Patent ID: 12257817

DESCRIPTION OF EMBODIMENTS

Composite panel structure

A composite panel structure (hereinafter suitably abbreviated as “panel structure”) according to an exemplary embodiment will be specifically described with reference toFIGS.1A,1B, and2.

The panel structure is a press-formed product made of a composite material containing reinforced fibers and matrix resin. A specific configuration of the panel structure is not especially limited. For example, the panel structure is a panel structure10A in which ribs intersect with each other in a cross shape as shown inFIG.1Aor a panel structure10B having an isogrid as shown inFIG.1B.

For ease of explanation, a plane where a substrate portion11is placed is referred to as an X-Y plane, and a direction in which the ribs stand is referred to as a z-axis.

Each of the panel structure10A shown inFIG.1Aand the panel structure10B shown inFIG.1Bincludes the substrate portion11and at least two ribs12standing on the substrate portion11. A reference sign13indicates a rib intersecting portion13where the ribs12intersect with each other. Continuous fibers or slit continuous fibers are arranged at the ribs12.

The slit continuous fibers are discontinuous fibers prepared by forming slits at continuous fibers oriented in one direction.

In the panel structure10A shown inFIG.1A, each of the ribs12extends in an x-axis direction or a y-axis direction and stands in a z-axis direction. To be specific, each rib12extends in a rib longitudinal direction. The two ribs12intersect with each other at right angles at the rib intersecting portion13.

In the panel structure10B shown inFIG.1B, the three ribs12intersect with each other at equal angles at the rib intersecting portion13. The intersecting angles of the ribs12are not limited to “right angles” or “equal angles.”

Each ofFIGS.1A and1Bshows a basic unit of the panel structure, and each of the actual panel structure10A and10B is a combination of basic units.

Moreover, inFIGS.1A and1B, the substrate portion11has a flat plate shape. However, the substrate portion11may be curved depending on use, and the shape and thickness of the substrate portion11are not limited to these. Similarly, a specific shape, thickness, and height of the rib12is not especially limited. Since the ribs12are provided to reinforce the substrate portion11, the thicknesses and heights of the ribs may be set in accordance with required strength of the substrate portion11.

As one example, the ribs12and the rib intersecting portion13in the panel structure10A shown inFIG.1Awill be described with reference toFIG.2.

Each of the substrate portion11and the ribs12is made of at least matrix resin21and reinforced fibers22. The substrate portion11is formed by, for example, laminating composite material layers on each other. The reinforced fibers22used in the substrate portion11are continuous fibers or slit continuous fibers as with the rib12. The orientation direction of the reinforced fibers of the substrate11is a direction within the X-Y plane.

Or, the substrate portion11may contain short fibers as the reinforced fibers22instead of the continuous fibers. Moreover, as long as the reinforced fibers and the matrix resin are used in at least the ribs12, the reinforced fibers do not necessarily have to be used in portions other than the ribs12. For example, a known resin compound may be contained instead of the reinforced fibers.

FIG.2shows an example in which at least the continuous fibers or the slit continuous fibers are used as the reinforced fibers22in the substrate portion11and the ribs12. In an upper side ofFIG.2, the reinforced fibers22are schematically shown by long broken lines, and white portions other than the reinforced fibers22correspond to the matrix resin21. In a lower side ofFIG.2, since the reinforced fibers22aare oriented in an arbitrary direction within the X-Y plane, for convenience sake, the reinforced fibers22aare schematically shown by dots. Moreover, the reinforced fibers22bare schematically shown by long broken lines as with the upper side ofFIG.2.

As shown in the upper side ofFIG.2, at each rib12, the reinforced fibers22containing at least continuous fibers each having the orientation direction that is the longitudinal direction of the rib12, i.e., the x-axis direction or the y-axis direction are arranged. Moreover, at the rib intersecting portion13where the ribs12intersect with each other at right angles, the reinforced fibers22are arranged so as to overlap each other.

