Patent Description:
Some aircraft components such as a fuselage, a main wing, and the like of an aircraft are made of a composite material, for example, carbon fiber reinforced plastic (CFRP).

CFRP structure members (composite material structures) of aircraft components have various sectional shapes. One of the methods for manufacturing such a composite material structure is a method of laminating a plurality of fiber sheets (prepregs or the like) to fabricate a planar laminated body of fiber sheets (also referred to as a "charge") and forming this laminated body by using a shaping die to provide a desired sectional shape (for example, as in <CIT> and <CIT>).

<CIT> discloses a method of laminating an extra laminated body on a portion where fiber sheets of a laminated body are expected to be insufficient when the laminated body is bent.

Further, <CIT> discloses a method of correcting an undevelopable surface to a developable surface by changing a bending line of a shaping die.

<CIT> and <CIT> are examples of the related arts.

However, in the method of <CIT>, it is not possible to eliminate excess of a fiber sheet. Further, the method of <CIT> involves a change of the final shape of a product, which is not preferable. <CIT> describes a method and an apparatus for fabricating highly contoured composite stiffeners with reduced wrinkling. <CIT> describes the formation of composite laminates having one or more divergent flanges.

The dependent claims describe optional features and distinct embodiments. The present disclosure has been made in view of such circumstances, and an object is to provide a laminated body and a forming method that can eliminate excess of a fiber sheet or insufficiency of a fiber sheet.

To achieve the above object, the laminated body and the forming method of the present disclosure employ the following solutions.

Specifically, the laminated body according to one aspect of the present disclosure is a laminated body configured to be overlapped on a shaping die having a shaping die reference surface curved or bent relative to a predetermined direction and a shaping die bend surface intersecting the shaping die reference surface along the predetermined direction. The laminated body is made of a plurality of laminated fiber sheets and includes: a laminated body reference surface curved or bent relative to the predetermined direction and configured to be overlapped on the shaping die reference surface; and a laminated body bend surface intersecting the laminated body reference surface along the predetermined direction and configured to be overlapped on the shaping die bend surface, an angle between the laminated body reference surface and the laminated body bend surface is larger than an angle between the shaping die reference surface and the shaping die bend surface, and when a ridge where the shaping die reference surface and the shaping die bend surface intersect with each other is defined as a shaping die edge, and a ridge where the laminated body reference surface and the laminated body bend surface intersect with each other is defined as a laminated body edge, the laminated body edge is displaced from the shaping die edge on the shaping die reference surface in a state where the laminated body reference surface is overlapped on the shaping die reference surface.

Further, the forming method according to one aspect of the present disclosure is a forming method of overlapping and forming a laminated body made of a plurality of laminated fiber sheets on a shaping die, the shaping die has a shaping die reference surface curved or bent relative to a predetermined direction and a shaping die bend surface intersecting the shaping die reference surface along the predetermined direction, the laminated body has a laminated body reference surface curved or bent relative to the predetermined direction and a laminated body bend surface intersecting the laminated body reference surface along the predetermined direction, and an angle between the laminated body reference surface and the laminated body bend surface is larger than an angle between the shaping die reference surface and the shaping die bend surface. The forming method includes: overlapping the laminated body reference surface on the shaping die reference surface; and bending the laminated body bend surface toward the shaping die bend surface along a bending line extending in the predetermined direction, and when a ridge where the laminated body reference surface and the laminated body bend surface intersect with each other is defined as a laminated body edge, the bending line is displaced from the laminated body edge.

According to the present disclosure, it is possible to eliminate excess of a fiber sheet or insufficiency of a fiber sheet.

Embodiments of the laminated body and the forming method according to the present disclosure will be described below with reference to the drawings.

In the present embodiment, a composite material structure that is a molded article with the final shape is manufactured by overlapping and forming a laminated body <NUM> (charge) on a shaping die <NUM>, the laminated body <NUM> being made of a plurality of laminated fiber sheets.

As illustrated in <FIG>, the shaping die <NUM> is a block-like member having a shaping die reference surface <NUM> and a shaping die bend surface <NUM>. By the laminated body <NUM> described later being overlapped on the shaping die <NUM>, the laminated body <NUM> will be formed into a shape in accordance with the shape of the shaping die <NUM>.

