Patent ID: 12214577

DESCRIPTION OF EMBODIMENTS

Hereinafter, one embodiment of a composite structure manufacturing method and of a composite structure manufacturing device according to the present invention will be described with reference to the drawings.

The composite structure manufacturing method and the composite structure manufacturing device according to the present embodiment are used when a composite structure is manufactured from a laminate2having a plate shape which is formed by laminating fiber sheets infiltrated with a resin such as prepregs (hereinafter, referred to as “fiber reinforcing resin sheets”). Examples of the composite structure include a stringer used for a fuselage, a main wing, or the like of an aircraft.

Incidentally, in the following description, a longitudinal direction of the laminate2will be described as an X-axis direction, a lateral direction of the laminate2will be described as a Y-axis direction, and a thickness direction of the laminate2will be described as a Z-axis direction. In the present embodiment, since an example will be described in which the Z-axis direction is an up-down direction, the Z-axis direction may be described as the up-down direction.

As shown inFIG.1, the composite structure manufacturing device of the present embodiment (hereinafter, simply referred to as a “recess and projection processing device1”) is a device that performs processing to form a recessed portion or a projecting portion in the laminate2having a plate shape which is formed by laminating fiber reinforcing resin sheets that are a composite material. The laminate2is formed by laminating fiber reinforcing resin sheets having different fiber extending directions in order to improve the strength of the laminate2. Namely, in the laminate2, the extending directions of the fibers forming the laminate2are not uniform and are various.

The recess and projection processing device1according to the present embodiment includes a first processing device10that processes an end portion of the laminate2in the lateral direction (Y-axis direction), and a second processing device20that processes a central portion of the laminate2in the lateral direction. Incidentally, the configuration of the recess and projection processing device1is not limited to the example of the present embodiment. For example, only one of the first processing device10and the second processing device20may be provided. In addition, the recess and projection processing device1can move each of the first processing device10and the second processing device20to an arbitrary position.

First, the first processing device10will be described.

As shown inFIG.1, the first processing device10includes a first roller (rotating body)11and a second roller (rotating body)12that come into contact with an upper surface2aof the laminate2, and a third roller (rotating body)13that comes into contact with a lower surface2bof the laminate2. In addition, the first processing device10includes a first moving portion14that supports and moves the first roller11, a second moving portion15that supports and moves the second roller12, a third moving portion16that supports and moves the third roller13, and a control device (not shown) that controls the first moving portion14, the second moving portion15, and the third moving portion16.

Each of the first roller11, the second roller12, and the third roller13is a rotating body having a cylindrical outer peripheral surface, and rotates around a central axis extending in a direction along a plate surface of the laminate2(Y-axis direction in the present embodiment).

The first roller11and the second roller12are located above the laminate2. The outer peripheral surfaces of the first roller11and the second roller12come into contact with the upper surface2aof the laminate2, and roll along the upper surface2aof the laminate2. The first roller11and the second roller12are disposed side by side in the X-axis direction.

The third roller13is located below the laminate2. The outer peripheral surface of the third roller13comes into contact with the lower surface2bof the laminate2and rolls therealong. The position of the third roller13in the Y-axis direction is substantially the same as that of the first roller11and the second roller12. In addition, the position of the third roller13in the X-axis direction is located between the first roller11and the second roller12.

The first moving portion14moves the first roller11in one direction along the X-axis direction using a driving force from a driving source (not shown). The second moving portion15moves the second roller12in the other direction along the X-axis direction using a driving force from a driving source (not shown). Namely, the second moving portion15moves the second roller12in a direction opposite to a moving direction of the first roller11. The third moving portion16moves the third roller13in the Z-axis direction. Namely, the third moving portion16moves the third roller13in the up-down direction. In addition, each of the moving portions can fix the corresponding roller so as not to be moved from a predetermined position.

The control device controls the first moving portion14, the second moving portion15, and the third moving portion16such that the first roller11, the second roller12, and the third roller13make a predetermined movement. In addition, the control device controls the first moving portion14, the second moving portion15, and the third moving portion16to adjust movement amounts of the first roller11, the second roller12, and the third roller13.

The control device includes, for example, a central processing unit (CPU), a random access memory (RAM), a read only memory (ROM), a computer-readable storage medium, and the like. Then, as one example, a series of processes for realizing various functions are stored in the storage medium or the like in the form of a program, and the CPU reads the program into the RAM or the like and executes information processing and arithmetic processing, to realize the various functions. Incidentally, a form in which the program is installed in the ROM or another storage medium in advance, a form in which the program is provided in a state where the program is stored in the computer-readable storage medium, a form in which the program is distributed via wired or wireless communication means, and the like may be applied. Examples of the computer-readable storage medium include magnetic disks, magneto-optical disks, CD-ROMs, DVD-ROMs, semiconductor memories, and the like.