In the lower side ofFIG.2, the reinforced fibers22ain the substrate portion11are oriented in the arbitrary direction within the X-Y plane. Moreover, at the time of press-forming, the reinforced fibers22alocated in the substrate portion11and close to the rib12are pushed up to the rib12. As a result, the reinforced fibers22bof the rib12are formed at a tip end portion of the rib12.

Therefore, the orientation directions of some of the reinforced fibers22bat the tip end portion of the rib12substantially coincide with the longitudinal direction of the rib12, and the reinforced fibers22aderived from the substrate11and having the arbitrary orientation direction are arranged in the vicinity of a root of the rib12.

When manufacturing the panel structures10A and10B made of the composite material, prepregs are typically used. Each of the prepregs is a sheet prepared in such a manner that a base material made of the reinforced fibers22is impregnated with the matrix resin21. When thermosetting resin is used as the matrix resin21as described below, the matrix resin21in the prepreg may be in a semi-cured state.

Specific types of the matrix resin21and the reinforced fibers22are not especially limited, and known applicable materials may be suitably selected and used.

Typical examples of the matrix resin21include thermosetting resin and thermoplastic resin. A specific type of the thermosetting resin is not especially limited. Examples of the thermosetting resin include epoxy resin, polyester resin, vinylester resin, phenol resin, cyanate ester resin, polyimide resin, and polyamide resin. These thermosetting resins may be used alone or in combination of plural types. Further, a more specific chemical structure of the thermosetting resin is not especially limited, and the thermosetting resin may be a polymer formed by polymerizing known various monomers or may be a copolymer formed by polymerizing a plurality of monomers. Further, an average molecular weight, structures of a main chain and a side chain, and the like are not especially limited.

A specific type of the thermoplastic resin is not especially limited. However, engineering plastic, such as polyphenylene sulfide (PPS), polyether ether ketone (PEEK), and polyether imide (PEI), are preferably used. A more specific chemical structure of the thermoplastic resin is not especially limited, and the thermoplastic resin may be a polymer formed by polymerizing known various monomers or may be a copolymer formed by polymerizing monomers. Further, an average molecular weight, structures of a main chain and a side chain, and the like are not especially limited.

Components, such as a known additive, may be added to the matrix resin21. Examples of the additive include known curing agents, curing accelerators, and reinforcing materials and fillers other than fiber base materials. A specific type, composition, and the like of the additive are not especially limited, and an additive of a known type or composition may be suitably used.

When the matrix resin21contains a component other than the resin, the matrix resin21can be regarded as a resin composition constituted by the resin and the component.

A specific type of the reinforced fibers22used in the composite material is not especially limited. Examples of the reinforced fibers22include carbon fibers, polyester fibers PBO (polyparaphenylene benzobisoxazole) fibers, boron fibers, aramid fibers, glass fibers, silica fibers (quartz fibers), silicon carbide (SiC) fibers, and nylon fibers. As the reinforced fibers22, these fibers may be used alone or in suitable combination of two or more types. The base material of the reinforced fibers22is not especially limited. Typical examples of the base material of the reinforced fibers22include woven fabric, braid fabric, knit fabric, and nonwoven fabric.

Continuous fibers or long fibers (which are discontinuous fibers but are long) may be used as the reinforced fibers22. Moreover, plural types of fibrous materials, fillers, or reinforcing materials may be used as the reinforced fibers22. For example, in the substrate portion11, the short fibers may be used together with the matrix resin21instead of the continuous fibers, and a particle-shaped filler or reinforcing material (filler) may be used instead of a fiber-shaped filler. As the filler or the reinforcing material, known fillers or known reinforcing materials may be suitably used in accordance with the type of the composite material or the type of the matrix resin21.

When plural types of fibrous materials are used together, the short fibers may be used together with the continuous fibers. When the reinforced fibers22are constituted as the base material, such as woven fabric or braid fabric, of the continuous fibers, the base material may partially include slits. When the reinforced fibers22are the base material, the base material including the slits and a normal base material not including the slits may be used together. In this case, especially, in terms of strength, it is preferable that portions, corresponding to the rib intersecting portion13, of the reinforced fibers22do not contain the slits.