The shaping die reference surface <NUM> is a bent surface, which is the upper surface of the shaping die <NUM> in <FIG>. A laminated body reference surface <NUM> of the laminated body <NUM> described later is overlapped on the shaping die reference surface <NUM>.

The shaping die reference surface <NUM> is bent such that the height in the Z-axis direction changes in the X-axis direction. Specifically, when viewed from the front in the Y-axis direction, the shaping die reference surface <NUM> has a convex shape having the top at substantially the center (hereafter, referred to as a "shaping die top 11a"). The shaping die top 11a extends linearly in the Y-axis direction and defines a ridge of the shaping die reference surface <NUM>.

The shaping die bend surface <NUM> is a surface connected to the shaping die reference surface <NUM>, which is the front surface of the shaping die <NUM> in <FIG>. A laminated body bend surface <NUM> of the laminated body <NUM> described later is bent and overlapped on the shaping die bend surface <NUM>.

The shaping die bend surface <NUM> is connected to the edge of the shaping die reference surface <NUM> extending in the X-axis direction and intersects the shaping die reference surface <NUM> on this edge.

Note that the angle between the shaping die reference surface <NUM> and the shaping die bend surface <NUM> is <NUM> degrees in <FIG> when viewed from the side, namely, viewed from the X-axis direction, but the angle is not limited thereto. In this regard, however, the angle is smaller than the angle between the laminated body reference surface <NUM> and the laminated body bend surface <NUM> described later.

Herein, the ridge on which the shaping die reference surface <NUM> and the shaping die bend surface <NUM> intersect with each other is defined as a shaping die edge <NUM>.

The shaping die edge <NUM> is bent such that the height in the Z-axis direction changes in the X-axis direction in the same manner as the shaping die reference surface <NUM>. This is natural given that the shaping die edge <NUM> is also the edge of the shaping die reference surface <NUM>.

As illustrated in <FIG>, the laminated body <NUM> is made up of a plurality of laminated fiber sheets.

The fiber sheet is made of a fiber base material whose fiber directions are matched to be parallel to the longitudinal direction of the fiber sheet and a resin impregnated into the fiber base material.

For the fiber base material, any fibers such as carbon fibers, glass fibers, or the like may be used.

For the resin impregnated into the fiber base material, a thermosetting resin cured when heated may be used. Examples thereof include an epoxy resin, polyimide, polyurethan, and unsaturated polyester.

Besides the above, a thermoplastic resin solidified through heating may also be used. Examples thereof include polyamide, polyethylene, polystyrene, and polyvinyl chloride.

Note that the fiber sheet is not limited to the fiber sheets described above. For example, the fiber sheet may be a formable dry sheet. Further, for example, the fiber direction may be a direction that is not parallel to the longitudinal direction of the sheet.

The laminated body <NUM> has the laminated body reference surface <NUM> and the laminated body bend surface <NUM>.

The laminated body reference surface <NUM> is a bent surface. The laminated body reference surface <NUM> is overlapped on the shaping die reference surface <NUM> of the shaping die <NUM>.

The laminated body reference surface <NUM> is bent such that the height in the Z-axis direction changes in the X-axis direction. Specifically, when viewed from the front in the Y-axis direction, the laminated body reference surface <NUM> has a convex shape having the top at substantially the center (hereafter, referred to as a "laminated body top 21a"). This convex shape corresponds to the convex shape of the shaping die reference surface <NUM>. The laminated body top 21a extends linearly in the Y-axis direction and defines a ridge of the laminated body reference surface <NUM>.

The laminated body bend surface <NUM> is a surface connected to the laminated body reference surface <NUM>. The laminated body bend surface <NUM> is bent toward the shaping die bend surface <NUM> of the shaping die <NUM> and overlapped thereon.

The laminated body bend surface <NUM> is connected to the edge of the laminated body reference surface <NUM> extending in the X-axis direction and intersects the laminated body reference surface <NUM> on this edge.