Next, a method for forming a recessed portion or a projecting portion in the laminate2using the first processing device10will be described with reference toFIGS.2A and2B.

First, as shown inFIG.2A, the laminate2is inserted into a gap between the third roller13and both the first roller11and the second roller12from the X-axis direction. At this time, the first roller11and the second roller12are disposed side by side in the X-axis direction to be close to each other or to abut each other. Then, the first roller11and the second roller12are brought into contact with the upper surface2aof the laminate2, and the third roller13is brought into contact with the lower surface2bof the laminate2. Namely, the laminate2is sandwiched between the first roller11, the second roller12, and the third roller13in the up-down direction. Specifically, the first roller11, the second roller12, and the third roller13sandwich an end portion of the laminate2in the Y-axis direction.

Next, as indicated by arrows inFIG.2A, the first roller11is moved in the one direction of the X-axis direction by the first moving portion14, and the second roller12is moved in the other direction of the X-axis direction by the second moving portion15. At this time, the first moving portion14and the second moving portion15move the first roller11and the second roller12in a state where contact between the upper surface2aof the laminate2and each of the first roller11and the second roller12is maintained. Specifically, the first roller11and the second roller12are moved such that a separation distance between the first roller11and the second roller12is larger than a diameter of the third roller13.

In addition, as indicated by arrows inFIG.2A, as the first roller11and the second roller12are moved, the third roller13is moved upward by the third moving portion16. At this time, the first moving portion14and the second moving portion15restrict up and down movement of the first roller11and of the second roller12. Accordingly, as shown inFIG.2B, the laminate2is deformed to protrude upward by the amount of movement of the third moving portion16. Specifically, the laminate2is deformed such that a recessed portion is formed in the upper surface2aand a projecting portion is formed in the lower surface2b.

The first moving portion14, the second moving portion15, and the third moving portion16move the first roller11, the second roller12, and the third roller13according to a signal from the control device.

In such a manner, the projecting portion that protrudes upward is formed at the end portion of the laminate2in the Y-axis direction.

Incidentally, in the above description, an example has been described in which when the laminate2is inserted into the gap between the third roller13and both the first roller11and the second roller12in the X-axis direction, the first roller11and the second roller12are disposed to be close to each other or to abut each other; however, the present invention is not limited thereto. For example, when the laminate2is inserted, the first roller11and the second roller12may be separated from each other by a predetermined distance (length larger than the diameter of the third roller13). In this case, after the laminate2is inserted into the gap between the third roller13and both the first roller11and the second roller12in the X-axis direction, the third roller13is moved upward without the first roller11and the second roller12being moved in the X-axis direction. Even in such a manner, as shown inFIG.2B, the laminate2can be deformed such that a recessed portion is formed in the upper surface2aand a projecting portion is formed in the lower surface2b.

Next, the second processing device20will be described.

As shown inFIG.3, the second processing device20includes a first roller unit21, a second roller unit22, and a third roller unit23that sandwich the laminate2in the up-down direction. The first roller unit21, the second roller unit22, and the third roller unit23are disposed side by side in the Y-axis direction. In addition, the second processing device20includes a first support portion24that supports the first roller unit21, a second support portion25that supports and moves the second roller unit22in the Z-axis direction, a fourth moving portion26that supports the third roller unit23, and a control device (not shown) that controls the fourth moving portion26.

The first roller unit21includes a first upper roller21athat comes into contact with the upper surface2aof the laminate2, and a first lower roller21bthat comes into contact with the lower surface2bof the laminate2. Each of the first upper roller21aand the first lower roller21bis a rotating body having a cylindrical outer peripheral surface, and rotates around a central axis extending in the Y-axis direction. The first upper roller21aand the first lower roller21bare disposed such that the outer peripheral surfaces thereof face each other with the laminate2sandwiched therebetween. The first upper roller21aand the first lower roller21bare supported by the first support portion24to be located at predetermined positions.

The second roller unit22includes a second upper roller22athat comes into contact with the upper surface2aof the laminate2, and a second lower roller22bthat comes into contact with the lower surface2bof the laminate2. Each of the second upper roller22aand the second lower roller22bis a rotating body having a cylindrical outer peripheral surface, and rotates around a central axis extending in the Y-axis direction. The second upper roller22aand the second lower roller22bare disposed such that the outer peripheral surfaces thereof face each other with the laminate2sandwiched therebetween. The second upper roller22aand the second lower roller22bare supported by the second support portion25to be located at predetermined positions.

