Patent Description:
In the related art, a fiber-reinforced composite such as a fiber-reinforced plastic in which a resin is reinforced with a fiber base material such as a glass fiber or a carbon fiber is known (for example, refer to <CIT>). <CIT> discloses a forming method for the fiber-reinforced composite to which vacuum assisted resin transfer molding (VaRTM) for infiltrating the resin into the fiber base material by using a differential pressure between a vacuum pressure and an atmospheric pressure is applied. PTL <NUM> discloses the followings. A core is installed in a hollow part when a composite having a hollow structure is formed, and the core is pulled out from the hollow part after the composite is formed.

<CIT> discloses a hollow structure of fiber-reinforced resin and a method of manufacturing such hollow structure. An inner mould is positioned on a stand. Substrate comprising reinforcing fiber is arranged at the surface of the mould. Next, the top of the substrate is covered with a bag and the interior pressure of the bag is reduced to below atmosphere pressure. Then, synthetic resin is injected into the reinforcing fiber.

<CIT> describes a method for producing a composite fiber component and a device for carrying out such method. First, a filter panel comprising a porous material is provided. In subsequent steps, a resin soaked fiber material is arranged on the filter panel, the fiber material on the filter panel is covered, and a negative pressure is generated at a side of the filter panel that faces away from the filter material.

<CIT>, <CIT> and <CIT> describe a fiber-reinforced composite forming method and apparatus which represent the closest prior art.

According to the forming method disclosed in <CIT>, a cylindrical or rod-shaped rigid reinforcing jig is inserted into the core to maintain a shape holding function of the core. However, when the core is installed in the hollow part of the composite, it is necessary to carry out work for inserting the reinforcing jig into the core.

In addition, when the core is pulled out after the composite is formed, it is necessary to carry out work for pulling out the reinforcing jig from the core, and thereafter, bending a portion thinner than other parts of the core. In this way, according to the forming method disclosed in <CIT>, it is necessary to provide the reinforcing jig, and it is necessary to carry out complicated work such as the work for inserting the reinforcing jig, the work for pulling out the reinforcing jig, and the work for bending the core.

The present disclosure is made in view of the above-described circumstances, and an object of the present disclosure is to provide a fiber-reinforced composite forming method and fiber-reinforced composite forming apparatus which can form a fiber-reinforced composite including a hollow part without requiring complicated work.

This object is solved by a fiber-reinforced composite forming method with the features of claim <NUM> and a fiber-reinforced composite forming apparatus with the features of claim <NUM>. Preferred embodiments follow from the other claims. According to an aspect of the present disclosure, there is provided a fiber-reinforced composite forming method including an alignment step of aligning a fiber base material in which a core part including an elastic long foam and a cover member for sealing the foam is accommodated in a hollow part, in a forming die, a sealing step of sealing the fiber base material in the forming die to form a sealed space, an injection step of suctioning air in the sealed space formed by the sealing step, reducing a pressure of the sealed space, and injecting a thermosetting resin material into the fiber base material sealed in the sealed space, a curing step of heating and curing the thermosetting resin material injected into the fiber base material by the injection step, a detachment step of detaching a fiber-reinforced composite including the thermosetting resin material cured by the curing step and the fiber base material, from the forming die, and a removal step of reducing a pressure of an internal space sealed by the cover member so that the foam contracts, and removing the core part accommodated in the hollow part of the fiber-reinforced composite.

According to another aspect of the present disclosure, there is provided a fiber-reinforced composite forming apparatus including a core part including an elastic long foam and a cover member for sealing the foam, a forming die in which a fiber base material accommodating the core part in a hollow part is aligned, a sealing member that seals the fiber base material in the forming die to form a sealed space, a suction part that suctions air in the sealed space to reduce a pressure of the sealed space, a resin injection part that injects a thermosetting resin material into the fiber base material sealed in the sealed space whose pressure is reduced by the suction part, and a heating part that heats and cures the thermosetting resin material injected into the fiber base material by the resin injection part in the sealed space whose pressure is reduced by the suction part. The core part includes a connection member that connects an internal space sealed by the cover member to a pressure-reducing source.

According to the present disclosure, it is possible to provide the fiber-reinforced composite forming method and the fiber-reinforced composite forming apparatus which can form the fiber-reinforced composite including the hollow part without requiring complicated work.

Hereinafter, a forming apparatus (fiber-reinforced composite forming apparatus) <NUM> according to a first embodiment of the present disclosure and a fiber-reinforced composite forming method for using the forming apparatus will be described with reference to the drawings. <FIG> is a cross-sectional view illustrating the forming apparatus <NUM> according to the first embodiment of the present disclosure. <FIG> is a sectional view taken along line A-A of the forming apparatus <NUM> illustrated in <FIG>. <FIG> is a view illustrating an example of a composite <NUM> manufactured by the forming apparatus <NUM> illustrated in <FIG>.

The forming apparatus <NUM> of the present embodiment is the following apparatus. A bagging film <NUM> is used for an upper die. Fiber base materials FB1 and FB2 to be aligned in a forming die <NUM> serving as a lower die are sealed in a sealed space CS, and a pressure of the sealed space CS is reduced. In this manner, the forming apparatus <NUM> performs infusion molding for curing a thermosetting resin material RM by filling the sealed space CS with the thermosetting resin material RM.

As an example, the forming apparatus <NUM> of the present embodiment forms a composite (fiber-reinforced composite) <NUM> illustrated in <FIG>. The composite <NUM> illustrated in <FIG> is a stringer used as a reinforcing material for reinforcing a fuselage and a main wing structure of aircraft. The composite <NUM> is a member having a long shape extending along a longitudinal direction LD and having a protruding central part in a width direction WD. The width direction WD is a direction orthogonal to the longitudinal direction LD on a surface on which the composite <NUM> is installed.