Note that the angle between the laminated body reference surface <NUM> and the laminated body bend surface <NUM> is set to be larger than the angle between the shaping die reference surface <NUM> and the shaping die bend surface <NUM> when viewed from the side, namely, viewed from the X-axis direction. Thus, as with the state illustrated in <FIG>, the laminated body bend surface <NUM> is separated from the shaping die bend surface <NUM> when the laminated body <NUM> is placed on the shaping die <NUM> such that the laminated body reference surface <NUM> is overlapped on the shaping die reference surface <NUM>.

Herein, the ridge on which the laminated body reference surface <NUM> and the laminated body bend surface <NUM> intersect with each other is defined as a laminated body edge <NUM>.

The laminated body edge <NUM> is bent such that the height in the Z-axis direction changes in the X-axis direction in the same manner as the laminated body reference surface <NUM>. This is natural given that the laminated body edge <NUM> is also the edge of the laminated body reference surface <NUM>.

The laminated body edge <NUM> is set so as to have the following positional relationship with respect to the shaping die edge <NUM> between the shaping die <NUM> and the laminated body <NUM> described above.

As illustrated in <FIG> and <FIG>, the shaping die edge <NUM> runs straight in the X-axis direction.

On the other hand, the laminated body edge <NUM> is displaced from the shaping die edge <NUM> on the shaping die reference surface <NUM> in a state where the laminated body reference surface <NUM> is overlapped on the shaping die reference surface <NUM> so that the laminated body top 21a matches the shaping die top 11a.

In detail, the laminated body edge <NUM> matches the shaping die edge <NUM> at a portion (point) intersecting the laminated body top 21a and is displaced from the shaping die edge <NUM> in the remaining portion.

In more detail, the laminated body edge <NUM> is displaced from the shaping die edge <NUM> so as to be gradually spaced away from the shaping die edge <NUM> as a position on the laminated body edge <NUM> approaches a side end 21b from the laminated body top 21a. Accordingly, the amount of displacement of the laminated body edge <NUM> from the shaping die edge <NUM> increases as a position on the laminated body edge <NUM> approaches the side end 21b from the laminated body top 21a.

Thus, the laminated body edge <NUM> has substantially a V-shape in planar view from the Z-axis direction.

<FIG> illustrates sectional views taken along the Y-Z plane at several positions in the X-axis direction in <FIG>. In these sectional views, the A-A cross section corresponds to a sectional view passing through the laminated body top 21a, the C-C cross section corresponds to a sectional view passing through the side end 21b, and the B-B cross section corresponds to a sectional view between the A-A cross section and the C-C cross section.

In accordance with these views, the laminated body edge <NUM> is displaced from the shaping die edge <NUM> so as to be gradually spaced away from the shaping die edge <NUM> as a position on the laminated body edge <NUM> approaches the side end 21b from the laminated body top 21a. Thus, a position on the laminated body edge <NUM> is gradually spaced away from the shaping die edge <NUM> as the position approaches the C-C cross section from the A-A cross section.

The laminated body edge <NUM> set as described above works as follows.

First, as illustrated in <FIG>, the laminated body <NUM> is placed on the shaping die <NUM> so that the laminated body reference surface <NUM> overlaps the shaping die reference surface <NUM>.

Next, as illustrated in <FIG>, the laminated body bend surface <NUM> is bent toward the shaping die bend surface <NUM> so that the laminated body bend surface <NUM> overlaps the shaping die bend surface <NUM>.

In this state, as illustrated in <FIG>, the laminated body bend surface <NUM> moves and is overlapped on the shaping die bend surface <NUM> as follows at any position moved from the laminated body top 21a in the X-axis direction.

In a state before bent (represented by a dashed line), the laminated body bend surface <NUM> slopes downward starting from the point P1, which corresponds to the laminated body edge <NUM>, and shortcuts a corner of the shaping die <NUM> including the point P2, which corresponds to the shaping die edge <NUM>. Herein, a virtual intersection between the laminated body bend surface <NUM> before bent and the shaping die bend surface <NUM> is denoted as a point P3.

In a physical sense, however, the laminated body bend surface <NUM> does not actually shortcut the corner of the shaping die <NUM>. Thus, in reality, the laminated body bend surface <NUM> is overlapped on the shaping die bend surface <NUM> so as to pass through the point P2 and be bent at the point P2. Accordingly, the actual bending line is not along the laminated body edge <NUM> but along the shaping die edge <NUM>.