The third roller unit23includes a third upper roller23athat comes into contact with the upper surface2aof the laminate2, and a third lower roller23bthat comes into contact with the lower surface2bof the laminate2. Each of the third upper roller23aand the third lower roller23bis a rotating body having a cylindrical outer peripheral surface, and rotates around a central axis extending in the Y-axis direction. The third upper roller23aand the third lower roller23bare disposed such that the outer peripheral surfaces thereof face each other with the laminate2sandwiched therebetween. The third upper roller23aand the third lower roller23bare supported by the fourth moving portion26to be located at predetermined positions.

The fourth moving portion26moves the third roller unit23(in detail, the third upper roller23aand the third lower roller23b) in the Z-axis direction (up-down direction) using a driving force from a driving source (not shown).

The control device controls the fourth moving portion26such that the third roller unit23makes a predetermined movement. In addition, the fourth moving portion26is controlled to adjust the amount of movement of the third roller unit23. Incidentally, since a detailed configuration of the control device provided in the second processing device20is substantially the same as that of the control device provided in the first processing device10, a detailed description thereof will be omitted. Incidentally, the control device provided in the second processing device20and the control device provided in the first processing device10may be the same control device.

Next, a method for forming a recessed portion or a projecting portion in the laminate2using the second processing device20will be described with reference toFIGS.4A and4B.

First, as shown inFIG.4A, the laminate2is inserted into a gap between a group of the first upper roller21a, the second upper roller22a, and the third upper roller23aand a group of the first lower roller21b, the second lower roller22b, and the third lower roller23bin the X-axis direction. Then, the first upper roller21a, the second upper roller22a, and the third upper roller23aare brought into contact with the upper surface2aof the laminate2, and the first lower roller21b, the second lower roller22b, and the third lower roller23bare brought into contact with the lower surface2bof the laminate2. Namely, the laminate2is sandwiched between the first roller unit21, the second roller unit22, and the third roller unit23. In detail, the first roller unit21, the second roller unit22, and the third roller unit23sandwich the central portion of the laminate2in the Y-axis direction.

Next, as indicated by arrows inFIG.4A, the third roller unit23is moved upward by the fourth moving portion26. At this time, the first support portion24and the second support portion25restrict up and down movement of the first roller unit21and of the second roller unit22. Accordingly, as shown inFIG.4B, the laminate2is deformed to protrude upward by the amount of movement of the fourth moving portion26. Specifically, the laminate2is deformed such that a recessed portion is formed in the upper surface2aand a projecting portion is formed in the lower surface2b. As the laminate2is deformed, a force to deform the lower surface2bto protrude downward acts on regions adjacent to a region that the third roller unit23abuts, but since the first roller unit21and the second roller unit22provided adjacent to the third roller unit23sandwich the laminate2in the up-down direction, the deformation to protrude downward can be suppressed.

The fourth moving portion26moves the third roller unit23according to a signal from the control device.

In such a manner, the projecting portion that protrudes upward is formed at the central portion of the laminate2in the Y-axis direction.

Next, a method for manufacturing a composite structure according to the present embodiment will be described.

First, the laminate2made of a composite material and having a plate shape is formed by laminating a plurality of fiber reinforcing resin sheets (lamination step). Next, as for the laminate2having a plate shape, a recessed portion and a projecting portion are formed in the laminate2by the recess and projection processing device1(pressing deformation step). Next, the laminate2is deformed in the lateral direction such that a cross section in the longitudinal direction has a predetermined shape (lateral deformation step). In addition, the laminate2is deformed in the longitudinal direction such that a cross section in the lateral direction has a predetermined shape (longitudinal deformation step). In such a manner, the composite structure is manufactured. In the pressing deformation step, the recessed portion and the projecting portion are formed to include portions to be curved or bent in the longitudinal deformation step.

Next, a specific method for manufacturing a composite structure will be described. In the present embodiment, as one example, a method for manufacturing a composite structure30shown inFIG.5Aor a composite structure40shown inFIG.6Awill be described.

First, the method for manufacturing the composite structure30shown inFIG.5Awill be described.

The composite structure30is a long member in which a predetermined cross-sectional shape is provided to a cross section of the long member in the longitudinal direction (X-axis direction). In addition, the composite structure30is bent at two locations in the longitudinal direction. Namely, a predetermined cross-sectional shape is also provided to a cross section of the composite structure30in the lateral direction (Y-axis direction).

In detail, the cross-sectional shape of the composite structure30in the longitudinal direction includes a pair of flange portions31that are disposed at both ends in the Y-axis direction to extend in the Y-axis direction, a pair of web portions32extending diagonally inward from inner end portions of the flange portions31in the Y-axis direction, and a cap portion33that connects inner end portions of the pair of web portions32.

