined downward from the X-axis. The lower die  10  can be any shape including at least any one of a concave shape and a convex shape with respect to the width direction WD. 
     The upper die  20  is a block-like die for pressing the laminated body  200 , the second end region  200   b  of which is fixed to the lower die  10 , against the lower die  10  and forming the laminated body  200  along the surface shape of the lower die  10  and is made of a metal material, for example. The upper die  20  presses the laminated body  200  fixed to the lower die  10  against the side surface  12 , the convex surface  13 , the concave surface  14 , and the bottom surface  15  of the lower die  10  and forms the laminated body  200  along the surface shapes of the lower die  10  and the upper die  20 . 
     As illustrated in  FIG.  4   , the upper die  20  has a plurality of forming members  21 ,  22 ,  23 ,  24 ,  25 ,  26 ,  27 ,  28 , and  29  aligned adjacent to each other in the longitudinal direction LD. As illustrated in  FIG.  4   , the distances in the Z-axis direction from the forming members  21  to  29  to the bottom surface  15  of the lower die  10  are the same distance DO. That is, the distances from the forming members  21  to  29  to the bottom surface  15  of the lower die  10  before starting motion toward the lower die  10  are the same. 
     As illustrated in  FIG.  3   , the forming member  21  has an under surface  21   a , a side surface  21   b , and a convex surface  21   c  as the surface shape for forming the laminated body  200 . The under surface  21   a  of the forming member  21  is a surface extending planarly in a direction intersecting the X-axis. The side surface  21   b  of the forming member  21  is a surface extending planarly parallel to the Z-axis. The convex surface  21   c  is a surface connected between the under surface  21   a  and the side surface  21   b  and has a circular arc shape whose normal direction of the surface gradually changes so as to change from a surface intersecting the X-axis to a surface parallel to the Z-axis as a position on the convex surface  21   c  approaches the side surface  21   b  from the under surface  21   a  parallel to the X-axis. The convex surface  21   c  has a shape corresponding to the concave surface  14  of the lower die  10 . 
     The forming member  21  has been described above, and since the same applies to the forming members  22 ,  23 ,  24 ,  25 ,  26 ,  27 ,  28 , and  29 , the description thereof will be omitted below. Note that the shape of the lower die  10  may have different shapes at respective positions along the longitudinal direction LD. When the shape of the lower die has different shapes at respective positions along the longitudinal direction LD, the shapes of the forming members  22 ,  23 ,  24 ,  25 ,  26 ,  27 ,  28 , and  29  will differ, respectively. 
     As illustrated in  FIG.  3   , the upper die  30  is a block-like die for pressing a region at and near the second end region  200   b  of the laminated body  200  against the upper surface  11 , which is adjacent to one side in the width direction WD of the convex surface  13  of the lower die  10 , and is made of a metal material, for example. The upper die  30  presses the laminated body  200  fixed to the lower die  10  against the lower die  10  to form the laminated body  200  along the surface shapes of the lower die  10  and the upper die  30 . 
     The pushing force generating mechanism  40  is a mechanism that generates a pushing force for pressing the upper die  20  against the lower die  10 . As illustrated in  FIG.  4   , the pushing force generating mechanism  40  has pushing force generating units  41 ,  42 ,  43 ,  44 ,  45 ,  46 ,  47 ,  48 , and  49 . As illustrated in  FIG.  4   , the pushing force generating units  41  to  49  are connected to the forming members  21  to  29 , respectively, and generate pushing force for pressing the forming members  21  to  29  against the lower die  10 . 
     As illustrated in  FIG.  3   , the pushing force generating unit  41  has a fixing frame  41   a , a slide frame  41   b , and a drive unit  41   c . The fixing frame  41   a  is a member installed above the upper die  30  and extending in the horizontal direction parallel to the X-axis. 
     The slide frame  41   b  is a member extending in the perpendicular direction parallel to the Z-axis, which is a member attached movably along the Z-axis relative to the fixing frame  41   a . The slide frame  41   b  is made of aluminum, for example. It is preferable that the slide frame  41   b  be a partially hollowed light weight structure. The lower end of the slide frame  41   b  is connected to the forming member  21 . 