In this state, the laminated body bend surface <NUM> is overlapped on the shaping die bend surface <NUM> so as to take the long way around to pass through the point P2. Thus, the lower end of the laminated body bend surface <NUM> is pulled up toward the point P2 side for the distance corresponding to the taken long way.

In this state, the dimension Δd in which the laminated body bend surface <NUM> is pulled up is d12 + d23 - d13, where d12 is the distance between the point P1 and point P2, d23 is the distance between the point P2 and the point P3, and d13 is the distance between the point P1 and the point P3.

As described previously, as illustrated in <FIG>, the laminated body edge <NUM> is displaced from the shaping die edge <NUM> so as to be gradually spaced away from the shaping die edge <NUM> as a position on the laminated body edge <NUM> approaches the side end 21b from the laminated body top 21a. Thus, as illustrated in <FIG>, a region of the laminated body bend surface <NUM> which is closer to a side end 22b has a larger amount of the shortcut of the corner of the shaping die <NUM>. In other words, a region of the laminated body bend surface <NUM> which is closer to the side end 22b has a larger dimension Δd in which the laminated body bend surface <NUM> is pulled up.

This means that, as illustrated in <FIG>, the laminated body bend surface <NUM> overlapped on the shaping die bend surface <NUM> spreads to both sides (both the side end 22b sides) in the lateral direction when viewed from the front in the Y-axis direction. Thus, excess of the fiber sheet of the laminated body bend surface <NUM> at the center (excessive overlapping of the laminated body <NUM>) is cancelled.

Herein, d12 in <FIG>, that is, the distance along the shaping die reference surface <NUM> between the laminated body edge <NUM> and the shaping die edge <NUM> is determined as follows, for example.

As illustrated in <FIG> and <FIG>, in an X-X cross section on the Y-Z plane at any position x, a point corresponding to the laminated body edge <NUM> is denoted as a point Px1, and a point corresponding to the shaping die edge <NUM> is denoted as a point Px2. Thus, the intersection between this Y-Z plane and the laminated body edge <NUM> is the point Px1, and the intersection between this Y-Z plane and the shaping die edge <NUM> is the point Px2.

Further, in a cross section on the Y-Z plane passing through the shaping die top 11a of the shaping die reference surface <NUM>, a point corresponding to the shaping die edge <NUM> is denoted as a point Pt. Thus, the intersection between this Y-Z plane and the shaping die edge <NUM> is the point Pt.

Further, the distance between the point Pt and the point Px2 when viewed from the side in the X-axis direction, that is, the distance between the point Pt and the point Px2 in the Z-axis direction is denoted as z(x).

Then, the distance between the point Px1 and the point Px2 is determined as k × z(x). Herein, k is a predetermined constant of proportionality.

The constant of proportionality k is described below.

As illustrated in <FIG>, the constant of proportionality k is expressed by the following equation (Equation <NUM>), where θ is the angle between the shaping die reference surface <NUM> and the outer surface of the laminated body bend surface <NUM>, and ϕ is the angle between the extension line of the shaping die reference surface <NUM> and the shaping die bend surface <NUM>.

Note that an arbitrary ϕ is used for generalization in <FIG>, but <FIG> represents a case where ϕ is <NUM> degrees (<NUM>/2π [rad]), for example.

The laminated body <NUM> is manufactured by laminating fiber sheets on a lamination die <NUM> as illustrated in <FIG>. A lamination surface <NUM> corresponding to the upper surface of the lamination die <NUM> corresponds to the shape of the laminated body reference surface <NUM> and the laminated body bend surface <NUM> of the laminated body <NUM>.

The lamination of the fiber sheet on the lamination die <NUM> may be manually performed by an operator or may be automatically performed by a robot.

As illustrated in <FIG>, the shaping die reference surface <NUM> may be a curved surface.

The shaping die reference surface <NUM> is smoothly curved so that the height in the Z-axis direction changes in the X-axis direction. Specifically, the shaping die reference surface <NUM> has a smooth convex shape having the shaping die top 11a at substantially the center when viewed from the front in the Y-axis direction.

Further, the laminated body reference surface <NUM> may be a curved surface.

