JP2020157625A - Molding method of fiber reinforced composite material and molding method of fiber preform - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for forming a fiber-reinforced composite material and a method for forming a fiber preform, which can suppress a decrease in strength of a curved portion while suppressing an increase in cost due to an increase in the number of members. A method for forming a fiber-reinforced composite material CM, which comprises a step of forming a laminate 1 of prepregs P1 to P4 and a step of molding at least a part of the laminate 1 into a curved portion B1. In this method, an intermediate member 2 made of a thermoplastic resin is interposed between at least one layer of a portion B1a formed on the curved portion B1 of the laminated body 1. Specifically, the intermediate member 2 is interposed so that the actual length of the direction Xa corresponding to the circumferential direction X of the curved portion B1 is longer in the prepreg P1 formed in the outermost layer than in the prepreg P4 formed in the innermost layer. .. Then, the intermediate member 2 is heated and melted to bend the portion B1a. [Selection diagram] Fig. 3

Description

The present invention relates to a method for forming a fiber-reinforced composite material and a method for forming a fiber preform.

Patent Document 1 describes a first step of manufacturing a first prepreg of CFRP having a notch in a curved portion where a compressive force or a tensile force acts during molding by a mold, and a first step of CFRP that can be laminated on the curved portion of the first prepreg. 2 The second step of manufacturing the prepreg, the third step of press-molding the first prepreg into a predetermined shape with a mold to manufacture the first preform, and the second step of press-molding the second prepreg with a mold. Disclosure of a preform manufacturing method including a fourth step of manufacturing a reform and a fifth step of press-molding a second preform on a curved portion of the first preform with a die to integrate them. are doing.

JP-A-2018-75812

However, in the above manufacturing method, it is necessary to manufacture the second preform as an additional member in order to manufacture the curved portion, which increases the number of members and increases the cost. Further, in the above manufacturing method, it is necessary to form a notch in the curved portion of the first preform, and the notch reduces the strength of the curved portion.

An object of the present invention is to provide a method for forming a fiber-reinforced composite material and a method for forming a fiber preform, which can suppress a decrease in strength of a curved portion while suppressing an increase in cost due to an increase in the number of members. is there.

One aspect of the present invention is a method for forming a fiber-reinforced composite material, which comprises a step of forming a laminate of prepregs and a step of molding at least a part of the laminate into a curved portion. In this method, an intermediate member made of a thermoplastic resin is interposed between at least one or more layers of a portion of the laminated body to be molded into a curved portion. Specifically, the intermediate member is interposed so that the actual length in the direction corresponding to the circumferential direction of the curved portion is longer in the prepreg formed in the outermost layer than in the prepreg formed in the innermost layer. Then, the intermediate member is heated and melted to bend the above portion.

Another aspect of the present invention is a method for molding a fiber preform, which comprises a step of forming a fiber laminate and a step of molding at least a part of the fiber laminate into a curved portion. In this method, an intermediate member made of a thermoplastic resin is interposed between at least one or more layers of a portion of the fiber laminate to be molded into a curved portion. Specifically, the intermediate member is interposed so that the actual length in the direction corresponding to the circumferential direction of the curved portion is longer in the fiber base material formed in the outermost layer than in the fiber base material formed in the innermost layer. Then, the intermediate member is heated and melted to bend the above portion.

According to the above molding method, it is possible to suppress a decrease in strength of the curved portion while suppressing an increase in cost due to an increase in the number of members.

It is a figure explaining the process of forming the laminated body of a prepreg. It is a figure explaining the process of molding a part of a laminated body into a curved portion. It is a figure explaining the process of molding a part of a laminated body into a curved portion. It is a figure explaining the process of molding a part of a laminated body into a curved portion. It is a perspective view of a sheet-shaped or strip-shaped intermediate member. It is sectional drawing which shows the thread-like intermediate base material which forms the degassing passage. It is a perspective view which shows the granular intermediate member. It is a figure explaining the modification of the process of forming a laminated body of a prepreg. It is a figure explaining the process of forming a fiber laminate. It is a figure explaining the process of molding a part of a fiber laminate into a curved portion. It is a figure explaining the process of molding a part of a fiber laminate into a curved portion. It is a figure explaining the process of molding a part of a fiber laminate into a curved portion. It is a perspective view which shows the thread-like intermediate member fixed to the fiber base material.

Hereinafter, some embodiments and modifications thereof will be described with reference to FIGS. 1 to 13.