Laminated Prepregs

Next, laminated prepregs used to manufacture the panel structure10A and10B will be described with reference toFIGS.3A,3B,4A, and4B.

In an exemplary embodiment, for example, each of the panel structure10A and10B each including the substrate portion11, the ribs12, and the rib intersecting portion13is manufactured in such a manner that the prepregs are laminated on each other in a predetermined shape to form the laminated prepregs; and the laminated prepregs is subjected to the press-forming.

In the examples shown inFIGS.3A,3B,4A, and4B, when forming a laminated prepregs23, at least substrate prepregs20awhich constitute the substrate portion11and rib prepregs20bwhich constitute the ribs12are used. As shown inFIG.3B, according to need, a doubler prepreg20cwhich constitutes the ribs12and the rib intersecting portion13is used.

Specifically, the laminated prepregs23before the press-forming is constituted by at least a substrate material portion24and an additional lamination portion25. In an exemplary embodiment, the substrate material portion24is a portion (substrate lamination portion) in which the substrate prepregs20aconstituting the substrate portion11are laminated on each other. When the reinforced fibers of the substrate prepreg20aare continuous fibers or slit continuous fibers, the orientation direction of the reinforced fibers is the arbitrary direction within the X-Y plane. When the substrate prepregs20aare not used, the substrate material portion24is not the laminated prepregs and may be, for example, a single plate-shaped portion.

The additional lamination portion25is a portion where the rib prepregs20bare additionally laminated on each other at a position of the substrate material portion24which position corresponds to the ribs12and the rib intersecting portion13. Each ofFIGS.3A and3Bshows one example of the laminated prepregs23as an exploded perspective view, and each ofFIGS.4A and4Bshows another example of the laminated prepregs23as a schematic side view.

As shown inFIGS.3A and3B, the rib prepregs20bare additionally laminated on each other so as to overlap each other at the position corresponding to the ribs12and the rib intersecting portion13. With this, in the panel structure10A, the reinforced fibers22derived from the rib prepregs20bare arranged at a position corresponding to the rib intersecting portion13. Moreover, in the laminated prepregs23shown inFIG.3B, the doubler prepreg20csmaller in area than the substrate prepreg20ais additionally laminated at a position corresponding to the rib intersecting portion13and its peripheral portion (the ribs12adjacent to the rib intersecting portion13) so as to be interposed between the substrate prepregs20a.

The additional lamination portion25does not have a three-dimensional shape similar to the shape of the rib12but has such a shape that the thickness of the substrate material portion24is partially thick (at the position corresponding to the ribs12and the rib intersecting portion13).

As described below, by subjecting the laminated prepregs23having a substantially flat plate shape to the press-forming, the rib prepregs20b(or the rib prepregs20band the doubler prepreg20c) are introduced to a cavity, corresponding to the ribs12, of a molding die to form the ribs12. In an exemplary embodiment, for example, by using slit prepregs (or prepregs containing slit continuous fibers) as the substrate prepregs20a(and the doubler prepreg20c), the substrate prepregs20aconstituting the substrate material portion24can also be introduced to the ribs12.

However, since an introduction amount of substrate prepregs20ais limited, the rib intersecting portion13and the ribs12around the rib intersecting portion13(i.e., the rib12adjacent to the rib intersecting portion13) cannot be constituted only by the substrate prepregs20a. Therefore, as in the laminated prepregs23shown inFIGS.3A,4A, and4B, the volume of the rib intersecting portion13and the volumes of the ribs12around the rib intersecting portion13are supplemented by the rib prepregs20b. Moreover, as shown inFIG.3B, by using the doubler prepreg20cin addition to the rib prepregs20b, the volume of the rib intersecting portion13and the volumes of the ribs12around the rib intersecting portion13may be supplemented.

In the laminated prepregs23shown inFIGS.3A,4A, and4B, a prepreg having a strip shape having a substantially constant width in a longitudinal direction is used as the rib prepreg20b. However, a specific shape of the rib prepreg20bis not limited to this. The width of the rib prepreg20bin the longitudinal direction may change partially or gradually.