As illustrated in <FIG>, the composite <NUM> includes a flat part <NUM> having a width W1 along the width direction WD and formed in a flat shape, and a protruding part <NUM> connected to the flat part <NUM> and protruding upward in the central part in the width direction WD. The flat part <NUM> and the protruding part <NUM> are integrally formed by using the thermosetting resin material RM. The flat part <NUM> is obtained by infiltrating the thermosetting resin material RM into the fiber base material FB1 illustrated in <FIG> and <FIG>. The protruding part <NUM> is obtained by infiltrating the thermosetting resin material RM into the fiber base material FB2 illustrated in <FIG> and <FIG>.

For example, a fiber base material FB1 and a fiber base material FB2 are members in which sheets formed of a reinforcing fiber material such as a carbon fiber and a glass fiber are laminated over a plurality of layers. For example, the thermosetting resin material RM is an epoxy resin, unsaturated polyester, vinyl ester, phenol, cyanate ester or polyimide.

The composite <NUM> illustrated in <FIG> includes a hollow part HP defined by the flat part <NUM> and the protruding part <NUM> and extending along the longitudinal direction LD. The forming apparatus <NUM> of the present embodiment uses a core part <NUM> serving as a core inserted into the hollow part HP to constantly form the composite <NUM> having the hollow part HP. The composite <NUM> is formed in a state where the core part <NUM> is inserted into the hollow part HP. In this manner, a shape of the hollow part HP can be maintained to have a constant shape when the composite <NUM> is formed.

As illustrated in <FIG> and <FIG>, the forming apparatus <NUM> of the present embodiment includes the core part <NUM>, a forming die <NUM>, a bagging film (sealing member) <NUM>, a suction line (suction part) <NUM>, a resin injection line (resin injection part) <NUM>, a communication line <NUM>, a heating part <NUM>, a pressure plate <NUM>, a resin diffusion medium <NUM>, and a suction medium <NUM>.

The core part <NUM> includes a foam <NUM>, a cover member <NUM>, and a connection member <NUM>. The foam <NUM> is a member formed in a long shape in which a length in the longitudinal direction LD is longer than a length in the width direction WD. The foam <NUM> is formed of an elastic material having elasticity (for example, silicone rubber). For example, it is desirable that the elastic material for forming the foam <NUM> is an open cell material illustrated in <FIG> and <FIG>. The open cell material has internally formed bubbles communicating with each other, and has a function of contracting when air inside the foam flows outward.

Since the foam <NUM> is formed of the elastic material having an open cell, elasticity of the core part <NUM> can be improved. In addition, the elastic material is formed of a highly heat-resistant material such as silicone rubber. In this manner, sufficient heat resistance is provided by the heating part <NUM>, and the core part <NUM> can be provided with strength for holding the shape of the hollow part HP.

The cover member <NUM> is a film-shaped or sheet-shaped member that forms an internal space IS in which the foam <NUM> is sealed. It is preferable to use an elastic material to follow contraction and expansion of the foam. In addition, it is preferable that the cover member <NUM> has heat resistance to withstand heat curing of a thermosetting resin, and for example, a material thereof includes fluorocarbon rubber or the like. In addition, since the cover member <NUM> comes into contact with the thermosetting resin material RM infiltrating into the fiber base materials FB1 and FB2, it is necessary to provide a surface of the cover member <NUM> with a mold release capability. Therefore, it is necessary to perform mold release treatment on the surface of the cover member or to wrap a mold release film.

The connection member <NUM> is a member that connects the internal space IS sealed by the cover member <NUM> to a pressure-reducing source <NUM> such as a vacuum pump via the communication line <NUM>. Since the communication line <NUM> is connected to the connection member <NUM>, the air existing in the internal space IS can be discharged from the internal space IS, and the pressure of the internal space IS can be reduced to a pressure lower than an atmospheric pressure.

In the forming die <NUM>, the fiber base material FB1 and the fiber base material FB2 in which the core part <NUM> is accommodated in the hollow part HP are aligned, and the die forms the fiber base material FB1 and the fiber base material FB2 into a desired shape. The forming die <NUM> illustrated in <FIG> and <FIG> is a female die including a flat surface <NUM> having the fiber base material FB1 aligned thereon and extending along the width direction WD, and a recessed place <NUM> having the fiber base material FB2 aligned thereon and having a shape recessed downward from the flat surface <NUM>.

The bagging film <NUM> is a member that forms the sealed space CS by sealing the fiber base materials FB1 and FB2 in the forming die <NUM>. For example, the bagging film <NUM> is formed of a resin material containing nylon as a main component. The bagging film <NUM> is joined to the flat surface <NUM> of the forming die <NUM> by the sealant tape ST to cover an entire periphery of the recessed place <NUM> of the forming die <NUM>.

The suction line <NUM> is a tube body in which one end is connected to a suction source <NUM> such as a vacuum pump and the other end is connected to the sealed space CS. Since the suction source <NUM> and the sealed space CS are connected to each other, the suction line <NUM> can discharge the air existing in the sealed space CS from the sealed space CS, and can reduce the pressure of the sealed space CS to a pressure lower than the atmospheric pressure.

The resin injection line <NUM> is a tube body that injects the thermosetting resin material RM into the fiber base materials FB1 and FB2 sealed in the sealed space CS whose pressure is reduced by the suction line <NUM>. One end of the resin injection line <NUM> is connected to a supply source <NUM> for supplying the thermosetting resin material RM, and the other end is connected to the sealed space CS. Since the supply source <NUM> and the sealed space CS are connected to each other, the resin injection line <NUM> can supply the thermosetting resin material RM from the supply source <NUM> to the sealed space CS whose pressure is reduced by the suction line <NUM>.

The communication line <NUM> is a tube body in which one end is connected to the pressure-reducing source <NUM> and the other end is connected to the connection member <NUM> of the core part <NUM>. The communication line <NUM> can reduce the pressure of the internal space IS of the core part <NUM> by connecting the pressure-reducing source <NUM> and the connection member <NUM> to each other. The communication line <NUM> is used so that the internal space IS is maintained at the atmospheric pressure when the thermosetting resin material RM is heated by the heating part <NUM>.