     The drive unit  41   c  has a motor, for example, and generates drive force for moving the slide frame  41   b  along the Z-axis relative to the fixing frame  41   a . The drive unit  41   c  moves the slide frame  41   b  downward along the Z-axis and thereby presses the side surface  21   b  of the forming member  21  against the laminated body  200  to form the laminated body  200  held between the side surface  21   b  and the side surface  12  of the lower die  10 . 
     Further, the drive unit  41   c  further moves the slide frame  41   b  downward along the Z-axis and thereby presses the under surface  21   a  of the forming member  21  against the laminated body  200  to form the laminated body  200  held between the under surface  21   a  and the bottom surface  15  of the lower die. Similarly, the drive unit  41   c  presses the convex surface  21   c  of the forming member  21  against the laminated body  200  to form the laminated body  200  held between the convex surface  21   c  and the concave surface  14  of the lower die. 
     The pushing force generating unit  41  has been described above, and since the same applies to the pushing force generating units  42 ,  43 ,  44 ,  45 ,  46 ,  47 ,  48 , and  49 , the description thereof will be omitted below. As illustrated in  FIG.  4   , the pushing force generating unit  42  has a fixing frame  42   a , a slide frame  42   b , and a drive unit  42   c . The pushing force generating unit  43  has a fixing frame  43   a , a slide frame  43   b , and a drive unit  43   c . The pushing force generating unit  44  has a fixing frame  44   a , a slide frame  44   b , and a drive unit  44   c.    
     The pushing force generating unit  45  has a fixing frame  45   a , a slide frame  45   b , and a drive unit  45   c . The pushing force generating unit  46  has a fixing frame  46   a , a slide frame  46   b , and a drive unit  46   c . The pushing force generating unit  47  has a fixing frame  47   a , a slide frame  47   b , and a drive unit  47   c . The pushing force generating unit  48  has a fixing frame  48   a , a slide frame  48   b , and a drive unit  48   c . The pushing force generating unit  49  has a fixing frame  49   a , a slide frame  49   b , and a drive unit  49   c.    
     The control unit  50  is a device that controls the pushing force generating mechanism  40 . As illustrated in  FIG.  5   , the control unit  50  transfers control signals to the pushing force generating units  41  to  49  via signal lines  51 , respectively. The control unit  50  controls a plurality of pushing force generating units  41  to  49  so that a pair of forming members arranged adjacent in the longitudinal direction LD are pressed against the lower die  10  at different timings from each other, as described later. 
     Next, a composite material molding method for molding a composite material by using the forming device  100  of the present embodiment to form the laminated body  200  will be described with reference to  FIG.  6    to  FIG.  13   .  FIG.  6    is a flowchart illustrating the composite material molding method using the forming device  100 .  FIG.  7    is a flowchart of a forming step illustrated in  FIG.  6   .  FIG.  8    is a sectional view illustrating the forming device  100  in a lamination step of  FIG.  6   . 
     In the lamination step of step S 101 , a plurality of fiber sheets are laminated, and thereby the laminated body  200  is made. As illustrated in  FIG.  8   , in a state where a sub-die  60  is assembled to the lower die  10 , a horizontal surface is established by the upper surface  11  of the lower die  10  and an upper surface  61  of the sub-die  60 , and a plurality of reinforced fiber sheets are laminated one by one on the horizontal surface. 
       FIG.  9    is a partial enlarged view of portion B of  FIG.  8   . As illustrated in  FIG.  9   , reinforced fiber sheets  201 ,  202 ,  203 ,  204 , and  205  are laminated in this order on the upper surface  11  of the lower die  10  and the upper surface  61  of the sub-die  60 , and thereby a planar laminated body  200  is made. Note that the number of layers of the reinforced fiber sheets of the laminated body  200  may be any number. 
     In a fixing step of step S 102 , the second end region  200   b  of the laminated body  200  is fixed on the upper surface  11  of the lower die  10 . For example, the laminated body  200  is fixed to the lower die  10  by attaching a fixing member (not illustrated) to the upper surface  11  and holding the second end region  200   b  between the fixing member (not illustrated) and the upper surface  11 . After the laminated body  200  is fixed to the lower die  10 , the sub-die  60  is removed from the lower die  10 . 