The laminated body reference surface <NUM> is smoothly curved so that the height in the Z-axis direction changes in the X-axis direction. Specifically, the laminated body reference surface <NUM> has a smooth convex shape having the laminated body top 21a at substantially the center when viewed from the front in the Y-axis direction. This convex shape corresponds to the convex shape of the shaping die reference surface <NUM>.

In the present embodiment, the following advantageous effects are achieved. The amount of displacement of the laminated body edge <NUM> from the shaping die edge <NUM> increases as a position on the laminated body edge <NUM> approaches the side end 21b from the laminated body top 21a in the convex shape. Thus, when the laminated body bend surface <NUM> is overlapped on the shaping die bend surface <NUM>, portions closer to both the side ends 22b of the laminated body bend surface <NUM> are pulled up to the shaping die edge <NUM> side, and portions closer to the laminated body top 21a are not pulled up to the shaping die edge <NUM> side. Thus, excess of the fiber sheet occurring on the laminated body bend surface <NUM> when the laminated body bend surface <NUM> is overlapped on the shaping die bend surface <NUM> can be cancelled by the displacement between the shaping die edge <NUM> and the laminated body edge <NUM>.

As illustrated in <FIG>, if the shaping die edge <NUM> and the laminated body edge <NUM> match, the fiber sheet will be excessive in the laminated body bend surface <NUM> compared to the case of the above embodiment when the laminated body bend surface <NUM> is overlapped on the shaping die bend surface <NUM>. This is because that portions on both the side end 22b sides of the laminated body bend surface <NUM> are not pulled up to the shaping die edge <NUM> side.

Further, the distance between the shaping die edge <NUM> and the laminated body edge <NUM> at the position x is defined as k × z(x), and it is thus possible to set the distance between the shaping die edge <NUM> and the laminated body edge <NUM> based on the distance z(x).

As illustrated in <FIG>, the shaping die <NUM> is a block-like member having the shaping die reference surface <NUM> and the shaping die bend surface <NUM>. By the laminated body <NUM> described later being overlapped on the shaping die <NUM>, the laminated body <NUM> will be formed into a shape in accordance with the shape of the shaping die <NUM>.

The shaping die reference surface <NUM> is a bent surface, which is the upper surface of the shaping die <NUM> in <FIG>. The laminated body reference surface <NUM> of the laminated body <NUM> described later is overlapped on the shaping die reference surface <NUM>.

The shaping die reference surface <NUM> is bent such that the height in the Z-axis direction changes in the X-axis direction. Specifically, when viewed from the front in the Y-axis direction, the shaping die reference surface <NUM> has a concave shape having the bottom at substantially the center (hereafter, referred to as a "shaping die bottom 11c"). The shaping die bottom 11c extends linearly in the Y-axis direction.

The shaping die bend surface <NUM> is a surface connected to the shaping die reference surface <NUM>, which is the front surface of the shaping die <NUM> in <FIG>. The laminated body bend surface <NUM> of the laminated body <NUM> described later is bent and overlapped on the shaping die bend surface <NUM>.

Herein, the ridge on which the shaping die reference surface <NUM> and the shaping die bend surface <NUM> intersect with each other is defined as the shaping die edge <NUM>.

The laminated body reference surface <NUM> is bent such that the height in the Z-axis direction changes in the X-axis direction. Specifically, when viewed from the front in the Y-axis direction, the laminated body reference surface <NUM> has a concave shape having the bottom at substantially the center (hereafter, referred to as a "laminated body bottom 21c"). This concave shape corresponds to the concave shape of the shaping die reference surface <NUM>. The laminated body bottom 21c extends linearly in the Y-axis direction.

Herein, the ridge on which the laminated body reference surface <NUM> and the laminated body bend surface <NUM> intersect with each other is defined as the laminated body edge <NUM>.

On the other hand, the laminated body edge <NUM> is displaced from the shaping die edge <NUM> on the shaping die reference surface <NUM> in a state where the laminated body reference surface <NUM> is overlapped on the shaping die reference surface <NUM> so that the laminated body bottom 21c matches the shaping die bottom 11c.