<First Embodiment>
The first embodiment is a method for molding a fiber-reinforced composite material CM (hereinafter, also referred to as “composite material CM”). In this method, first, as shown in FIG. 1, a sheet-like prepreg P ₁ to P ₄ which is impregnated with a resin R into the reinforcing fibers F in a semi-cured state is cut into a predetermined shape, and laminating these layered Form body 1.

Reinforcing fibers F of the prepreg P ₁ to P ₄ are aligned in one direction, consisting of substantially continuous fibers which are arranged parallel to one another. The form of the reinforcing fiber F is not particularly limited, and may be, for example, a woven fabric such as a biaxial woven fabric or a triaxial woven fabric, a multiaxial stitched base material, or the like. The material of the reinforcing fiber F is not particularly limited, and for example, carbon fiber, glass fiber, polyaramid fiber, alumina fiber, boron fiber, silicon carbide fiber and the like can be used. As the carbon fiber, for example, polyacrylonitrile (PAN-based), pitch-based, cellulose-based, hydrocarbon-based vapor-growth-based carbon fiber, graphite fiber, or the like can be used. Two or more kinds of these fibers may be used in combination.

The continuous fiber is a fiber in which the filaments constituting the reinforcing fiber F are continuous, and the average fiber length thereof is not particularly limited, but is, for example, 500 [mm] or more. The average fiber length can be obtained as a value obtained by dividing the sum of the squares of the fiber lengths of the filaments constituting the reinforcing fiber F by the sum of the fiber lengths of the filaments. The fiber length of each filament can be measured by observing the length of each filament with an optical microscope or the like.

Resin as a matrix material of the prepreg P ₁ to P ₄ R, it is possible to use a thermosetting resin. Specific examples thereof include epoxy resin, phenol resin, unsaturated polyester resin, vinyl ester resin, and polyimide resin. The resin R may contain a thermoplastic resin such as a polycarbonate resin, a polyamide resin, and a polyphenylene sulfide (PPS) resin.

Next, the formed laminate 1 is set in the molding die 10 as shown in FIG. The molding die 10 has an upper die 11 and a lower die 12 as shown in FIGS. 2 to 4. The upper mold 11 has a molding surface 11a for molding the upper surface of the composite material CM, and the lower mold 12 has a molding surface 12a for molding the lower surface of the composite material CM. The molding surface 12a of the lower mold 12 includes a convex surface 12b that is convexly curved toward the molding surface 11a of the upper mold 11, and the molding surface 11a of the upper mold 11 is concavely curved toward the molding surface 12a of the lower mold 12. Includes the concave surface 11b. When the molding die 10 is closed, the concave surface 11b faces the convex surface 12b at a predetermined distance (for example, a distance corresponding to the thickness of the composite material CM) from the convex surface 12b.

Next, as shown in FIG. 3, the upper die 11 is moved (lowered) toward the lower die 12, and the laminated body 1 is heated by the upper die 11 and the lower die 12 while being laminated on the convex surface 12b by the concave surface 11b. By pressing the body 1, the laminated body 1 is curved convexly toward the molding surface 11a of the upper mold 11. Then, the molding die 10 is closed, and as shown in FIG. 4, the laminate 1 is molded by pressurizing and heating the upper die 11 and the lower die 12 at a predetermined temperature (for example, the curing temperature of the resin R). To do. As a result, the composite material CM having the curved portion B1 which is the first curved portion is formed. Then, the mold is opened and the molded composite material CM is taken out from the molding mold 10.

In the step of forming the laminated body 1, as shown in FIG. 1, an intermediate member 2 is interposed between each layer of a portion B1a (hereinafter, referred to as “part B1a”) formed in the curved portion B1 of the laminated body 1. .. Specifically, the circumferential direction X direction corresponds to (see FIG. 4) Xa curved portion B1 (hereinafter, referred to as "Xa direction") actual length of the prepreg _P 1 to P ₄ in the more outer curved portion B1 An intermediate member 2 is interposed between each layer of the portion B1a so as to be longer as the prepreg formed in the layer of. Incidentally, the difference between the actual length between each other prepreg P ₁ to P ₄ in the difference in circumferential length, i.e., the portion B1a between layers adjacent to each other in the curved section B1 can be easily determined by calculation. For example, when the thickness of each layer is t [mm] and the radius of curvature of the convex surface 12b in the angle range of θ [rad] is constant, the difference in actual length is tθ [mm]. When the shape of the curved portion B1 is more complicated, the actual length of each layer may be obtained by drawing.