     In a first forming step of step S 103 , the upper die  30  is pressed against the upper surface  11  adjacent to one side in the width direction WD of the convex surface  13  of the lower die  10  to form the laminated body  200 . Specifically, the upper die  30  is installed above the second end region  200   b  of the laminated body  200  fixed to the upper surface  11  of the lower die  10 , the pushing force generating mechanism  40  is installed above the upper die  30 , and the second end region  200   b  of the laminated body  200  is formed along the shape of the upper surface  11  by the weights of the upper die  30  and the pushing force generating mechanism  40 . 
     Although the laminated body  200  is formed along the shape of the lower die  10  by the weights of the upper die  30  and the pushing force generating mechanism  40  herein, another manner may be possible. For example, the upper die  30  can also be structured such that the laminated body  200  is fixed to the lower die  10  to have a predetermined thickness by using a fastening structure. In such a case, by adjusting the predetermined thickness, it is possible to suitably adjust the forming force of the upper die  30  pressing the laminated body  200  against the lower die  10 . 
     In a second forming step of step S 104 , the upper die  20  is pressed against the laminated body  200  downward along the Z-axis by the pushing force generating mechanism  40  to form the laminated body  200  along the surface shape of the lower die  10 . Herein, the second forming step will be described in detail with reference to  FIG.  7   . 
     As illustrated in  FIG.  7   , in step S 201 , the control unit  50  controls the drive unit  41   c  of the pushing force generating unit  41  to start motion of the forming member  21  toward the lower die  10  from the state illustrated in  FIG.  3   . 
     In step S 202 , the control unit  50  controls the drive units  42   c ,  43   c  of the pushing force generating units  42 ,  43  to start motion of the forming members  22 ,  23  toward the lower die  10  at a timing that a predetermined time has elapsed from the start of the motion of the forming member  21  toward the lower die  10 . 
     In step S 203 , the control unit  50  controls the drive units  44   c ,  45   c  of the pushing force generating units  44 ,  45  to start motion of the forming members  24 ,  25  toward the lower die  10  at a timing that a predetermined time has elapsed from the start of the motion of the forming members  22 ,  23  toward the lower die  10 . 
     In step S 204 , the control unit  50  controls the drive units  46   c ,  47   c  of the pushing force generating units  46 ,  47  to start motion of the forming members  26 ,  27  toward the lower die  10  at a timing that a predetermined time has elapsed from the start of the motion of the forming members  24 ,  25  toward the lower die  10 . 
     In step S 205 , the control unit  50  controls the drive units  48   c ,  49   c  of the pushing force generating units  48 ,  49  to start motion of the forming members  28 ,  29  toward the lower die  10  at a timing that a predetermined time has elapsed from the start of the motion of the forming members  26 ,  27  toward the lower die  10 . With the above operations, each motion of the forming members  21  to  29  toward the lower die  10  is started, and the state illustrated in  FIG.  10    and  FIG.  11    is obtained. 
       FIG.  10    is a sectional view illustrating the forming device  100  in the second forming step of  FIG.  6    and illustrates a state where the upper die  20  is moving toward the lower die  10 .  FIG.  11    is a right side view of the forming device  100  illustrated in  FIG.  10    and illustrates a state where the upper die  20  is moving toward the lower die  10 .  FIG.  10    is a sectional view taken along the arrow C-C of  FIG.  11   . 
     As illustrated in  FIG.  10   , when the forming member  21  moves along the side surface  12  of the lower die  10  from above to below along the Z-axis, the laminated body  200  is pressed against the side surface  12  of the lower die  10  by the side surface  21   b  of the forming member  21  to form the laminated body  200  along the shape of the side surface  12 . 
     As illustrated in  FIG.  11   , the distances in the Z-axis direction from the forming members  21  to  29  to the bottom surface  15  of the lower die  10  are not the same. The distance in the Z-axis direction from the forming member  21  to the bottom surface  15  is D 1 , each distance in the Z-axis direction from the forming members  22 ,  23  to the bottom surface  15  is D 2 , and each distance in the Z-axis direction from the forming members  24 ,  25  to the bottom surface  15  is D 3 . Further, each distance in the Z-axis direction from the forming members  26 ,  27  to the bottom surface  15  is D 4 , and each distance in the Z-axis direction from the forming members  28 ,  29  to the bottom surface  15  is D 5 . As illustrated in  FIG.  11   , the distance D 2  is longer than the distance D 1 , the distance D 3  is longer than the distance D 2 , the distance D 4  is longer than the distance D 3 , and the distance D 5  is longer than distance D 4 . 