The heating part <NUM> is a heat source that heats and cures the thermosetting resin material RM injected into the fiber base materials FB1 and FB2 by the resin injection line <NUM> in the sealed space CS whose pressure is reduced by the suction line <NUM>. As illustrated in <FIG> and <FIG>, the heating part <NUM> is aligned above the bagging film <NUM>. The heating part <NUM> may be aligned not only above the bagging film <NUM> but also below the forming die <NUM> or inside the forming die <NUM>. In addition, the heating part <NUM> may be aligned only below the forming die <NUM> or only inside the forming die <NUM>, and may perform heating by using a method for blowing hot air into a space, such as an oven.

The pressure plate <NUM> is a plate-like component aligned above the fiber base material FB1 aligned in the forming die <NUM>, and is formed of a metallic material, for example. The pressure plate <NUM> uses its own weight to apply a pressure to the fiber base material FB1. In this manner, the pressure plate <NUM> can smooth the surface of the flat part <NUM> of the composite <NUM> obtained by infiltrating the thermosetting resin material RM into the fiber base material FB1.

The resin diffusion medium <NUM> is a sheet-shaped medium for supplying the thermosetting resin material RM supplied from the resin injection line <NUM> to the sealed space CS while diffusing the thermosetting resin material RM to the entire fiber base material FB1. For example, the resin diffusion medium <NUM> has a net-shaped internal structure, and has a structure through the inside of which the thermosetting resin material RM can pass. Therefore, the thermosetting resin material RM supplied to the sealed space CS whose pressure is reduced by the suction line <NUM> passes through the inside of the resin diffusion medium <NUM>, and is diffused to the entire surface of the fiber base material FB1, and infiltrates into the fiber base material FB1.

The suction medium <NUM> is a sheet-shaped medium for guiding the surplus thermosetting resin material RM passing through the fiber base material FB1 and the fiber base material FB2 to the suction line <NUM> while diffusing the surplus thermosetting resin material RM. For example, the suction medium <NUM> has a net-shaped internal structure, and has a structure through the inside of which the thermosetting resin material RM can pass. Therefore, the surplus thermosetting resin material RM passing through the fiber base material FB1 and the fiber base material FB2 is guided to the suction medium <NUM> from the surface of the fiber base material FB2, passes through the inside of the suction medium <NUM>, and is guided to the suction line <NUM>.

Next, a composite forming method according to the present embodiment will be described with reference to the drawings. <FIG> is a flowchart illustrating the composite forming method according to the present embodiment. <FIG> is a cross-sectional view illustrating the forming apparatus <NUM> before the fiber base materials FB1 and FB2 are aligned in the forming die <NUM>.

In Step S101 (alignment step), the fiber base material FB1 and the fiber base material FB2 in which the core part <NUM> is accommodated in the hollow part HP are aligned in the recessed place <NUM> of the forming die <NUM>. Specifically, the suction medium <NUM> is aligned in the recessed place <NUM> of the forming die <NUM>, the fiber base material FB2 is aligned on the suction medium <NUM>, and the core part <NUM> is aligned on the fiber base material FB2.

In addition, the fiber base material FB2 is aligned on the core part <NUM>, the resin diffusion medium <NUM> is aligned on the fiber base material FB2, and the pressure plate <NUM> is aligned on the resin diffusion medium <NUM>. When the alignment step in Step S101 is completed, the forming apparatus <NUM> is brought into a state illustrated in <FIG> is a cross-sectional view illustrating the forming apparatus <NUM> after the fiber base materials FB1 and FB2 are aligned in the forming die <NUM>.

In Step S102 (sealing step), the fiber base material FB1 and the fiber base material FB2 are sealed in the forming die <NUM> to form the sealed space CS. Specifically, the bagging film <NUM> is joined to the flat surface <NUM> of the forming die <NUM> by the sealant tape ST to cover an entire periphery of the recessed place <NUM> of the forming die <NUM>, thereby forming the sealed space CS. When the sealing step in Step S102 is completed, the forming apparatus <NUM> is brought into a state illustrated in <FIG>.

When the sealed space CS is formed in Step S102 (sealing step), the resin injection line <NUM> connected to the supply source <NUM> of the thermosetting resin material RM and the sealed space CS are brought into a state of communicating with each other. In addition, when the sealed space CS is formed, the suction line <NUM> connected to the suction source <NUM> and the sealed space CS are brought into a state of communicating with each other.

In Step S103 (injection step), the air in the sealed space CS formed by Step S102 (sealing step) is suctioned to reduce the pressure of the sealed space CS, and the thermosetting resin material RM is injected into the fiber base materials FB1 and FB2 sealed in the sealed space CS. Specifically, the suction source <NUM> is operated, the air existing in the sealed space CS is discharged from the sealed space CS via the suction line <NUM>, and the pressure of the sealed space CS is reduced to a vacuum state where the pressure is lower than the atmospheric pressure or a pressure close to the vacuum state.

Thereafter, the supply source <NUM> is brought into a state where the thermosetting resin material RM can be supplied to the resin injection line <NUM>, and the thermosetting resin material RM is supplied to the sealed space CS by using a pressure difference between the resin injection line <NUM> and the sealed space CS whose pressure is reduced. The thermosetting resin material RM supplied to the sealed space CS passes through the inside of the resin diffusion medium <NUM>, is diffused to the entire surface of the fiber base material FB1, and is injected into the fiber base material FB1. In this manner, the thermosetting resin material RM is brought into a state of infiltrating into the fiber base materials FB1 and FB2.

A portion of the thermosetting resin material RM infiltrating into the fiber base material FB1 further infiltrates into the fiber base material FB2. A portion of the thermosetting resin material RM infiltrating into the fiber base material FB2 passes through the inside of the suction medium <NUM>, is guided to the suction line <NUM>, and is discharged to the suction line <NUM> as the surplus thermosetting resin material RM.