In addition, the composite structure30integrally includes one end portion34that is one end side in the longitudinal direction, the other end portion35that is the other end side in the longitudinal direction, and a central portion36that connects the one end portion34and the other end portion35. The one end portion34, the other end portion35, and the central portion36have substantially the same length in the longitudinal direction. The one end portion34and the central portion36are connected to each other in a bent shape to form a predetermined angle in a cross section in the lateral direction. Hereinafter, a connecting portion between the one end portion34and the central portion36is referred to as a first bent portion37a. At the first bent portion37a, an angle formed by plate surfaces on one side of the laminate2(lower surface2bin the present embodiment) is an acute angle. The other end portion35and the central portion36are connected to each other in a bent shape to form a predetermined angle in a cross section in the lateral direction. Hereinafter, a connecting portion between the other end portion35and the central portion36is referred to as a second bent portion37b. At the second bent portion37b, an angle formed by plate surfaces on the other side of the laminate2(upper surface2ain the present embodiment) is an acute angle. Namely, the composite structure30has a shape in which the one end portion34and the other end portion35are offset in a predetermined direction (Z-axis direction in the present embodiment) and the one end portion34and the other end portion35are connected to each other by the central portion36.

The composite structure30having such a shape is manufactured by the following method.

First, the laminate2made of a composite material and having a plate shape is formed by laminating a plurality of fiber reinforcing resin sheets (lamination step).

Next, the pressing deformation step will be described in detail. Incidentally, hereinafter, an example will be described in which a recessed portion38is formed by the first processing device10; however, when the recessed portion38is formed by the first processing device10, the first processing device10is used upside down from the above description. Namely, the third roller13presses the laminate2from above to form the recessed portion38.

In the pressing deformation step, as shown inFIG.5B, two recessed portions38are formed in predetermined portions of the laminate2having a plate shape by the first processing device10. The predetermined portions are portions that serve as the second bent portion37bafter the longitudinal deformation step is performed (vicinity of one third from the other end of the laminate2in the X-axis direction), and are both end portions of the laminate2in the Y-axis direction. Each of the recessed portions38is recessed downward. In addition, each of the recessed portions38is formed such that the length in the X-axis direction is shortened and the depth is shallowed from the end portion toward a central portion in the Y-axis direction. In addition, the two recessed portions38are not connected to each other, and a flat surface exists between the two recessed portions38. The flat surface serves as the cap portion33after the longitudinal deformation step is performed. In other words, the recessed portions38are formed at positions corresponding to the flange portion31and to the web portion32after the longitudinal deformation step is performed.

Next, a projecting portion39is formed in a predetermined portion of the laminate2having a plate shape by the second processing device20. The predetermined portion is a portion that serves as the first bent portion37aafter the longitudinal deformation step is performed (vicinity of one third from one end of the laminate2in the X-axis direction), and is a central portion of the laminate2in the Y-axis direction. The projecting portion39protrudes upward. In addition, the projecting portion39is formed such that the length in the X-axis direction is shortened and the height decreases from the central portion toward both end portions in the Y-axis direction. The projecting portion39does not reach the end portion in the Y-axis direction, and a flat surface exists between the projecting portion39and the end portion in the Y-axis direction. The flat surface serves as the flange portion31after the longitudinal deformation step is performed. In other words, the projecting portion39is formed at a position corresponding to the cap portion33and to the web portion32after the longitudinal deformation step is performed.

When the recessed portions38and the projecting portion39are formed, the laminate2is taken out from the recess and projection processing device1, and the lateral deformation step and the longitudinal deformation step are performed on the laminate2.

In the lateral deformation step, the laminate2in which the recessed portions38and the projecting portion39are formed is deformed in the lateral direction to form the flange portions31, the web portions32, and the cap portion33. In addition, in the longitudinal deformation step, the laminate2in which the recessed portions38and the projecting portion39are formed is deformed in the longitudinal direction to form the first bent portion37aand the second bent portion37b. Any means may be adopted as means for performing the lateral deformation step and the longitudinal deformation step. For example, the lateral deformation step and the longitudinal deformation step may be performed by pressing the laminate2against a mandrel corresponding to the shape of the composite structure30after completion. In this case, the lateral deformation step and the longitudinal deformation step are performed at the same time. In addition, a roll molding device may perform the longitudinal deformation step after the lateral deformation step is performed.

Next, the method for manufacturing the composite structure40shown inFIG.6Awill be described.