In detail, the laminated body edge <NUM> matches the shaping die edge <NUM> at a portion (point) on the laminated body reference surface <NUM> intersecting the side end 21b and is displaced from the shaping die edge <NUM> in the remaining portion.

In more detail, the laminated body edge <NUM> is displaced from the shaping die edge <NUM> so as to be gradually spaced away from the shaping die edge <NUM> as a position on the laminated body edge <NUM> approaches the laminated body bottom 21c from the side end 21b. Accordingly, the amount of displacement of the laminated body edge <NUM> from the shaping die edge <NUM> increases as a position on the laminated body edge <NUM> approaches the laminated body bottom 21c from the side end 21b.

Thus, the laminated body edge <NUM> has substantially an inverse V-shape in planar view from the Z-axis direction.

<FIG> illustrates sectional views taken along the Y-Z plane at several positions in the X-axis direction in <FIG>. In these sectional views, the A-A cross section corresponds to a sectional view passing through the laminated body bottom 21c, the C-C cross section corresponds to a sectional view passing through the side end 21b, and the B-B cross section corresponds to a sectional view between the A-A cross section and the C-C cross section.

In accordance with these views, the laminated body edge <NUM> is displaced from the shaping die edge <NUM> so as to be gradually spaced away from the shaping die edge <NUM> as a position on the laminated body edge <NUM> approaches the laminated body bottom 21c from the side end 21b. Thus, a position on the laminated body edge <NUM> is gradually spaced away from the shaping die edge <NUM> as the position approaches the C-C cross section from the A-A cross section.

The laminated body edge <NUM> set as described above works as follows. Note that the basic principle is the same as that in the first embodiment.

As described previously, as illustrated in <FIG>, the laminated body edge <NUM> is displaced from the shaping die edge <NUM> so as to be gradually spaced away from the shaping die edge <NUM> as a position on the laminated body edge <NUM> approaches the laminated body bottom 21c from the side end 21b. Thus, a region of the laminated body bend surface <NUM> located on the center side has a larger amount of the shortcut of the corner of the shaping die <NUM>. In other words, a region of the laminated body bend surface <NUM> located on the center side has a larger dimension Δd in which the laminated body bend surface <NUM> is pulled up.

This means that the laminated body bend surface <NUM> overlapped on the shaping die bend surface <NUM> comes to the center side when viewed from the front in the Y-axis direction. Thus, insufficiency of the fiber sheet of the laminated body bend surface <NUM> at the center is compensated.

Note that z(x) in the present embodiment has a reference at the point Pt corresponding to the shaping die edge <NUM> in a cross section on the Y-Z plane passing through the side end 21b of the laminated body <NUM>. Thus, the intersection between this Y-Z plane and the shaping die edge <NUM> is defined as the point Pt.

The shaping die reference surface <NUM> is smoothly curved so that the height in the Z-axis direction changes in the X-axis direction. Specifically, the shaping die reference surface <NUM> has a smooth concave shape having the shaping die bottom 11c at substantially the center when viewed from the front in the Y-axis direction.

The laminated body reference surface <NUM> is smoothly curved so that the height in the Z-axis direction changes in the X-axis direction. Specifically, the laminated body reference surface <NUM> has a smooth concave shape having the laminated body bottom 21c at substantially the center when viewed from the front in the Y-axis direction. This concave shape corresponds to the concave shape of the shaping die reference surface <NUM>.

In the present embodiment, the following advantageous effects are achieved.

The amount of displacement of the laminated body edge <NUM> from the shaping die edge <NUM> increases as a position on the laminated body edge <NUM> approaches the laminated body bottom 21c from the side end 21b in the concave shape. Thus, when the laminated body bend surface <NUM> is overlapped on the shaping die bend surface <NUM>, portions closer to the center of the laminated body bend surface <NUM> are pulled up to the shaping die edge <NUM> side, and portions closer to the side ends 22b are not pulled up to the shaping die edge <NUM> side. Thus, insufficiency of the fiber sheet occurring on the laminated body bend surface <NUM> when the laminated body bend surface <NUM> is overlapped on the shaping die bend surface <NUM> can be compensated by the displacement between the shaping die edge <NUM> and the laminated body edge <NUM>.