In Step S103 (injection step), the pressure of the sealed space CS is reduced to the vacuum state or the pressure close to the vacuum state. Accordingly, the fiber base materials FB1 and FB2 and the thermosetting resin material RM infiltrating into the fiber base materials FB1 and FB2 are pressurized by the atmospheric pressure. In this case, in order to hold the shape of the hollow part HP of the fiber base materials FB1 and FB2, it is necessary to hold the shape of the core part <NUM> accommodated in the hollow part HP.

Therefore, in Step S103 (injection step), the pressure-reducing source <NUM> communicating with the internal space IS of the core part <NUM> via the communication line <NUM> is adjusted so that the pressure of the internal space IS maintains an atmospheric pressure state or the pressure close to the atmospheric pressure. In this manner, the shape of the core part <NUM> accommodated in the hollow part HP is held.

In Step S104 (curing step), the thermosetting resin material RM injected into the fiber base material FB1 and the fiber base material FB2 in Step S103 (injection step) is heated to a temperature the same as or higher than a thermosetting temperature by the heating part <NUM>, and the thermosetting resin material RM is cured.

In Step S104 (curing step), the internal space IS of the core part <NUM> is heated by the heating part <NUM>. Therefore, when the internal space IS remains in a sealed state, the air in the internal space IS expands, thereby causing a possibility that the shape of the hollow part HP may be deformed.

Therefore, in Step S104 (curing step), the pressure-reducing source <NUM> communicating with the internal space IS of the core part <NUM> via the communication line <NUM> is adjusted. Alternatively, the communication line <NUM> is caused to communicate with an external space maintained to have the atmospheric pressure, and the pressure of the internal space IS maintains the atmospheric pressure state or the pressure close to the atmospheric pressure. In this manner, the shape of the core part <NUM> accommodated in the hollow part HP is held.

In addition, the forming apparatus <NUM> of the present embodiment may be accommodated in a sealed container (not illustrated). In Step S104 (curing step), an internal pressure of the sealed container may be adjusted so that the pressure of the internal space IS and the internal pressure of the sealed container maintain a predetermined pressure difference.

In addition, as the pressure plate <NUM>, a pressure plate having a sufficient weight to such an extent that the pressure plate does not move with respect to the pressure generated by expansion of the air in the internal space IS may be adopted. In this case, even when a force of expanding the hollow part HP acts due to the expansion of the air in the internal space IS, the pressure plate <NUM> does not move due to the force. Accordingly, it is possible to prevent the shape of the hollow part HP from being deformed.

In addition, in <FIG> and <FIG>, in a state before heating starts to be performed by the heating part <NUM>, the cover member <NUM> of the core part <NUM> is aligned in a state of being in contact with the fiber base material FB1. However, other aspects may be adopted. For example, in the state before heating starts to be performed by the heating part <NUM>, a slight clearance may be formed between the core part <NUM> and the fiber base material FB1.

That is, in the alignment step, in a state where a portion of the core part <NUM> is not in contact with the fiber base material FB1, the fiber base material FB1 and the fiber base material FB2 are aligned in the forming die <NUM>. Since the core part <NUM> thermally expands due to the heating, the clearance is formed. In this manner, it is possible to prevent the fiber base material FB1 and the fiber base material FB2 from being excessively pushed due to filling of the clearance between the cover member <NUM> and the fiber base material FB1 when the heating is performed in the curing step.

In Step S105 (detachment step), the composite <NUM> including the thermosetting resin material RM cured in Step S104 (curing step), the fiber base material FB1, and the fiber base material FB2 is detached from the forming die <NUM>. Specifically, the sealant tape ST that joins the bagging film <NUM> and the flat part <NUM> of the forming die <NUM> is removed, and the bagging film <NUM> is detached from the forming die <NUM>.

The pressure plate <NUM> and the resin diffusion medium <NUM> are detached from the forming die <NUM> from which the bagging film <NUM> is detached. Thereafter, the composite <NUM> in a state where the core part <NUM> is inserted into the hollow part HP is detached from the recessed place <NUM> of the forming die <NUM>. <FIG> is a longitudinal sectional view illustrating the composite <NUM> and the core part <NUM> which are detached from the forming die <NUM>.

In Step S106 (removal step), the pressure of the internal space IS sealed by the cover member <NUM> is reduced so that the foam <NUM> contracts, and the core part <NUM> accommodated in the hollow part HP of the composite <NUM> is removed. Specifically, the pressure-reducing source <NUM> is operated to discharge the air existing in the internal space IS from the internal space IS, and the pressure in the internal space IS is reduced to the pressure lower than the atmospheric pressure.

<FIG> is a longitudinal sectional view illustrating the core part <NUM> and the composite <NUM> in which the pressure of the internal space IS is reduced. As illustrated in <FIG>, when the pressure in the internal space IS is reduced to the pressure lower than the atmospheric pressure, the foam <NUM> of the core part <NUM> contracts due to an action of the atmospheric pressure. In this manner, a clearance CL1 is formed between the core part <NUM> and the flat part <NUM> of the composite <NUM>, and a clearance CL2 is formed between the core part <NUM> and the protruding part <NUM> of the composite <NUM>.

The core part <NUM> is moved in a direction away from the composite <NUM> along the longitudinal direction LD in a state where the foam <NUM> of the core part <NUM> contracts. In this manner, the core part <NUM> accommodated in the hollow part HP of the composite <NUM> is pulled out, and is removed from the composite <NUM>. <FIG> is a longitudinal sectional view illustrating the composite <NUM> and the core part <NUM> partially pulled out from the hollow part HP of the composite <NUM>.

In the present embodiment described above, the core part <NUM> inserted into the hollow part HP of the composite <NUM> includes the cover member <NUM> and the foam <NUM> aligned in the internal space IS of the cover member <NUM>. However, other aspects may be adopted. For example, as illustrated in a modification example in <FIG>, the core part 10A inserted into the hollow part HP of the composite <NUM> may include a cover member 12A including an inner cover 12Aa and an outer cover 12Ab, and the foam <NUM>.