The composite structure40is a long member in which a predetermined cross-sectional shape is provided to a cross section of the long member in the longitudinal direction (X-axis direction). The cross-sectional shape of the composite structure40in the longitudinal direction shown inFIG.6Aincludes a flange portion41, a web portion42, and a cap portion43substantially similarly to the cross-sectional shape of the composite structure30in the longitudinal direction shown inFIG.5A.

In addition, the composite structure40is curved in an arch shape to form an arc in the longitudinal direction. In the present embodiment, the composite structure40is curved such that a radius of curvature of the cap portion43is smaller than a radius of curvature of the flange portion41.

The composite structure40having such a shape is manufactured by the following method.

First, the laminate2made of a composite material and having a plate shape is formed by laminating a plurality of fiber reinforcing resin sheets (lamination step).

Next, the pressing deformation step will be described in detail. Incidentally,FIG.6Bis a view virtually showing a length of the laminate2in the X-axis direction in which a recessed portion and a projecting portion are formed in the pressing deformation step. Namely,FIG.6Bshows a state where the length of a portion in the X-axis direction in which the recessed portion or the projecting portion is formed is lengthened by the amount of detour of the recessed portion or the projecting portion. In addition, inFIG.6B, a reference sign44is assigned to a portion corresponding to the flange portion41after the longitudinal deformation step is performed, a reference sign45is assigned to a portion corresponding to the web portion42after the longitudinal deformation step is performed, and a reference sign46is assigned to a portion corresponding to the cap portion43after the longitudinal deformation step is performed.

In the pressing deformation step, the projecting portion is formed in a predetermined portion of the laminate2having a plate shape by the first processing device10or by the second processing device20. The predetermined portion is a region other than a central portion of the laminate2in the Y-axis direction, and is the entire region in the X-axis direction. In detail, the recessed portion or the projecting portion is formed in the portions corresponding to the flange portion41and to the web portion42after the longitudinal deformation step is performed.

The recess and projection processing device1continuously forms a plurality of the recessed portions or the projecting portions in the X-axis direction. As shown inFIG.6B, in the portion corresponding to the flange portion41after the longitudinal deformation step is performed, the recessed portions or the projecting portions are formed to have the same length in the X-axis direction. In the portion corresponding to the web portion42after the longitudinal deformation step is performed, the recessed portion or the projecting portion is formed such that the length in the X-axis direction is lengthened toward an outer side in the Y-axis direction. As a method for adjusting the length in the X-axis direction, the length may be adjusted by changing the number of the recessed portions or the projecting portions to be formed, or the length may be adjusted by changing the depth or height of the recessed portion or the projecting portion to be formed.

Since the lamination step, the lateral deformation step, and the longitudinal deformation step are the same as those in the case of manufacturing the composite structure30ofFIG.5A, a detailed description thereof will be omitted.

In the present embodiment, the following effects are exhibited.

In the case of performing deformation in the longitudinal direction (X-axis direction) and deformation in the lateral direction (Y-axis direction) on the laminate2, when the laminate2is deformed in the longitudinal direction (namely, a cross section in the lateral direction is deformed), a portion having a large radius of curvature and a portion having a small radius of curvature are generated depending on the position of a curved or bent portion in the lateral direction. For example, in the example ofFIG.6A, the radius of curvature of the cap portion43is smaller than the radius of curvature of the flange portion41. A tensile force acts on the portion having a large radius of curvature in the longitudinal direction, and a compressive force acts on the portion having a small radius of curvature in the longitudinal direction.

In the present embodiment, before the laminate2is deformed in the lateral direction and in the longitudinal direction, the recessed portion or the projecting portion is formed in the predetermined portion of the laminate2. When the recessed portion or the projecting portion is formed, the laminate2is deformed and elongated by the amount of detour of the recessed portion or the projecting portion. Hence, in a region including the portion in which the recessed portion or the projecting portion is formed, the length of the laminate2in the longitudinal direction is lengthened by the amount of detour of the recessed portion or the projecting portion. For example, in the example ofFIG.6A, the length of the portion in the longitudinal direction corresponding to the flange portion41in which the projecting portions are continuously formed (length A inFIG.6B) is longer than the length of the portion in the longitudinal direction corresponding to the cap portion43in which the projecting portion is not formed (length B inFIG.6B).

Therefore, when the laminate2is deformed in the longitudinal direction after the recessed portion or the projecting portion is formed, the tensile force generated in the portion having a large radius of curvature (flange portion41in the example ofFIG.6A) is suppressed by an amount by which the length of the laminate2in the longitudinal direction is lengthened. Since the tensile force generated in the portion having a large radius of curvature is suppressed, the compressive force acting on the portion having a small radius of curvature is also suppressed. Therefore, the generation of ripples or wrinkles can be suppressed. Hence, the strength of the composite structure can be improved.