As illustrated in <FIG>, if the shaping die edge <NUM> and the laminated body edge <NUM> match, insufficiency of the fiber sheet will occur in the laminated body bend surface <NUM> compared to the case of the above embodiment when the laminated body bend surface <NUM> is overlapped on the shaping die bend surface <NUM>. This is because that portions on the center side of the laminated body bend surface <NUM> are not pulled up to the shaping die edge <NUM> side.

Note that, when the shaping die reference surface <NUM> and the shaping die bend surface <NUM> intersect with each other by being connected via an R-part in the first embodiment and the second embodiment as illustrated in <FIG>, the shaping die edge <NUM> will be a virtual ridge where the extension line of the shaping die reference surface <NUM> and the extension line of the shaping die bend surface <NUM> intersect with each other.

Further, the laminated body reference surface <NUM> and the laminated body bend surface <NUM> may be connected via an R-part. In such a case, the laminated body edge <NUM> is a virtual ridge where the extension line of the laminated body reference surface <NUM> and the extension line of the laminated body bend surface <NUM> intersect with each other.

The embodiments described above are understood as follows, for example.

The laminated body (<NUM>) according to the first aspect of the present disclosure is a laminated body configured to be overlapped on a shaping die (<NUM>) having a shaping die reference surface (<NUM>) curved or bent relative to a predetermined direction and a shaping die bend surface (<NUM>) intersecting the shaping die reference surface along the predetermined direction. The laminated body is made of a plurality of laminated fiber sheets and includes: a laminated body reference surface (<NUM>) curved or bent relative to the predetermined direction and configured to be overlapped on the shaping die reference surface; and a laminated body bend surface (<NUM>) intersecting the laminated body reference surface along the predetermined direction and configured to be overlapped on the shaping die bend surface, an angle between the laminated body reference surface and the laminated body bend surface is larger than an angle between the shaping die reference surface and the shaping die bend surface, and when a ridge where the shaping die reference surface and the shaping die bend surface intersect with each other is defined as a shaping die edge (<NUM>), and a ridge where the laminated body reference surface and the laminated body bend surface intersect with each other is defined as a laminated body edge (<NUM>), the laminated body edge is displaced from the shaping die edge on the shaping die reference surface in a state where the laminated body reference surface is overlapped on the shaping die reference surface.

According to the laminated body of the present aspect, the laminated body edge is displaced from the shaping die edge in a state where the laminated body reference surface is overlapped on the shaping die reference surface. Thus, the laminated body bend surface corresponding to the position of the laminated body edge displaced from the shaping die edge is pulled up to the shaping die edge side when the laminated body bend surface is overlapped on the shaping die bend surface. Accordingly, by adjusting the amount of displacement of the laminated body edge from the shaping die edge to adjust the amount of the pulled-up laminated body bend surface, it is possible to eliminate excess of the fiber sheet or insufficiency of the fiber sheet.

Further, the laminated body according to the second aspect of the present disclosure is such that, in the laminated body according to the first aspect, the shaping die reference surface and the laminated body reference surface are curved or bent in a convex shape relative to the predetermined direction, and in a state where the laminated body reference surface is overlapped on the shaping die reference surface, an amount of displacement of the laminated body edge from the shaping die edge increases as a position on the laminated body edge approaches a side end (21b) from a laminated body top (21a), which is a top of the convex shape.

According to the laminated body of the present aspect, the shaping die reference surface and the laminated body reference surface are curved or bent in a convex shape relative to the predetermined direction, and in a state where the laminated body reference surface is overlapped on the shaping die reference surface, the amount of displacement of the laminated body edge from the shaping die edge increases as a position on the laminated body edge approaches the side end from the laminated body top, which is the top of the convex shape. Thus, when the laminated body bend surface is overlapped on the shaping die bend surface, portions closer to both the side ends of the laminated body bend surface are pulled up to the shaping die edge side, and portions closer to the laminated body top are not pulled up to the shaping die edge side. Accordingly, excess of the fiber sheet occurring on the laminated body bend surface when the laminated body bend surface is overlapped on the shaping die bend surface can be cancelled by the displacement between the shaping die edge and the laminated body edge.