In the laminated prepregs23shown inFIG.3A, the rib prepregs20bthat are substantially the same in shape (strip shape) as each other are laminated on each other. However, in the laminated prepregs23shown inFIGS.4A and4B, prepregs that are different in width from each other are used as the rib prepregs20b. For example, in the additional lamination portion25of the laminated prepregs23shown inFIG.4A, the rib prepregs20bthat are substantially the same in shape as each other are laminated on each other, and a rib outer surface prepreg20dthat is larger in width than the rib prepreg20bis laminated at an outermost surface side. Or, used in the additional lamination portion25of the laminated prepregs23shown inFIG.4Bare width-changing rib prepregs20ewhich gradually increase in width as the width-changing rib prepregs20eare located at the outer surface side (upper side in an exemplary embodiment; opposite side of the substrate material portion24).

In the panel structure10A obtained by the configuration shown inFIG.4A or4B, the outer surface side of the rib12can be covered with the wider composite material layer. Therefore, the possibility of peel-off of the composite material layers constituting the rib12can be further suppressed. The width of the rib outer surface prepreg20dis not especially limited, and the width of the widest one of the width-changing rib prepregs20eis not especially limited. Typically, each of the width of the rib outer surface prepreg20dand the width of the widest one of the width-changing rib prepregs20emay be larger than at least the width (thickness) of the rib12.

For example, the shapes of the prepregs20ato20c, the number of prepregs20ato20claminated, laminating directions of the prepregs20ato20c, and the like may be suitably set in accordance with the shape, use, type, and the like of the panel structure10A to be manufactured. In the example shown inFIG.3A, a prepreg having a thin and long band shape corresponding to the shape of the rib12is used as the rib prepreg20b. However, a prepreg that spreads as with the doubler prepreg20cmay be used as the rib prepreg20b. InFIGS.3A,3B,4A, and4B, the number of substrate prepregs20alaminated is four to five, the number of rib prepregs20blaminated is three to five, and the number of doubler prepregs20claminated is one. However, each of these numbers of prepregs shown in the drawings is merely and schematically shown by a one digit number for convenience of explanation. Actually, a large number of prepregs may be laminated on each other in accordance with the structure of the panel structure10A.

The laminated prepregs23may include a metal mesh layer or metal foil as another material layer. Since the metal mesh layer and the metal foil have stretchability, each of the metal mesh layer and the metal foil can be suitably used as the above-described another material layer of the panel structure10A according to the present disclosure. For example, a copper mesh layer may be laminated on the surface of the laminated prepregs23. The panel structure10A including the surface on which the copper mesh is formed can be manufactured by subjecting the laminating prepregs23including the copper mesh layer to heating-pressurizing forming. For example, a composite-material part including the copper mesh layer is preferably used for a thunder resistance protection measure.

Moreover, as yet another material layer, the laminated prepregs23may include a material layer made of a non-conductive composite material (glass fiber reinforced plastic (GFRP), for example). The non-conductive composite material may be laminated on the entire surface of the laminated prepregs23or may be partially laminated on the surface of the laminated prepregs23. The panel structure10A including the surface on which the layer made of the non-conductive composite material is formed can be manufactured by subjecting the laminated prepregs including the layer made of the non-conductive composite material to the heating-pressurizing forming as described below.

The non-conductive composite material on the surface is typically used for an electrocorrosion measure (for example, a measure for, when CFRP and a metal member that is far from the CFRP in terms of ionization tendency are brought into contact with each other, suppressing corrosion of the metal member). A specific type of the non-conductive composite material is not especially limited, and a known material may be suitably used. Moreover, the use of the non-conductive composite material is not limited to the electrocorrosion measure and may be used for other known use.

Method of Manufacturing Panel Structure

Next, a method of manufacturing the panel structure will be specifically described with reference toFIGS.5A and5B.