     As illustrated in  FIG.  11   , the distances in the Z-axis direction from the forming members  21  to  29  to the bottom surface  15  of the lower die  10  are not the same, because timings to move respective forming members toward the lower die  10  have been differentiated. The control unit  50  controls the pushing force generating units  41  to  49  so that the timings that the forming members  22  to  29  arranged on the end side with respect to the center position in the longitudinal direction LD of the laminated body  200  are moved toward the lower die  10  are delayed from the timing that the forming member  21  arranged at the center position (predetermined position) in the longitudinal direction LD of the lower die  10  is moved toward the lower die  10 . 
     Further, the control unit  50  controls the pushing force generating units  41  to  49  so that a plurality of forming members  22  to  29  are pressed against the lower die  10  sequentially from the center position in the longitudinal direction LD of the lower die  10  to the ends of the longitudinal direction LD of the laminated body  200  with the timings being sequentially delayed from the timing for the forming member  21 . The control unit  50  controls the pushing force generating units  41  to  49  to first press the forming member  21  against the lower die  10 , subsequently press the forming members  22 ,  23  against the lower die  10 , subsequently press the forming members  24 ,  25  against the lower die  10 , subsequently press the forming members  26 ,  27  against the lower die  10 , and finally press the forming members  28 ,  29  against the lower die  10 . 
     In step S 206 , the control unit  50  controls the pushing force generating unit  41  to stop the motion of the forming member  21  in response to establishment of a state where the laminated body  200  is held between the forming member  21  and the bottom surface  15  of the lower die  10 . 
     In step S 207 , the control unit  50  controls the pushing force generating units  42 ,  43  to stop the motion of the forming members  22 ,  23  in response to establishment of a state where the laminated body  200  is held between the forming members  22 ,  23  and the bottom surface  15  of the lower die  10 . 
     In step S 208 , the control unit  50  controls the pushing force generating units  44 ,  45  to stop the motion of the forming members  24 ,  25  in response to establishment of a state where the laminated body  200  is held between the forming members  24 ,  25  and the bottom surface  15  of the lower die  10 . 
     In step S 209 , the control unit  50  controls the pushing force generating units  46 ,  47  to stop the motion of the forming members  26 ,  27  in response to establishment of a state where the laminated body  200  is held between the forming members  26 ,  27  and the bottom surface of the lower die  10 . 
     In step S 210 , the control unit  50  controls the pushing force generating units  48 ,  49  to stop the motion of the forming members  28 ,  29  in response to establishment of a state where the laminated body  200  is held between the forming members  28 ,  29  and the bottom surface  15  of the lower die  10 . In response to the end of step S 210 , the state illustrated in  FIG.  12    and  FIG.  13    is established. 
       FIG.  12    is a sectional view illustrating the forming device  100  in the second forming step of  FIG.  6    and illustrates a state where the motion of the upper die  20  toward the lower die  10  has completed.  FIG.  13    is a right side view of the forming device  100  illustrated in  FIG.  12    and illustrates a state where the motion of the upper die  20  toward the lower die  10  has completed.  FIG.  12    is a sectional view taken along the arrow D-D of  FIG.  13   . With the above operations, the process of the second forming step of  FIG.  6    ends. 
     Although, in the above second forming step, the forming member  21  arranged at the center in the longitudinal direction LD out of the plurality of forming members  21  to  29  is moved toward the lower die  10  at the earliest timing, another manner may be possible. For example, when a portion having a large shape change in the longitudinal direction LD (a portion where a wrinkle is likely to occur) is present at a predetermined position in the longitudinal direction LD, it is preferable to move a forming member closest to that portion at the earliest timing toward the lower die  10 . In such a case, the control unit  50  performs control to first move the forming member close to the portion having a large shape change in the longitudinal direction LD, toward the lower die  10  and then move the forming members adjacent thereto toward the lower die  10 . 
     For some shape of the lower die  10 , it may be suitable to move forming members toward the lower die  10  simultaneously at a plurality of positions (for example, adjacent positions) in the longitudinal direction LD in order to suppress a wrinkle. In such a case, the control unit  50  controls the pushing force generating units  41  to  49  to move two or more forming members of the forming members  21  to  29  simultaneously toward the lower die  10 . 
