Patent ID: 8273206

Claim:
A method for continuously forming a composite material shape member having a varied cross-sectional shape by supplying a composite material prepreg having thermosetting resin impregnated in a carbon fiber intermittently in a longitudinal direction and passing the same through a mold and an after-cure furnace, the method comprising: a step of preparing a movable mold having a cross-sectional shape corresponding to the cross-sectional shape of the shape member, the moveable mold comprising a first mold portion, a second mold portion disposed on one side of the first mold portion, and a third mold portion disposed on an opposite side of the first mold portion, wherein an inner surface of the movable mold is formed of a flat planar surface, an outermost surface of the first mold portion has a greater height and a greater width than an outermost surface of the second mold portion, and an outermost surface of the third mold portion has a smaller height and a smaller width than the second mold portion, wherein the moveable mold is not a peel ply; a step of pre-laminating composite material prepreg sheets on the outermost surface of the movable mold so that the surface of the whole sheets constitute a planar surface; a step of passing the prepreg sheets through a preforming device and forming a preform member having an even thickness; a step of overlapping to an inner side of the preform member the movable mold having a composite prepreg sheet laminated thereto in advance, and subjecting the same to a hot press; a step of additionally heating the hot-pressed member in an after-cure furnace so as to complete thermosetting; and a step of removing the movable mold from the member having completed thermosetting.