First, each of the panel structure10A and10B is formed in such a manner that the laminated prepregs23is formed by the prepregs20aand20b, the prepregs20ato20c, the prepregs20a,20b, and20d, the prepregs20aand20e, or the like and is then subjected to the press-forming. In an exemplary embodiment, the laminated prepregs23ofFIG.4) to which the doubler prepreg20cofFIG.3Bis added will be described for convenience sake in the explanation of forming the ribs12and the rib intersecting portion13by the press-forming in the manufacturing method according to the present disclosure.

As shown inFIG.5A, a molding die30used at the time of the press-forming is a die used to manufacture the panel structure10A having a cross structure shown inFIG.1Aand includes an upper die31, a lower die32, an upper hot plate33, a lower hot plate34, and the like.

In the example shown inFIG.5A, the upper die31corresponds to a lower surface of the substrate portion11(lower surface inFIG.1A), and the lower die32corresponds to an upper surface of the substrate portion11(upper surface inFIG.1A) and the ribs12. A cavity35is formed between the upper die31and the lower die32.

As shown in an upper side ofFIG.5B, the laminated prepregs23is constituted by the substrate prepregs20a, the rib prepregs20b, the doubler prepreg20c, and the rib outer surface prepreg20d. In an exemplary embodiment, slit prepregs are used as the doubler prepreg20cand at least some substrate prepregs20alocated at the upper side among the substrate prepregs20a. As each of the rib prepregs20band the rib outer surface prepreg20d, a normal prepreg constituted by continuous fibers having no slits may be used, or a slit prepreg may be used.

Moreover, in the laminated prepregs23, the substrate material portion24may be constituted as the substrate lamination portion as shown inFIGS.5A and5B, or may be the above-described single-layer structure, not the substrate lamination portion. Or, the laminated prepregs23may not include the doubler prepreg20cas shown inFIG.4A, or the width-changing rib prepregs20emay be used instead of the rib prepregs20bas shown inFIG.4B.

The upper hot plate33is provided at an outer side (upper side) of the upper die31, and the lower hot plate34is provided at an outer side (lower side) of the lower die32. The hot plates33and34apply heat and pressure to the upper die31and the lower die32. With this, the laminated prepregs23interposed between the upper die31and the lower die32is subjected to heating and pressurizing (hot pressing), and thus, the panel structure10A is formed. The lower die32includes a complex depression-projection structure corresponding to the ribs12and the rib intersecting portion13. Therefore, in the example shown inFIG.5A, the lower die32is constituted by fastening and fixing die members with fasteners36. The configuration of the molding die30is not limited to the configuration shown inFIG.5A.

As shown in the upper side ofFIG.5B, first, the laminated prepregs23is arranged between the upper die31and the lower die32. Next, as shown in a lower side ofFIG.5B, the upper die31and the lower die32are subjected to heating and pressurizing (hot pressing) by the upper and lower hot plates33and34. In the lower side ofFIG.5B, arrows schematically indicate a pressurizing direction. With this, the matrix resin21constituting the prepregs20ato20dflows, and the reinforced fibers22flow or stretch (or flow and stretch) together with the matrix resin21.

As a result, the rib prepregs20bare introduced into a space of the cavity35which space corresponds to the ribs12and the rib intersecting portion13. Moreover, in an exemplary embodiment, since the slit prepregs are used as the substrate prepregs20a, some substrate prepregs20alocated at the ribs12side (“upper” side of the laminated prepregs23in an exemplary embodiment; lower side inFIG.5B) among the substrate prepreg20aare introduced into the space corresponding to the rib intersecting portion13and the ribs12around the rib intersecting portion13. Moreover, the doubler prepreg20cwhich is laminated at a position corresponding to the ribs12and is the slit prepreg is also introduced to the rib intersecting portion13and the ribs12around the rib intersecting portion13.

With this, as shown in the lower side ofFIG.5B, composite material layers14bderived from the rib prepregs20bare formed at a tip end side of each rib12. At this time, since the rib outer surface prepreg20dis laminated at a most tip end side of the rib12, a tip-end outer surface of the rib12is covered with a composite material layer14dderived from the rib outer surface prepreg20d. Moreover, in an exemplary embodiment, since the doubler prepreg20cis used, a composite material layer14cderived from the doubler prepreg20cand composite material layers14aderived from the substrate prepregs20aare formed at most portions of the ribs12including root portions of the ribs12.