     Further, it is preferable to store in advance, in a storage unit (not illustrated), timings to start motion of the plurality of forming members  21  to  29  suitable to suppress occurrence of a wrinkle in the laminated body  200  when forming the laminated body  200  by using the lower die  10 , the upper die  20 , and the upper die  30 . In such a case, in the second forming step of  FIG.  6   , the control unit  50  reads the timings to start motion of the plurality of forming members  21  to  29  stored in the storage unit and controls the timings to start motion of the plurality of forming members  21  to  29 . 
     In a resin injection step of step S 105 , the laminated body  200  formed along the surface shapes of the lower die  10  and the upper die  20  is arranged in a molding die (not illustrated). A resin material is then injected inside the molding die to impregnate the resin material into the plurality of reinforced fiber sheets of the laminated body  200 . 
     The resin injection step may be performed by vacuum assisted resin transfer molding (VaRTM) in which only the lower die  10  is used, the upper surface of the laminated body  200  formed by the lower die  10  is covered with a vacuum bag film (not illustrated) to reduce the internal pressure, and then a resin is injected therein. 
     In a curing step of step S 106 , the resin material impregnated into the plurality of reinforced fiber sheets of the laminated body  200  is cured. When the resin material is thermosetting, the resin material is heated at a curing temperature or higher to cure the resin material. When the resin material is a thermoplastic resin, the resin material is cooled at a temperature lower than a softening temperature to cure the resin material. With step S 101  to step S 106  described above, a composite material molding method for forming the laminated body  200  to mold a composite material by using the forming device  100  is performed. 
     Effects and advantages achieved by the forming device  100  of the present embodiment described above will be described. 
     According to the forming device  100  of the present embodiment, the upper die  20  is pressed against the lower die  10  having the convex surface  13  with respect to the width direction WD, and thereby the laminated body  200  is formed along the surface shape of the lower die  10 . The pushing force generating mechanism  40  is controlled by the control unit  50  to apply, to the upper die  20 , pushing force for performing the pressing against the lower die  10 . 
     The upper die  20  has the plurality of forming members  21  to  29  aligned in the longitudinal direction LD, and the plurality of pushing force generating units  41  to  49  of the pushing force generating mechanism  40  are connected thereto, respectively. The control unit  50  controls the plurality of pushing force generating units  41  to  49  so that a pair of forming members arranged adjacent in the longitudinal direction LD are pressed against the lower die  10  at different timings from each other. 
     According to the forming device  100  of the present embodiment, a pair of forming members arranged adjacent in the longitudinal direction LD are pressed against the lower die  10  at different timings from each other. When one of the pair of forming members forms the laminated body  200  held between the one and the lower die  10 , a clearance is formed between the other of the pair of forming members and the lower die  10 , and therefore, deformation of the laminated body  200  is tolerated. Thus, compared to a case where press molding using molds with an upper die of one-piece structure and a lower die of one-piece structure is performed or a case where all the plurality of forming members are pressed against the lower die  10  at the same timing in the forming device  100 , it is possible to suppress occurrence of a wrinkle which would otherwise be caused by not tolerating deformation of the laminated body  200 . 
     According to the forming device  100  of the present embodiment, the timing to move the forming members  22 ,  23 , which are arranged on the end side of the laminated body  200  with respect to a predetermined position in the longitudinal direction LD (for example, the center position), toward the lower die  10  is delayed from the timing to move the forming member  21 , which is arranged at the predetermined position, toward the lower die  10 , and thereby deformation of the laminated body  200  occurring when the forming members  21  to  29  are pressed against the lower die  10  can be propagated from the predetermined position to the ends of the laminated body  200 . Accordingly, it is possible to suppress occurrence of a wrinkle which would otherwise be caused by not tolerating deformation of the laminated body  200 . 
     According to the forming device  100  of the present embodiment, the plurality of forming members  21  to  29  are pressed against the lower die  10  sequentially from the predetermined position to the ends of the laminated body  200  with sequentially delayed timings. Thus, deformation of the laminated body  200  occurring when the forming members  21  to  29  are pressed against the lower die  10  is propagated continuously from the predetermined position to the ends of the laminated body  200  without being retained between the lower die  10  and the upper die  20 , and occurrence of a wrinkle can be suppressed. 