<FIG> is a cross-sectional view illustrating the forming apparatus <NUM> according to a modification example of the embodiment. In the core part 10A of the forming apparatus <NUM> according to the modification example, the inner cover (inner cover) 12Aa is a film-shaped or sheet-shaped member that forms a first internal space IS1 in which the foam <NUM> is sealed. The first internal space IS1 sealed by the inner cover 12Aa is connected to the pressure-reducing source <NUM> illustrated in <FIG>.

In the core part 10A of the forming apparatus <NUM> according to the modification example, the outer cover (outer cover) 12Ab is a film-shaped or sheet-shaped member that accommodates the inner cover 12Aa and forms a second internal space IS2 with the inner cover 12Aa. The second internal space IS2 is connected to another pressure-reducing source (not illustrated) different from the pressure-reducing source <NUM>.

In the modification example, when Step S103 (injection step) and Step S104 (curing step) are performed, the pressure-reducing source <NUM> connected to the first internal space IS1 reduces the pressure of the first internal space IS1 sealed by the inner cover 12Aa to the pressure lower than the atmospheric pressure, and adjusts the foam <NUM> not to expand after being heated by the heating part <NUM>.

On the other hand, a pressure-reducing source (not illustrated) connected to the second internal space IS2 is adjusted so that the second internal space IS2 sealed by the outer cover 12Ab is maintained at the atmospheric pressure. The pressure of the sealed space CS is reduced by the suction source <NUM>. However, the second internal space IS2 aligned inside the sealed space CS maintains the atmospheric pressure. Therefore, it is possible to prevent the outer cover 12Ab from being deformed so that the hollow part HP contracts after coming into contact with the fiber base materials FB1 and FB2.

In the modification example, the pressure of the first internal space IS1 is reduced to the pressure lower than the atmospheric pressure, and the second internal space IS2 is adjusted to be maintained at the atmospheric pressure. Therefore, in Step S103 (injection step) and Step S104 (curing step), it is possible to suppress a possibility that a force of expanding the hollow part HP may act due to the expansion of the air in the first internal space IS1 and the second internal space IS2. Therefore, the pressure plate <NUM> illustrated in <FIG> may not be provided.

An operation and an advantageous effect of the forming method of the composite <NUM> of the present embodiment described above will be described.

According to the fiber-reinforced composite forming method of the present embodiment, the fiber base materials FB1 and FB2 in which the core part <NUM> is accommodated in the hollow part HP are aligned in the forming die <NUM>. The fiber base materials FB1 and FB2 are sealed in the forming die <NUM> to form the sealed space CS. The pressure of the sealed space CS is reduced, the thermosetting resin material RM is injected into the fiber base materials FB1 and FB2, and the thermosetting resin material RM is heated and cured. In this manner, the composite <NUM> including the cured thermosetting resin material RM and fiber base materials FB1 and FB2 is formed. When the thermosetting resin material RM is cured after being injected into the fiber base materials FB1 and FB2, the core part <NUM> is accommodated in the hollow part HP of the fiber base materials FB1 and FB2. Therefore, the shape of the hollow part HP of the fiber base materials FB1 and FB2 can be maintained.

In addition, according to the fiber-reinforced composite forming method of the present embodiment, after the composite <NUM> is detached from the forming die <NUM>, the pressure of the internal space IS of the core part <NUM> sealed by the cover member <NUM> is reduced so that the foam <NUM> contracts. In this manner, the clearances CL1 and CL2 are formed between the core part <NUM> and the hollow part HP of the composite <NUM>. Therefore, the core part <NUM> accommodated in the hollow part HP can be easily removed. In this way, according to the fiber-reinforced composite forming method of the present embodiment, the composite <NUM> including the hollow part HP can be formed without requiring complicated work.

In addition, according to the fiber-reinforced composite forming method of the present embodiment, the thermosetting resin material RM can be injected into the fiber base materials FB1 and FB2 via the resin injection line <NUM> by reducing the pressure of the sealed space CS via the suction line <NUM>. The thermosetting resin material RM can infiltrate into the fiber base materials FB1 and FB2 by utilizing a differential pressure between the pressure of the sealed space CS and the atmospheric pressure.

In addition, according to the fiber-reinforced composite forming method of the present embodiment, the internal space IS maintains the atmospheric pressure when the thermosetting resin material RM is heated. Therefore, it is possible to suppress a disadvantage that the hollow part HP of the fiber base materials FB1 and FB2 may be deformed when the air existing in the internal space IS is pressurized to the atmospheric pressure or higher.

In addition, according to the fiber-reinforced composite forming method of the present embodiment, the foam <NUM> is formed of the elastic material having the open cell. Therefore, the foam can sufficiently contract by reducing the pressure of the internal space IS sealed by the cover member <NUM>. <NUM>, and the core part <NUM> can be easily removed from the hollow part HP of the fiber-reinforced composite.

Next, a forming apparatus 100A according to a second embodiment of the present disclosure will be described with reference to the drawings. <FIG> is a longitudinal sectional view illustrating the forming apparatus 100A according to the second embodiment of the present disclosure. The present embodiment is a modification example of the first embodiment, and is the same as the first embodiment except for a case described below. Thus, description thereof will be omitted below.

The core part <NUM> of the forming apparatus <NUM> of the first embodiment connects the connection member <NUM> and the pressure-reducing source <NUM> to each other via the communication line <NUM>. In contrast, the forming apparatus 100A of the present embodiment connects the connection member <NUM> and the sealed space CS to each other via a communication part <NUM>.

As illustrated in <FIG>, the core part <NUM> of the forming apparatus 100A of the present embodiment includes the communication part <NUM> and a membrane <NUM>. The communication part <NUM> is a tube body in which one end is connected to the connection member <NUM> and the other end is open to the sealed space CS. The membrane <NUM> is attached to an end portion where the communication part <NUM> is open to the sealed space CS.

The membrane <NUM> is a separation membrane that does not allow permeation of the thermosetting resin material RM while allowing the air to permeate between the internal space IS and the sealed space CS. The membrane <NUM> is provided to prevent the thermosetting resin material RM injected into the sealed space CS from entering the internal space IS of the core part <NUM>.