As above, the ribs12include the composite material layers14bderived from the rib prepregs20b. Since the continuous fibers or the slit continuous fibers are used as the reinforced fibers22of the rib prepregs20b, not only the strengths of the ribs12but also the strength of the rib intersecting portion13can be further improved.

The arrangement of the continuous fibers at the rib intersecting portion13will be more specifically described with reference toFIGS.6A to6C. Each ofFIGS.6A and6Bis a diagram taken along line I-I (one-dot chain line) in the panel structure10A shown inFIG.1Aand schematically shows a section (vertical section) of the rib12having the longitudinal direction that is the y-axis direction out of the two ribs12having the cross structure.FIG.6Cis a schematic diagram when the section ofFIG.6Ais viewed from the x-axis direction.

FIG.6Ais an exploded perspective view showing the composite material layers14blocated a tip end side (outer surface side) of the rib12and the composite material layer14dlocated at an outermost side (most tip end side) of the rib12. Moreover,FIG.6Bis an exploded perspective view showing composite material layers14elocated at the tip end side of the rib12.

FIG.6Acorresponds to a configuration in which: the rib prepregs20bthat are substantially the same in shape as each other are laminated on each other; and the rib outer surface prepreg20dis laminated at the most tip end side. Therefore, the composite material layers14bshown inFIG.6Aare layers derived from the rib prepregs20bthat are substantially the same in shape as each other as shown inFIG.4A, and the composite material layer14dis a layer derived from the rib outer surface prepreg20dshown inFIG.4A. The composite material layers14bare layers simply laminated on the tip end portion of the rib12, and the composite material layer14dcovers at least part of the outer surface side of the rib12or the entire outer surface side of the rib12as described above.

FIG.6Bcorresponds to a configuration in which the width-changing rib prepregs20eofFIG.4Bare laminated on each other. Therefore, the composite material layers14eshown inFIG.6Bare layers derived from the width-changing rib prepregs20eshown inFIG.4B. Since the width-changing rib prepregs20egradually increase in width as the width-changing rib prepregs20eare located at the tip end side of the rib12(z-axis direction), the composite material layers14eare layers which increase in area as the layers are located at the tip end side, the area being an area where the layer covers the tip end portion of the rib12.

Moreover, as shown inFIG.6C, in the rib intersecting portion13of one of the ribs12having the cross structure, the composite material layers14b(or the composite material layer14dor the composite material layers14e) constituting the one rib12and the composite material layers14b(or the composite material layer14dor the composite material layers14e) constituting the other rib12are laminated on each other.

With this, in the panel structure10A made of the composite material by the press-forming, the continuous fibers or the slit continuous fibers are arranged at not only the ribs12but also the rib intersecting portion13. Therefore, the substrate portion11can be reinforced by not only the ribs12but also the rib intersecting portion13. In addition, the composite material layers14b(or the composite material layer14dor the composite material layers14e) are laminated on each other in an extending direction of the rib12. Therefore, the continuous fibers or the slit continuous fibers are also arranged at the rib intersecting portion13along the extending direction of the rib12and are arranged at the rib intersecting portion13such that the continuous fibers or the slit continuous fibers also intersect with each other by the intersecting of the ribs12. Thus, the effect of reinforcing the substrate portion11by the rib intersecting portion13can be further improved.

For example, when the three-dimensional structure, such as the cross structure, is included, the prepregs are laminated so as to form a three-dimensional shape corresponding to such complex shape. Therefore, a time required for the laminating typically becomes long. Moreover, since it is normally difficult to subject the complex three-dimensional shape laminated as above to the press-forming, autoclave molding is practically used. However, a molding time of the autoclave molding is long. Manufacturing the panel structure having the three-dimensional structure by using prior art as above requires a large amount of time, and therefore, mass production is difficult.