     According to the forming device  100  of the present embodiment, by pressing the laminated body  200  against the upper surface  11  adjacent to one side in the width direction WD of the convex surface  13  of the lower die  10 , it is possible to form a region on one side in the width direction WD of the laminated body  200  along the shape of the upper surface  11 . Further, by pressing the upper die  20  against the side surface  12  adjacent to the other side in the width direction WD of the convex surface  13  of the lower die  10 , it is possible to form a region on the other side in the width direction WD of the laminated body  200  along the shape of the side surface  12 . Further, it is possible to form the region interposed between the one side and the other side in the width direction WD of the laminated body  200  along the shape of the convex surface  13 . 
     According to the forming device  100  of the present embodiment, by moving the upper die  20  along the side surface  12  of the lower die  10 , it is possible to form the laminated body  200  along the side surface  12  from a region close to the convex surface  13  to the end in the width direction WD while tolerating deformation of the laminated body  200 . Since the laminated body  200  is formed while deformation thereof is tolerated, occurrence of a wrinkle can be suppressed. 
     Second Embodiment 
     Next, a forming device  100 A according to the second embodiment of the present disclosure will be described with reference to the drawings. The present embodiment is a modified example of the first embodiment, and except as specifically described below, the present embodiment is the same as the first embodiment, and duplicated description will be omitted below. 
       FIG.  14    is a sectional view illustrating the forming device  100 A according to the present embodiment and illustrates a state before the upper die  20  starts motion toward the lower die  10 .  FIG.  15    is a sectional view illustrating the forming device  100 A according to the present embodiment and illustrates a state where the upper die  20  is moving toward the lower die  10 .  FIG.  16    is a sectional view illustrating the forming device  100 A according to the present embodiment and illustrates a state where the upper die  20  has completed the motion toward the lower die  10 . 
     In the forming device  100  of the first embodiment, the pushing force generating mechanism  40  is to move the slide frame  41   b  relative to the fixing frame  41   a  installed above the upper die  20 . In contrast, a pushing force generating mechanism  40 A of the forming device  100 A of the present embodiment is to move a slide frame  41 Ab relative to a support frame  41 Ad installed on the installation surface S. 
     As illustrated in  FIG.  14    to  FIG.  16   , the pushing force generating unit  41 A of the pushing force generating mechanism  40 A of the forming device  100 A has the slide frame  41 Ab, the support frame  41 Ad, and connection frames  41 Ae and  41 Af. The lower end of the slide frame  41 Ab is connected to the forming member  21 . A plate  70  for applying pushing force used for forming the laminated body  200  to the upper die  30  is arranged above the upper die  30 . 
     The support frame  41 Ad is fixed to the installation surface S. The slide frame  41 Ab is fixed to the connection frames  41 Ae,  41 Af. The connection frames  41 Ae,  41 Af are attached to the support frame  41 Ad movably along the Z-axis. The slide frame  41 Ab moves in a direction along the Z-axis integrally with the connection frames  41 Ae,  41 Af in response to drive force being applied by the drive unit  41 Ac. 
     Since the support frame  41 Ad is fixed to the installation surface S, the forming device  100 A of the present embodiment is reliably supported by the support frame  41 Ad so that the slide frame  41 Ab is not separated from the side surface  12  of the lower die  10 . Thus, when the upper die  20  is moved toward the lower die  10 , pushing force for pressing the laminated body  200  against the lower die  10  can be reliably applied. 
     The forming devices described in the above embodiments are understood as follows, for example. 
     The forming device according to the present disclosure is a forming device ( 100 ) for forming a laminated body ( 200 ) of a plurality of laminated sheet materials containing reinforced fibers, the forming device includes: a first forming die ( 10 ) having a curved surface ( 13 ) that extends in a longitudinal direction (LD) and includes at least any one of a concave shape and a convex shape with respect to a width direction (WD); a second forming die ( 20 ) configured to form the laminated body along a surface shape of the first forming die by pressing the laminated body against the first forming die; a pushing force generating mechanism ( 40 ) configured to generate pushing force for pressing the second forming die against the first forming die; and a control unit ( 50 ) configured to control the pushing force generating mechanism, the second forming die has a plurality of forming members ( 21  to  29 ) aligned in the longitudinal direction, the pushing force generating mechanism has a plurality of pushing force generating units ( 41  to  49 ) connected to the plurality of forming members and configured to generate pushing force for pressing the forming members against the first forming die, and the control unit controls the plurality of pushing force generating units so as to press a pair of the forming members arranged adjacent in the longitudinal direction against the first forming die at different timings from each other. 