As shown in FIG. 5, the intermediate member 2 is the sheet-shaped or strip-shaped member 2A made of the thermoplastic resin. Since it is made of thermoplastic resin, it is easy to handle in a normal temperature environment. In the present embodiment, the sheet-shaped or strip-shaped member 2A is formed in a net shape by knitting the molten yarn made of the thermoplastic resin. The thickness is not particularly limited, but is, for example, about 0.1 [mm].

Further, when the portion B1a of the laminated body 1 is curved, the intermediate member 2 is heated by pressing the portion B1a against the concave surface 11b and the convex surface 12b of the molded surfaces 11a and 12a to heat the intermediate member 2, and this is gradually melted. Curve while.

Hereinafter, the action and effect of the present embodiment will be described.

(1) In the molding method of the present embodiment, in a portion B1a of the laminate 1, the actual length of the Xa direction of the prepreg P ₁ to P ₄ is longer as a prepreg that is molded into a more outer layer of the curved portion B1 An intermediate member 2 is interposed between each layer of the portion B1a so as to be. Then, the intervening intermediate member 2 is heated and melted to bend the portion B1a. In other words, the intermediate member 2 holds each prepreg so that the actual length of the portion B1a becomes longer as the prepreg of the outer layer of the curved portion B1 becomes longer when the portion B1a is not curved, and the portion B1a starts bending. At the stage after this, it melts and releases the holding. Therefore, when the portion B1a is curved in the thickness direction, the excess or deficiency of the fibers caused by the difference in the peripheral length of each layer can be suppressed as compared with the case where the intermediate member 2 is not interposed. As a result, buckling due to excess fibers in the inner layer and pulling of fibers inward in the radial direction of the curved portion B1 due to insufficient fiber length in the outer layer can be suppressed, and the composite material CM which is a molded product can be used. The appearance can be improved.

(2) Further, according to this method, unlike the technique of Patent Document 1, an additional member (for example, a prepreg) is not required, and an increase in cost due to an increase in the number of members can be suppressed. Further, unlike the technique of Patent Document 1, it is not necessary to form a notch, and the strength of the curved portion B1 of the composite material CM can be maintained high.

(3) Further, according to this method, molten intermediate member 2 thermoplastic resin, spreading the interlayer gap of the curved portion B1, or to penetrate into the resin R prepreg P ₁ to P _4, the curved portion It is possible to suppress the generation of cracks in B1 or the growth of the generated cracks.

(4) Further, in this method, since the intermediate member 2 is a sheet-shaped or strip-shaped member 2A made of a thermoplastic resin, it is possible to maintain a state in which adjacent layers of the portions B1a are separated from each other in a surface region. .. Further, in this method, the shape and area (length, width, etc.) of the regions to be separated can be accurately controlled by cutting the sheet-shaped or strip-shaped member 2A into a desired shape. The form of the sheet-shaped or strip-shaped member 2A is not limited to the net-like shape, but may be a cloth-like shape, a film-like shape, or the like.

<Modification example>
The intermediate member 2 is interposed between each layer of the portion B1a (when the total number of layers is n, all n-1 layers), but the present invention is not limited to this. For example, an intermediate member 2 is interposed any one or more n-1 less than the interlayer, the actual length in the Xa direction, than the prepreg P ₄ that is formed on at least the innermost layer lengthened prepreg P ₁ to be molded as the outermost layer It may be. According to this modification, when the portion B1a is curved, the excess or deficiency of fibers caused by the difference in peripheral length between the innermost layer and the outermost layer can be suppressed by a smaller number of intermediate members 2. As a result, buckling due to excess fibers in the innermost layer and pulling of fibers inward in the radial direction of the curved portion B1 due to insufficient fiber length in the outermost layer can be suppressed, and the composite material CM which is a molded product can be used. The appearance can be improved.

Further, the intermediate member 2 may be a plurality of filamentous members 2B made of the above-mentioned thermoplastic resin. In this case, as shown in FIG. 6, a plurality of filamentous members 2B may be arranged side by side so as to extend in one direction to form a minute degassing path 3 along the filamentous member 2B. According to this modification, it becomes easy to guide the gas such as air remaining in the interlayer gap to the outside through the degassing path 3 at the time of pressure molding, so that the formation of voids in the composite material CM can be prevented. Examples of the thread-like member 2B forming the degassing path 3 include a large-diameter molten thread made of a thermoplastic resin or a bundle (toe) of the molten thread. Large-diameter molten yarns or bundles of molten yarns may be connected to each other by molten yarns having a smaller diameter. The size of the diameter of the molten yarn is not particularly limited, but is a large-diameter molten yarn or a bundle of molten yarns, for example, about 0.1 to 0.5 [mm].