On the other hand, in an exemplary embodiment, since the laminated prepregs23has a substantially flat plate shape, the laminated prepregs23can be subjected to the press-forming, and therefore, the panel structure having the complex three-dimensional shape including the ribs12can be easily manufactured.

Moreover, it is conventionally difficult to arrange the continuous fibers at a three-dimensional structure part, such as a rib, by the press-forming. However, by subjecting the laminated prepregs23including the additional lamination portion25to the press-forming, the panel structure including the rib intersecting portion13at which the continuous fibers or the slit continuous fibers are arranged and having improved strength and rigidity can be manufactured.

The following will be described with reference toFIGS.7A and7B. Each ofFIGS.7A and7Bshows one example of the actually manufactured panel structure10B having the isogrid shown inFIG.1B.FIG.7Ashows one example of the laminated prepregs23in which the prepregs are laminated on each other.FIG.7Bshows one example of the panel structure10B manufactured by subjecting the laminated prepregs23ofFIG.7Ato the hot pressing.

As shown inFIG.7A, the additional lamination portion25is visible on the upper surface of the substrate material portion24, but the laminated prepregs23itself has a substantially flat plate shape. The panel structure10B shown inFIG.7Bis manufactured by subjecting the laminated prepregs23to the hot pressing. As is clear fromFIG.7B, in the panel structure10B, the ribs12standing on the substrate portion11can be formed, and the ribs12can intersect with each other to form the rib intersecting portion13.

As above, the composite panel structure according to the present disclosure is a panel structure that is a press-formed product made of a composite material containing reinforced fibers and matrix resin. The composite panel structure according to the present disclosure includes a substrate portion, plate-shaped ribs standing on the substrate portion, and a rib intersecting portion where the ribs intersect with each other. In the ribs and the rib intersecting portion, continuous fibers or slit continuous fibers are arranged as the reinforced fibers.

Moreover, a method of manufacturing a composite panel structure according to the present disclosure is a method of manufacturing a panel structure made of a composite material containing reinforced fibers and matrix resin by press-forming. The panel structure includes a substrate portion, plate-shaped ribs standing on the substrate portion, and a rib intersecting portion where the ribs intersect with each other. A substrate material portion constituting the substrate portion is formed by using at least the matrix resin. Part of the ribs and part of the rib intersecting portion are formed at a position of the substrate material portion which position corresponds to the ribs and the rib intersecting portion. Rib prepregs in which continuous fibers or slit continuous fibers are used as the reinforced fibers are additionally laminated to form an additional lamination portion. The obtained laminated prepregs is subjected to press-forming with a molding die.

According to this configuration, in the panel structure made of the composite material by the press-forming, the continuous fibers are arranged at not only the ribs but also the rib intersecting portion. With this, the substrate portion can be reinforced by not only the ribs but also the rib intersecting portion. Therefore, in the composite panel structure, the strength of the intersecting portion of the ribs provided on the substrate portion can be further improved.

A specific use of the panel structure10A and10B according to the present disclosure is not especially limited. The panel structure10A and10B according to the present disclosure can be suitably used as panel-shaped members used in various fields, such as an aerospace field, an automobile/two-wheeled vehicle field, a railcar field, a marine field, an industrial equipment field, a medical equipment field, a sports goods field, and an architecture/civil engineering field. More preferably, the panel structure10A and10B according to the present disclosure are used in an aerospace field of aircrafts, spacecrafts, and the like.

The present invention is not limited to the above-described embodiment and may be modified in various ways within the scope of the claims, and embodiments obtained by suitably combining technical means disclosed in different embodiments and/or plural modified examples are included in the technical scope of the present invention.

From the foregoing explanation, many modifications and other embodiments of the present invention are obvious to one skilled in the art. Therefore, the foregoing explanation should be interpreted only as an example and is provided for the purpose of teaching the best mode for carrying out the present invention to one skilled in the art. The structures and/or functional details may be substantially modified within the scope of the present invention.

INDUSTRIAL APPLICABILITY

The present invention can be widely and suitably used in a field of a composite panel structure including ribs standing on a substrate portion and a rib intersecting portion.