     According to the forming device of the present disclosure, the second forming die is pressed against the first forming die having the curved surface including at least any one of a concave shape and a convex shape with respect to the width direction, and thereby the laminated body is formed along the surface shape of the first forming die. The pushing force generating mechanism is controlled by the control unit to apply, to the second forming die, pushing force for performing the pressing against the first forming die. 
     The second forming die has a plurality of forming members aligned in the longitudinal direction, and a plurality of pushing force generating units of the pushing force generating mechanism are connected thereto, respectively. The control unit controls the plurality of pushing force generating units so that a pair of forming members arranged adjacent in the longitudinal direction are pressed against the first forming die at different timings from each other. 
     According to the forming device of the present disclosure, a pair of forming members arranged adjacent in the longitudinal direction are pressed against the first forming die at different timings from each other. When one of the pair of forming members forms the laminated body held between the one and the first forming die, a clearance is formed between the other of the pair of forming members and the first forming die, and therefore, deformation of the laminated body is tolerated. Thus, compared to a case where a pair of forming members are pressed against the first forming die at the same timing, it is possible to suppress occurrence of a wrinkle which would otherwise be caused by not tolerating deformation of the laminated body. 
     In the forming device according to the present disclosure, the plurality of forming members may include at least a forming member arranged at a predetermined position in the longitudinal direction and a forming member arranged on an end side of the laminated body with respect to the predetermined position, and the control unit may be configured to control the plurality of pushing force generating units so that a timing to move the forming member arranged on the end side toward the first forming die is delayed from a timing to move the forming member arranged at the predetermined position toward the first forming die. 
     According to the forming device of the present configuration, the timing to move the forming member arranged on the end side of the laminated body with respect to a predetermined position in the longitudinal direction toward the first forming die is delayed from the timing to move the forming member arranged at the predetermined position toward the first forming die, and thereby deformation of the laminated body occurring when the forming members are pressed against the first forming die can be propagated from the predetermined position to the end of the laminated body. Accordingly, it is possible to suppress occurrence of a wrinkle which would otherwise be caused by not tolerating deformation of the laminated body. 
     In the forming device of the above configuration, the control unit may be in a manner that controls the plurality of pushing force generating units so that the plurality of forming members are pressed against the first forming die sequentially from the predetermined position to the end of the laminated body with sequentially delayed timings. 
     According to the forming device of the present aspect, a plurality of forming members are pressed against the first forming die sequentially from the predetermined position to the end of the laminated body with sequentially delayed timings. Thus, deformation of the laminated body occurring when the forming members are pressed against the first forming die is propagated continuously from the predetermined position to the end of the laminated body without being retained between the first forming die and the second forming die, and occurrence of a wrinkle can be suppressed. 
     The forming device according to the present disclosure may include a third forming die ( 30 ) configured to press the laminated body against a first forming surface adjacent to one side in the width direction of the curved surface of the first forming die, and the pushing force generating mechanism may be configured to generate pushing force for pressing the second forming die against a second forming surface adjacent to the other side in the width direction of the curved surface of the first forming die. 
     According to the forming device of the present configuration, by pressing the laminated body against the first forming surface adjacent to one side in the width direction of the curved surface of the first forming die, it is possible to form a region on one side in the width direction of the laminated body along the shape of the first forming surface. Further, by pressing the second forming die against the second forming surface adjacent to the other side in the width direction of the curved surface of the first forming die, it is possible to form a region on the other side in the width direction of the laminated body along the shape of the second forming surface. Further, it is possible to form the region interposed between the one side and the other side in the width direction of the laminated body along the shape of the curved surface. 
     In the forming device according to the above configuration, the pushing force generating mechanism may be in a manner that forms the laminated body along the second forming surface by moving the second forming die along the second forming surface of the first forming die. 
     According to the forming device of the present aspect, by moving the second forming die along the second forming surface of the first forming die, it is possible to form the laminated body along the second forming surface from a region close to the curved surface to the end in the width direction while tolerating deformation of the laminated body. Since the laminated body is formed while deformation thereof is tolerated, occurrence of a wrinkle can be suppressed. 