The forming method for using the forming apparatus 100A of the present embodiment is different from the forming method for using the forming apparatus <NUM> of the first embodiment in the following points.

A first different point is that an operation in Step S103 (injection step) in <FIG> according to the first embodiment is different. In the first embodiment, the shape of the core part <NUM> accommodated in the hollow part HP is held by causing the pressure of the internal space IS to maintain the atmospheric pressure state or the pressure close to the atmospheric pressure.

In contrast, in the present embodiment, the internal space IS and the sealed space CS communicate with each other via the communication part <NUM>. Therefore, in the injection step of the present embodiment, the air in the internal space IS is guided to the suction line <NUM> via the internal space IS by reducing the pressure of the sealed space CS via the suction line <NUM>.

Since the internal space IS and the sealed space CS communicate with each other, as in the sealed space CS, the pressure of the internal space IS is reduced to the vacuum state or the pressure close to the vacuum state. When the sealed space CS is reduced to the vacuum state or the pressure close to the vacuum state, the bagging film <NUM> and the pressure plate 80A are pressed toward the forming die <NUM> by the action of the atmospheric pressure.

On the other hand, the pressure plate 80A of the present embodiment has a shape that comes into contact with the flat surface <NUM> of the forming die <NUM> to surround the recessed place <NUM>. Therefore, even when the pressure plate 80A is pressed toward the forming die <NUM>, the pressure plate 80A comes into contact with the forming die <NUM> so that a position of the pressure plate 80A is maintained. Therefore, the shapes of the fiber base materials FB1 and FB2 aligned below the pressure plate 80A are maintained.

In addition, since the pressure in the internal space IS is the same as the pressure of the sealed space CS, the shape of the core part <NUM> is maintained. In this manner, the shapes of the fiber base materials FB1 and FB2 are maintained in the injection step.

A second different point is that an operation in Step S104 (curing step) in <FIG> according to the first embodiment is different. In the first embodiment, the pressure of the internal space IS of the core part <NUM> maintains the atmospheric pressure state or the pressure close to the atmospheric pressure so that the shape of the core part <NUM> accommodated in the hollow part HP is held.

In contrast, in the present embodiment, the pressure of the internal space IS of the core part <NUM> maintains the same pressure as the pressure of the sealed space CS. That is, the internal space IS and the sealed space CS communicate with each other by the communication part <NUM>. Therefore, the pressure of the internal space IS of the core part <NUM> and the pressure of the sealed space CS are maintained to be the same as each other.

In the curing step, the air in the internal space IS expands by the heating part <NUM>. However, when the pressure of the internal space IS is reduced to the vacuum state or a state close to the vacuum state where the pressure of the internal space IS is the same as the pressure of the sealed space CS, all or most of the air in the internal space IS are discharged outward. Therefore, even when the air in the internal space IS expands by the heating part <NUM>, the shape of the core part <NUM> is hardly changed. Therefore, the shape of the core part <NUM> accommodated in the hollow part HP can be held.

According to the forming method for using the forming apparatus 100A of the present embodiment described above, the core part <NUM> includes the communication part <NUM>. Therefore, the pressure of the sealed space CS is reduced via the suction line <NUM> in the injection step. In this manner, the air in the internal space IS is guided to the suction line <NUM> via the sealed space CS. In the curing step, the internal space IS is heated in a state where the air is reduced. Therefore, even when the internal space expands due to the heating, there is no possibility that the core part may be excessively deformed to deform the hollow part of the fiber base material.

In the above description, the resin injection line <NUM> is provided above the forming die <NUM>, and the suction line <NUM> is provided in the recessed place <NUM> of the forming die <NUM>. However, other aspects may be adopted. For example, the resin injection line <NUM> may be provided in the recessed place <NUM> of the forming die <NUM>, and the suction line <NUM> may be provided above the forming die <NUM>.

In addition, in the above description, the forming die <NUM> is the female die having the flat surface <NUM> and the recessed place <NUM> having a shape recessed downward from the flat surface <NUM>. However, other aspects may be adopted. For example, the forming die <NUM> may be a male die having a flat surface and a protruding part protruding upward from the flat surface.

The fiber-reinforced composite forming method in the above-described embodiment can be understood as follows, for example.

According to the present disclosure, there is provided the fiber-reinforced composite forming method including the alignment step (S101) of aligning the fiber base material (FB1, FB2) in which the core part (<NUM>) including the elastic long foam (<NUM>) and the cover member (<NUM>) for sealing the foam is accommodated in the hollow part (HP), in the forming die (<NUM>), the sealing step (S102) of sealing the fiber base material in the forming die to form the sealed space (CS), the injection step (S103) of suctioning the air in the sealed space formed by the sealing step, reducing the pressure in the sealed space, and injecting the thermosetting resin material into the fiber base material sealed in the sealed space, the curing step (S104) of heating and curing the thermosetting resin material injected into the fiber base material by the injection step, the detachment step (S105) of detaching the fiber-reinforced composite (<NUM>) including the thermosetting resin material cured by the curing step and the fiber base material, from the forming die, and the removal step (S106) of reducing the pressure of the internal space (IS) sealed by the cover member so that the foam contracts, and removing the core part accommodated in the hollow part of the fiber-reinforced composite.

According to the fiber-reinforced composite forming method in the present disclosure, the fiber base material in which the core part is accommodated in the hollow part is aligned in the forming die. The fiber base material is sealed in the forming die to form the sealed space. The pressure of the sealed space is reduced, the thermosetting resin material is injected into the fiber base material, and the thermosetting resin material RM is heated and cured. In this manner, the fiber-reinforced composite including the cured thermosetting resin material and the fiber base material is formed. When the thermosetting resin is cured after being injected into the fiber base material, the core part is accommodated in the hollow part of the fiber base material. Therefore, the shape of the hollow part of the fiber base material can be maintained.