In addition, in the present embodiment, the recessed portion or the projecting portion is formed in the laminate2by the rollers (first roller11and the like) that roll on the plate surface of the laminate2. In addition, the movement distance or the like of each roller is adjusted by the control device. Accordingly, for example, the recessed portion or the projecting portion having a desired shape can be formed in the laminate2at a desired position by adjusting the position or pressing force of each roller. The shape of the recessed portion or the projecting portion formed in the laminate2having a plate shape varies depending on the shape of the composite structure (refer toFIGS.5A to6B), and with one recess and projection processing device1of the present embodiment, a composite structure of any shape can be dealt with. Hence, for example, the cost can be more suppressed as compared to a case where a recessed portion or a projecting portion that wants to be formed is formed in the laminate2using a mold prepared according to the position or shape of the recessed portion or the projecting portion.

In addition, in the present embodiment, the pressing deformation step, the lateral deformation step, and the longitudinal deformation step are performed on the laminate2in which the fiber reinforcing resin sheets are laminated. Accordingly, the time taken to manufacture the composite structure can be more shortened as compared to a case where the pressing deformation step, the lateral deformation step, and the longitudinal deformation step are performed on the fiber reinforcing resin sheets one by one, and then the fiber reinforcing resin sheets are laminated.

In addition, in the present embodiment, the recessed portion or the projecting portion is formed to include the portion to be curved or bent in the longitudinal deformation step. Accordingly, when the laminate2is deformed in the longitudinal direction, the tensile force generated in the portion having a large radius of curvature can be more favorably suppressed. Therefore, the compressive force acting on the portion having a small radius of curvature can be suppressed, and the generation of ripples or wrinkles can be more favorably suppressed. Hence, the strength of the composite structure can be more favorably improved.

Modification Example 1

Next, a modification example of the first embodiment will be described with reference toFIGS.7A to7C. The present modification example is different from the first embodiment in that a laminate50is formed in the lamination step such that the lengths of regions in the longitudinal direction including a predetermined portion forming a recessed portion or a projecting portion in the pressing deformation step are longer than the lengths of other regions in the longitudinal direction. The same configurations as those of the first embodiment are denoted by the same reference signs, and a detailed description thereof will be omitted.

In the present modification example, as shown inFIG.7A, when the laminate50is conceptually divided into a plurality of regions (seven regions from a first region50A to a seventh region50G in the present modification example) in the Y-axis direction, the laminate50is formed such that the lengths of regions (from the first region50A to the third region50C) in the longitudinal direction including a predetermined portion forming a projecting portion51(refer toFIGS.7B and7C) in the pressing deformation step are longer than the lengths of other regions (from the fourth region50D to the seventh region50G) in the longitudinal direction in which the projecting portion51is not formed.

In the present modification example, the projecting portion51is formed such that the length in the X-axis direction is shortened and the height decreases from an end portion of the laminate50toward a central portion in the Y-axis direction. For this reason, a relationship between the lengths of the first region50A to the third region50C in the longitudinal direction is the first region50A>the second region50B>the third region50C.

According to the present modification example, the following effects are exhibited.

In order to improve the strength of the laminate50, the laminate50according to the present modification example in which a plurality of fiber reinforcing resin sheets are laminated is formed by laminating the fiber reinforcing resin sheets having different extending directions of fibers. The fiber reinforcing resin sheet is easy to elongate in a direction orthogonal to the fibers, and is difficult to elongate in the extending direction of the fibers. Hence, no matter what direction the laminate50is deformed, since the laminate50includes a fiber reinforcing resin sheet that is difficult to elongate, the laminate50is more difficult to deform than a laminate formed of one fiber reinforcing resin sheet.

Since the laminate50is difficult to deform in such a manner, the lengths of the regions (from the first region50A to the third region50C) in the longitudinal direction including the predetermined portion may not be able to be sufficiently lengthened only by the deformation (elongation) of the laminate50. In the present embodiment, the laminate50is formed such that the lengths of the regions (from the first region50A to the third region50C) in the longitudinal direction including the predetermined portion forming the projecting portion51in the pressing deformation step are longer than the lengths of the other regions (from the fourth region50D to the seventh region50G) in the longitudinal direction. Accordingly, in the longitudinal deformation step, even when the lengths of the regions in the longitudinal direction including the predetermined portion cannot be sufficiently lengthened only by the deformation (elongation) of the laminate50, an insufficient elongation amount can be covered by a portion that is formed to be longer than the other regions (portion indicated by a broken line circle inFIG.7A). Therefore, the length of the region in the longitudinal direction including the predetermined portion can be sufficiently lengthened. Hence, it is possible to favorably suppress the generation of ripples or wrinkles even in the laminate that is difficult to deform.