Further, the laminated body according to the third aspect of the present disclosure is such that, in the laminated body according to the first aspect, the shaping die reference surface and the laminated body reference surface are curved or bent in a concave shape relative to the predetermined direction, and in a state where the laminated body reference surface is overlapped on the shaping die reference surface, an amount of displacement of the laminated body edge from the shaping die edge increases as a position on the laminated body edge approaches a laminated body bottom (21c), which is a bottom of the concave shape, from an side end (21b).

According to the laminated body of the present aspect, the shaping die reference surface and the laminated body reference surface are curved or bent in a concave shape relative to the predetermined direction, and in a state where the laminated body reference surface is overlapped on the shaping die reference surface, the amount of displacement of the laminated body edge from the shaping die edge increases as a position on the laminated body edge approaches the laminated body bottom, which is the bottom of the concave shape, from the side end. Thus, when the laminated body bend surface is overlapped on the shaping die bend surface, portions closer to the laminated body bottom of the laminated body bend surface are pulled up to the shaping die edge side, and portions closer to both the side ends are not pulled up to the shaping die edge side.

Accordingly, insufficiency of the fiber sheet occurring on the laminated body bend surface when the laminated body bend surface is overlapped on the shaping die bend surface can be compensated by the displacement between the shaping die edge and the laminated body edge.

Further, the laminated body according to the fourth aspect of the present disclosure is such that, in the laminated body according to the second aspect, a distance between the shaping die edge and the laminated body edge at a position x along the shaping die edge is k × z(x), where z(x) is a distance from the shaping die edge at a shaping die top, which is a top of the convex shape of the shaping die, to the shaping die edge at a position x when viewed from the predetermined direction, and k is a predetermined constant of proportionality.

According to the laminated body of the present aspect, the distance between the shaping die edge and the laminated body edge at the position x is defined as k × z(x), and it is thus possible to set the distance between the shaping die edge and the laminated body edge based on the distance z(x).

Further, the laminated body according to the fifth aspect of the present disclosure is such that, in the laminated body according to the third aspect, a distance between the shaping die edge and the laminated body edge at a position x along the shaping die edge is k × z(x), where z(x) is a distance from the shaping die edge corresponding to a position of the side end to the shaping die edge at a position x when viewed from the predetermined direction, and k is a predetermined constant of proportionality.

Claim 1:
A forming method of overlapping and forming a laminated body (<NUM>) made of a plurality of laminated fiber sheets on a shaping die (<NUM>),
wherein the shaping die (<NUM>) has a shaping die reference surface (<NUM>) curved or bent relative to a predetermined direction and a shaping die bend surface (<NUM>) intersecting the shaping die reference surface (<NUM>) along the predetermined direction,
wherein the laminated body (<NUM>) has a laminated body reference surface (<NUM>) curved or bent relative to the predetermined direction and a laminated body bend surface (<NUM>) intersecting the laminated body reference surface (<NUM>) along the predetermined direction, and
wherein an angle at a concave side between the laminated body reference surface (<NUM>) and the laminated body bend surface (<NUM>) is larger than an angle at a concave side between the shaping die reference surface (<NUM>) and the shaping die bend surface (<NUM>),
the forming method comprising:
overlapping the laminated body reference surface (<NUM>) on the shaping die reference surface (<NUM>); and
bending the laminated body bend surface (<NUM>) toward the shaping die bend surface (<NUM>),
wherein when a ridge where the shaping die reference surface (<NUM>) and the shaping die bend surface (<NUM>) intersect with each other is defined as a shaping die edge (<NUM>) and when a ridge where the laminated body reference surface (<NUM>) and the laminated body bend surface (<NUM>) intersect with each other is defined as a laminated body edge (<NUM>), the laminated body edge (<NUM>) is displaced from the shaping die edge (<NUM>) on the shaping die reference surface (<NUM>), after the step of overlapping the laminated body reference surface (<NUM>) on the shaping die reference surface (<NUM>) and before the step of bending the laminated body bend surface (<NUM>) toward the shaping die bend surface (<NUM>), and
wherein a bending line, which is formed on the laminated body (<NUM>) after bending the laminated body bend surface (<NUM>) toward the shaping die bend surface (<NUM>), is along the shaping die edge (<NUM>).