In addition, according to the fiber-reinforced composite forming method in the present disclosure, after the fiber-reinforced composite is detached from the forming die, the pressure of the internal space of the core part sealed by the cover member is reduced so that the foam contracts. In this manner, the clearance is formed between the core part and the hollow part of the fiber-reinforced composite. Therefore, the core part accommodated in the hollow part can be easily removed. In this way, according to the fiber-reinforced composite forming method in the present disclosure, the fiber-reinforced composite including the hollow part can be formed without requiring complicated work.

In the fiber-reinforced composite forming method according to the present disclosure, it is preferable to adopt the following configuration. In the sealing step, the resin injection line (<NUM>) connected to the supply source (<NUM>) of the thermosetting resin material and the sealed space are caused to communicate with each other, and the suction line (<NUM>) connected to the suction source (<NUM>) and the sealed space are caused to communicate with each other. In the injection step, the thermosetting resin material is injected into the fiber base material via the resin injection line by reducing the pressure of the sealed space via the suction line.

According to the fiber-reinforced composite forming method having this configuration, the thermosetting resin material can be injected into the fiber base material via the resin injection line by reducing the pressure of the sealed space via the suction line. The thermosetting resin material can infiltrate into the fiber base material by utilizing the differential pressure between the pressure of the sealed space and the atmospheric pressure.

In the fiber-reinforced composite forming method having the above-described configuration, it is preferable to adopt the following configuration. In the curing step, the internal space is maintained at the atmospheric pressure when the thermosetting resin material is heated.

According to the fiber-reinforced composite forming method having this configuration, the internal space maintains the atmospheric pressure when the thermosetting resin material is heated. Therefore, it is possible to suppress a disadvantage that the hollow part of the fiber base material may be deformed when the air existing in the internal space is pressurized to the atmospheric pressure or higher.

In the fiber-reinforced composite forming method having the above-described configuration, it is preferable to adopt the following configuration. The core part includes the communication part (<NUM>) through which the internal space and the sealed space communicate with each other. In the curing step, the air in the internal space is guided to the suction line via the sealed space by reducing the pressure of the sealed space via the suction line.

According to the fiber-reinforced composite forming method having this configuration, the core part includes the communication part. Therefore, in the injection step, the air in the internal space is guided to the suction line via the sealed space by reducing the pressure of the sealed space via the suction line. In the curing step, the heating is performed in a state where the air in the internal space is reduced. Therefore, even when the internal space expands due to the heating, there is no possibility that the core part may be excessively deformed to deform the hollow part of the fiber base material.

In the fiber-reinforced composite forming method having the above-described configuration, it is preferable to adopt the following configuration. The cover member includes the inner cover for sealing the foam and the outer cover for accommodating the inner cover. In the curing step, the pressure of the first internal space sealed by the inner cover is reduced to the pressure lower than the atmospheric pressure, and the pressure of the second internal space between the inner cover and the outer cover is maintained at the atmospheric pressure.

According to the fiber-reinforced composite forming method having this configuration, the pressure of the first internal space sealed by the inner cover is reduced to the pressure lower than the atmospheric pressure. In this manner, the foam can be adjusted not to expand after being heated by the heating part. In addition, since the pressure of the second internal space between the outer cover and the inner cover is maintained at the atmospheric pressure, it is possible to prevent the hollow part of the core part from being deformed to contract.

In the fiber-reinforced composite forming method having the above-described configuration, it is preferable to adopt the following configuration. In the alignment step, the fiber base material is aligned in the forming die in a state where a portion of the core part is not in contact with the fiber base material.

According to the fiber-reinforced composite forming method having this configuration, a portion of the core part does not come into contact with the fiber base material in a state before the heating starts to be performed by the heating step. Therefore, when the heating starts to be performed by the heating step and the foam expands, it is possible to prevent the fiber base material from being excessively pushed due to filling of the clearance between the portion of the core part and the fiber base material.

In the fiber-reinforced composite forming method having the above-described configuration, the foam is formed of the elastic material having the open cell.

According to the fiber-reinforced composite forming method having this configuration, the foam is formed of the elastic material having the open cell. Therefore, the foam can sufficiently contract by reducing the pressure of the internal space sealed by the cover member, and the core part can be easily removed from the hollow part of the fiber-reinforced composite.

The fiber-reinforced composite forming apparatus in the above-described embodiment can be understood as follows, for example.

According to the present disclosure, there is provided the fiber-reinforced composite forming apparatus including the core part (<NUM>) including the elastic long foam (<NUM>) and the cover member (<NUM>) for sealing the foam, the forming die (<NUM>) in which the fiber base material (FB1, FB2) accommodating the core part in the hollow part (HP) is aligned, the sealing member (<NUM>) that seals the fiber base material in the forming die to form the sealed space (CS), the suction part (<NUM>) that suctions the air in the sealed space to reduce the pressure of the sealed space, the resin injection part (<NUM>) that injects the thermosetting resin material into the fiber base material sealed in the sealed space whose pressure is reduced by the suction part, and the heating part (<NUM>) that heats and cures the thermosetting resin material injected into the fiber base material by the resin injection part in the sealed space whose pressure is reduced by the suction part. The core part includes the connection member (<NUM>) that connects the internal space (IS) sealed by the cover member to the pressure-reducing source (<NUM>).

According to the fiber-reinforced composite forming apparatus in the present disclosure, the fiber base material in which the core part is accommodated in the hollow part is aligned in the forming die. The fiber base material is sealed in the forming die to form the sealed space. The pressure of the sealed space is reduced, the thermosetting resin material is injected into the fiber base material, and the thermosetting resin material is heated and cured. In this manner, the fiber-reinforced composite including the cured thermosetting resin material and the fiber base material is formed. When the thermosetting resin is cured after being injected into the fiber base material, the core part is accommodated in the hollow part of the fiber base material. Therefore, the shape of the hollow part of the fiber base material can be maintained.

In addition, according to the fiber-reinforced composite forming apparatus in the present disclosure, the core part includes the connection member that connects the internal space to the pressure-reducing source. Therefore, after the fiber-reinforced composite is detached from the forming die, the pressure of the internal space of the core part sealed by the cover member is reduced so that the foam contracts. In this manner, the clearance is formed between the core part and the hollow part of the fiber-reinforced composite. In this manner, the core part accommodated in the hollow part of the fiber-reinforced composite can be easily removed. In this way, according to the fiber-reinforced composite forming apparatus in the present disclosure, the fiber-reinforced composite including hollow part can be formed without requiring complicated work.