Modification Example 2

A modification example of the first embodiment will be described with reference toFIGS.8and9. The present modification example is different from the first embodiment in that a flexible film (flexible member)60is disposed between the rollers and the laminate2. The same configurations as those of the first embodiment are denoted by the same reference signs, and a detailed description thereof will be omitted. Incidentally, an example will be described in which the film60is applied to the first processing device10, but the film60may be applied to the second processing device20.

As shown inFIG.8, the films60of the present modification example cover the upper surface2aand the lower surface2bof the laminate2. Accordingly, when the third roller13presses the laminate2, the laminate2is pressed via the film60.

According to the present modification example, the following effects are exhibited.

As shown in the comparative example ofFIG.9, when the film60is not provided, since a pressing force of each roller acting on the plate surface is locally increased, as indicated by a broken line circle inFIG.9, unintended local deformation (deformation in an out-of-plane direction) may be generated.

In the present modification example, the third roller13presses the plate surfaces of the laminate2via the film60. Accordingly, the film60is pressed against the plate surface by the pressing force of the third roller13, and the film60is deformed into a shape corresponding to the plate surface. Therefore, the pressing force from each roller which acts on the plate surfaces of the laminate2is made uniform. Hence, unintended local deformation can be suppressed.

Modification Example 3

A modification example of the first embodiment will be described with reference toFIGS.10A to11. The present modification example is different from the first embodiment in that a track belt (flexible member)61is disposed between the rollers and the laminate2. The same configurations as those of the first embodiment are denoted by the same reference signs, and a detailed description thereof will be omitted. Incidentally, hereinafter, an example will be described in which the track belt61is applied to the second processing device20, but the track belt61may be applied to the first processing device10.

In the present modification example, as shown inFIG.10A, two track belts61are used. One track belt61covers the first upper roller21a, the second upper roller22a, and the third upper roller23a. The other track belt61covers the first lower roller21b, the second lower roller22b, and the third lower roller23b. As shown inFIG.10B, each of the track belts61is held by each roller and by a pulley portion62disposed above or below each roller. Accordingly, as shown inFIG.10A, when the third roller unit23presses the laminate2, the laminate2is pressed via the track belt61.

According to the present modification example, the following effects are exhibited.

As shown in the comparative example ofFIG.11, when the track belt61is not provided, since a pressing force of each roller acting on the plate surface is locally increased, as shown by a broken line circle inFIG.11, unintended local deformation (deformation in the out-of-plane direction) may be generated.

In the present modification example, the third roller unit23presses the plate surface of the laminate2via the track belt61. Accordingly, the track belt61is pressed against the plate surface by the pressing force of the third roller unit23, and the track belt61is deformed into a shape corresponding to the plate surface. Therefore, the pressing force from each roller which acts on the plate surfaces of the laminate2is made uniform. Hence, unintended local deformation can be suppressed.

Incidentally, the present invention is not limited to the embodiment, and can be appropriately modified without departing from the concept of the present invention.

For example, in the embodiment, the case of using the rollers having a cylindrical shape has been described, but the present invention is not limited thereto. For example, as shown inFIG.12, a roller64may be used in which a central portion in the Y-axis direction has a projecting shape when viewed in the X-axis direction. In addition, as shown inFIG.13, a roller65may be used in which a central portion in the Y-axis direction has a recessed shape when viewed in the X-axis direction.

In addition, as shown inFIG.14, a gear (rotating body)63may be used instead of the rollers. The gear63includes a plurality of (six in the example ofFIG.14) protrusion portions63aon an outer peripheral surface of the gear63. In addition, when the gear63is applied, two gears63are disposed to face each other in the Z-axis direction. When the laminate2is inserted into a gap between the two gears63, and the gears63are rotated, the protrusion portions63aof the gears63press the plate surfaces of the laminate2, and recessed and projecting portions are formed in the laminate2. This process is continuously repeated, so that the laminate2has a wavy shape. In such a manner, the gear63is particularly effective when used to form continuous recesses and projections (for example, when used to form recesses and projections in the portion corresponding to the flange portion41inFIG.6A). In addition, the shape of the gear is not limited. For example, the gear may be a spur gear in which teeth (protrusion portions) are substantially parallel to a central axis, may be a helical gear in which teeth are inclined with respect to a central axis, or may be a bevel gear in which a surface that comes into contact with the laminate2is inclined with respect to a central axis.

In addition, in the embodiment, an example has been described in which the laminate2has a flat plate shape, but the present invention is not limited thereto. The laminate2may have a plate shape and, for example, may be curved.