     The forming methods described in the above embodiments are understood as follows, for example. 
     The forming method according to the present disclosure is a forming method for forming a laminated body of a plurality of laminated sheet materials containing reinforced fibers, the forming method includes: a fixing step of fixing one end of the laminated body to a first forming die having a curved surface that extends in a longitudinal direction and includes at least any one of a concave shape and a convex shape with respect to a width direction; and a forming step of forming the laminated body along a surface shape of the first forming die by pressing a second forming die having a plurality of forming members aligned in the longitudinal direction against the first forming die, and the forming step presses a pair of the forming members arranged adjacent in the longitudinal direction against the first forming die at different timings from each other. 
     According to the forming method of the present disclosure, the second forming die is pressed against the first forming die having the curved surface including at least any one of a concave shape and a convex shape with respect to the width direction, and thereby the laminated body is formed along the surface shape of the first forming die. The second forming die has a plurality of forming members aligned in the longitudinal direction. 
     According to the forming method of the present disclosure, the forming step presses a pair of forming members arranged adjacent in the longitudinal direction against the first forming die at different timings from each other. When one of the pair of forming members forms the laminated body held between the one and the first forming die, a clearance is formed between the other of the pair of forming members and the first forming die, and therefore, deformation of the laminated body is tolerated. Thus, compared to a case where a pair of forming members are pressed against the first forming die at the same timing, it is possible to suppress occurrence of a wrinkle which would otherwise be caused by not tolerating deformation of the laminated body. 
     In the forming method according to the present disclosure, the plurality of forming members may include at least a forming member arranged at a predetermined position in the longitudinal direction and a forming member arranged on an end side of the laminated body with respect to the predetermined position, and the forming step may be configured to delay a timing to move the forming member arranged on the end side toward the first forming die from a timing to move the forming member arranged at the predetermined position toward the first forming die. 
     According to the forming method of the present configuration, the timing to move the forming member arranged on the end side of the laminated body with respect to a predetermined position in the longitudinal direction toward the first forming die is delayed from the timing to move the forming member arranged at the predetermined position toward the first forming die, and thereby deformation of the laminated body occurring when the forming members are pressed against the first forming die can be propagated from the predetermined position to the end of the laminated body. Accordingly, it is possible to suppress occurrence of a wrinkle which would otherwise be caused by not tolerating deformation of the laminated body. 
     In the forming method of the above configuration, the forming step may be in a manner that moves the plurality of forming members so that the plurality of forming members are pressed against the first forming die sequentially from the predetermined position to the end of the laminated body with sequentially delayed timings. 
     According to the forming method of the present aspect, a plurality of forming members are pressed against the first forming die sequentially from the predetermined position to the end of the laminated body with sequentially delayed timings. Thus, deformation of the laminated body occurring when the forming members are pressed against the first forming die is propagated continuously from the predetermined position to the end of the laminated body without being retained between the first forming die and the second forming die, and occurrence of a wrinkle can be suppressed. 
     In the forming method according to the present disclosure, the forming step may be configured to form the laminated body by pressing a third forming die against a first forming surface adjacent to one end in the width direction of the curved surface of the first forming die and pressing the second forming die against a second forming surface adjacent to the other side in the width direction of the curved surface of the first forming die. 
     According to the forming method of the present configuration, by pressing the laminated body against the first forming surface adjacent to one side in the width direction of the curved surface of the first forming die, it is possible to form a region on one side in the width direction of the laminated body along the shape of the first forming surface. Further, by pressing the second forming die against the second forming surface adjacent to the other side in the width direction of the curved surface of the first forming die, it is possible to form a region on the other side in the width direction of the laminated body along the shape of the first forming surface. Further, it is possible to form the region interposed between the one side and the other side in the width direction of the laminated body along the shape of the curved surface. 
     In the forming method according to the above configuration, the forming step may be in a manner that forms the laminated body along the second forming surface by moving the second forming die along the second forming surface of the first forming die. 
     According to the forming method of the present aspect, by moving the second forming die along the second forming surface of the first forming die, it is possible to form the laminated body along the second forming surface from a region close to the curved surface to the end in the width direction while tolerating deformation of the laminated body. Since the laminated body is formed while deformation thereof is tolerated, occurrence of a wrinkle can be suppressed.