In the fiber-reinforced composite forming apparatus according to the present disclosure, it is preferable to adopt the following configuration. The resin injection part is a tube body connected to the supply source (<NUM>) of the thermosetting resin material and communicating with the sealed space. The suction part is a tube body connected to the suction source (<NUM>) and communicating with the sealed space.

According to the fiber-reinforced composite forming apparatus having this configuration, the pressure of the sealed space is reduced via the tube body connected to the suction source. In this manner, the thermosetting resin material can be injected into the fiber base material via the tube body connected to the supply source. The thermosetting resin can infiltrate into the fiber base material by utilizing the differential pressure between the pressure of the sealed space and the atmospheric pressure.

In the fiber-reinforced composite forming apparatus having the above-described configuration, it is preferable to adopt the following configuration. The fiber-reinforced composite forming apparatus includes the communication line (<NUM>) that communicates with the internal space, and is maintained at the internal space at the atmospheric pressure when the thermosetting resin material is heated by the heating part.

According to the fiber-reinforced composite forming apparatus having this configuration, the fiber-reinforced composite forming apparatus includes the communication line. Therefore, the pressure of the internal space maintains the atmospheric pressure when the thermosetting resin material is heated. In this manner, it is possible to suppress a disadvantage that the hollow part of the fiber base material may be deformed when the air existing in the internal space is pressurized to the atmospheric pressure or higher.

In the fiber-reinforced composite forming apparatus having the above-described configuration, it is preferable to adopt the following configuration. The core part includes the communication part (<NUM>) through which the internal space and the sealed space communicate with each other.

According to the fiber-reinforced composite forming apparatus having this configuration, the core part includes the communication part. Therefore, when the thermosetting resin material is injected by the resin injection part, the pressure of the sealed space is reduced via the suction line. In this manner, the air in the internal space is guided to the suction line via the sealed space. When the thermosetting resin material is heated by the heating part, the foam is heated in a state where the air in the internal space is reduced. Therefore, even when the foam expands due to the heating, there is no possibility that the core part may be excessively deformed to deform the hollow part of the fiber base material.

In the fiber-reinforced composite forming apparatus having the above-described configuration, it is preferable to adopt the following configuration. The cover member includes the inner cover for sealing the foam and the outer cover for accommodating the inner cover. When the thermosetting resin material is heated by the heating part, the pressure of the first internal space sealed by the inner cover is reduced to the pressure lower than the atmospheric pressure, and the pressure of the second internal space between the inner cover and the outer cover maintains the atmospheric pressure.

According to the fiber-reinforced composite forming apparatus having this configuration, the pressure of the first internal space sealed by the inner cover is reduced to the pressure lower than the atmospheric pressure. In this manner, the foam can be adjusted not to expand after being heated by the heating part. In addition, since the pressure of the second internal space between the outer cover and the inner cover is maintained at the atmospheric pressure, it is possible to prevent the hollow part of the core part from being deformed to contract.

In the fiber-reinforced composite forming apparatus having the above-described configuration, it is preferable to adopt the following configuration. In a state where the thermosetting resin material is not heated by the heating part, the core part is accommodated in the hollow part in a state where a portion of the core part is not in contact with the fiber base material.

According to the fiber-reinforced composite forming apparatus having this configuration, a portion of the core part does not come into contact with the fiber base material in a state where the thermosetting resin material is not heated by the heating part. Therefore, when the thermosetting resin material starts to be heated by the heating part and the foam expands, it is possible to prevent the fiber base material from being excessively pushed due to filling of the clearance between the portion of the core part and the fiber base material.

In the fiber-reinforced composite forming apparatus having the above-described configuration, it is preferable to adopt the following configuration. The foam is formed of the elastic material having the open cell.

Claim 1:
A fiber-reinforced composite forming method comprising:
an alignment step (S101) of aligning a fiber base material (FB1, FB2) in which a core part (<NUM>) including an elastic long foam (<NUM>) and a cover member (<NUM>) for sealing the foam (<NUM>) is accommodated in a hollow part (HP), in a forming die (<NUM>);
a sealing step (S102) of sealing the fiber base material (FB1, FB2) in the forming die (<NUM>) to form a sealed space (CS);
an injection step (S103) of suctioning air in the sealed space (CS) formed by the sealing step (S102), reducing a pressure of the sealed space (CS), and injecting a thermosetting resin material (RM) into the fiber base material (FB1, FB2) sealed in the sealed space (CS);
a curing step (S104) of heating and curing the thermosetting resin material (RM) injected into the fiber base material (FB1, FB2) by the injection step (<NUM>);
a detachment step (S105) of detaching a fiber-reinforced composite (<NUM>) including the thermosetting resin material (RM) cured by the curing step (S104) and the fiber base material (FB1, FB2), from the forming die (<NUM>); and
a removal step (S106) of reducing a pressure of an internal space (CI) sealed by the cover member (<NUM>) so that the foam (<NUM>) contracts, and removing the core part (<NUM>) accommodated in the hollow part (HP) of the fiber-reinforced composite (<NUM>)
wherein in the sealing step (S102), a resin injection line (<NUM>) connected to a supply source (<NUM>) of the thermosetting resin material (RM) and the sealed space (CS) are caused to communicate with each other, and a suction line (<NUM>) connected to a suction source (<NUM>) and the sealed space (CS) are caused to communicate with each other,
in the injection step (<NUM>), the thermosetting resin material (RM) is injected into the fiber base material (FB1m FB2) via the resin injection line (<NUM>) by reducing the pressure of the sealed space (CS) via the suction line (<NUM>); and
characterized in that,
in the curing step (S104), the internal space (CI) is maintained at an atmospheric pressure when the thermosetting resin material (RM) is heated.