In addition, in the embodiment, an example has been described in which the recessed portion is formed by a roller of which the central axis is aligned with the Y-axis direction, but the present invention is not limited thereto. For example, the recessed portion may be formed by a roller of which a central axis is aligned with the X-axis direction. Namely, the roller may be applied in the lateral direction of the laminate2.

In addition, in the embodiment, an example has been described in which the recessed portion or the projecting portion is formed by a plurality of rollers, but the present invention is not limited thereto. For example, the recessed portion or the projecting portion may be formed by a single roller. When the recessed portion or the projecting portion is formed by a single roller, a fixing mechanism is provided which fixes the laminate2. The recessed portion or the projecting portion is formed by pressing the roller against the laminate2in a state where the movement of the laminate2in the thickness direction is restricted by the fixing mechanism.

In addition, the plurality of rollers may be made of a material having good mold releasability. Alternatively, a paint or the like having good mold releasability may be applied to the outer peripheral surfaces of the rollers. With such a configuration, it is possible to suppress a situation where the rollers and the laminate2adhere to each other.

In addition, the plurality of rollers may be made of a material having low slipperiness. Alternatively, a paint or the like having low slipperiness may be applied to the outer peripheral surfaces of the rollers. With this configuration, it is possible to suppress the slip of the rollers.

In addition, the rollers may include a transfer function. Namely, when the pressing deformation step and the lateral deformation step or the longitudinal deformation step are continuously performed, the laminate2may be transferred to a device that performs a next step, by a rotational force of the rollers.

In addition, the first processing device10may process the central portion of the laminate2in the Y-axis direction. In addition, the second processing device20may process the end portion of the laminate2in the Y-axis direction. Namely, processing device moving means may be provided which moves the first processing device10or the second processing device20to a predetermined position on the laminate2. In addition, each of the first processing device10and the second processing device20may include an angle changing mechanism that changes the angle of the central axis of each roller.

In addition, the pressing deformation step may be performed continuously or intermittently.

Namely, for example, the laminate2may be continuously sent to the first processing device10or to the second processing device20from a device that performs other processing on the laminate2. In other words, the laminate2may be sent to the first processing device10or to the second processing device20without stopping from another processing device. In addition, for example, the laminate2may be intermittently sent to the first processing device10or to the second processing device20from a device that performs other processing on the laminate2. In other words, when the laminate2is sent from another processing device to the first processing device10or to the second processing device20, the movement of the laminate2may be temporarily stopped, and processing may be performed on the laminate2.

In addition, in the lamination step, when fiber reinforcing sheets are laminated, slits may be formed in some of the fiber reinforcing sheets to divide fibers. Namely, a slit may be formed in a fiber reinforcing sheet that is difficult to deform, to cut fibers. With such a configuration, the laminate2can be easily deformed.

In addition, the recess and projection processing device1may include a mechanism that pulls the laminate2from a downstream side of the first processing device10or the second processing device20. With such a configuration, a tensile force can be applied to the laminate2, so that the laminate2can be favorably deformed.

In addition, the recess and projection processing device1may include position measurement equipment such as laser measurement equipment. The position measurement equipment measures the position of each roller with respect to the laminate2. With such a configuration, the recessed portion or the projecting portion can be formed at a desired position.

In addition, the recess and projection processing device1may include a heating mechanism that heats the laminate2. With such a configuration, the laminate2can be heated, so that the laminate2can be favorably deformed.

In addition, as shown inFIG.15, when each of the recessed portions38is formed in the laminate2, fibers may gather in a region70adjacent to the recessed portions38, and wrinkles may be generated in the region70. In addition, when the projecting portion39is formed, fibers may gather in each of regions71adjacent to the projecting portion39, and wrinkles may be generated. On the other hand, when the recessed portion38or the projecting portion39is formed in the laminate2, the region70or each of the regions71may be clamped by a clamp mechanism. With such a configuration, the generation of wrinkles in the region70or in each of the regions71can be suppressed. The clamp mechanism may be, for example, rollers or flat plates. Specifically, when the end portion of the laminate2in the lateral direction (Y-axis direction) is processed as shown inFIG.1, as shown inFIG.16, a clamp mechanism73is added which clamps a region72on the laminate2. Accordingly, the generation of wrinkles in the region72can be suppressed. In addition, when the central portion of the laminate2in the lateral direction (Y-axis direction) is processed as shown inFIG.3, as shown inFIG.17, clamp mechanisms75and76are added which clamp regions74adjacent to the central portion in the Y-axis direction. Accordingly, the generation of wrinkles in each of the regions74can be suppressed.