Further, as shown in FIG. 7, the intermediate member 2 may be the granular member 2C made of the thermoplastic resin. According to this modification, the thickness of the intermediate member 2 can have a distribution in the plane direction (for example, a distribution in the Xa direction and a distribution in the Y direction orthogonal to the Xa direction). For example, in a case where the difference between the actual length of the Xa direction between the prepreg P ₁ to P ₄ between the portions B1a gradually changes in accordance with the Y-direction position, it is easy to adjust the difference of the actual length. The granular member 2C can be produced by cutting, for example, a plurality of strands (about 0.1 [mm] in diameter) made of a thermoplastic resin into a desired length with a cutter.

In the above embodiment and its modification, as shown in FIG. 1, but to form a laminated body 1 by stacking prepregs P ₁ to P ₄ on a flat surface 14, as shown in FIG. 8 to, it may form a laminate 1 by laminating the prepregs P ₁ to P ₄ on the surface where recesses 15 are formed. Specifically, the prepreg P ₁ to be molded as the outermost layer, on the surface where recesses 15 are formed, placed in alignment so that the recess 15 and portions B1a facing, the prepreg P ₁ over, it may be sequentially stacked prepregs P ₂ to P ₄ to be molded in the inner layer than the outermost layer.

The portion B1a of the laminated body 1 formed by this method is curved in the opposite direction to the curved portion B1 due to the convex surface and the concave surface (not shown) in which the directions of the convex surface 12b and the concave surface 11b are opposite to each other. It can be molded into a part (not shown). That is, the convex surface in this case is a curved surface provided on the molding surface 11a of the upper mold 11 and curved convexly toward the molding surface 12a of the lower mold 12, and the concave surface is provided on the molding surface 12a of the lower mold 12. , A curved surface that is concavely curved toward the molding surface 11a of the upper mold 11. By pressing the laminated body 1 against the concave surface with this convex surface and bending the laminated body 1 while heating, the portion B1a can be formed into a curved portion that is convexly curved toward the molding surface 12a of the lower mold 12. it can.

Further, in this method, when the prepreg is placed on the surface on which the recess 15 is formed, at least the central portion of the prepreg portion B1a in the Xa direction is recessed by its own weight, so that the position where the intermediate member 2 should be arranged is determined. , It can be determined from the surface height of the prepreg. As a result, the work efficiency of the process of forming the laminated body 1 is improved.

<Second Embodiment>
Next, the second embodiment will be described with reference to FIGS. 9 to 12. In the description of the present embodiment, only the configurations different from those of the first embodiment and its modified examples will be described, and the elements having the same functions as the elements already described will be described by adding the same reference numerals. Is omitted.

The second embodiment is a method for forming a fiber preform PF. In this method, first, as shown in FIG. 9, sheet-shaped fiber base materials F _{1 to} F ₄ made of continuous fibers are cut into a predetermined shape, and these are laminated to form a fiber laminate 4.

The fiber base materials F _{1 to} F ₄ are composed of the reinforcing fibers F (reinforcing fibers F in a state not impregnated with the resin R) in the prepregs P _{1 to} P ₄ . The fiber base materials F _{1 to} F ₄ may be impregnated with an adhesive. By applying the adhesive, when the fiber base materials F _{1 to} F ₄ are shaped into a desired shape, the fiber base materials F _{1 to} F ₄ are adhered to each other, and the shape can be easily maintained. The material of the adhesive is not particularly limited, and the above-mentioned thermoplastic resin or thermosetting resin can be adopted.

Next, the formed fiber laminate 4 is set in the molding die 20 as shown in FIG. The molding die 20 has an upper die 21 and a lower die 22 as shown in FIGS. 10 to 12. Since the configurations of the upper mold 21 and the lower mold 22, the concave surface 21b and the convex surface 22b are the same as the configurations of the upper mold 11 and the lower mold 12, and the concave surface 11b and the convex surface 12b of the first embodiment, the description thereof will be omitted.

Next, as shown in FIG. 11, the upper mold 21 is moved (lowered) toward the lower mold 22, and while the fiber laminate 4 is heated by the upper mold 21 and the lower mold 22, the concave surface 21b becomes a convex surface 22b. By pressing the fiber laminate 4, the fiber laminate 4 is curved convexly toward the molding surface 21a of the upper mold 21. Then, as shown in FIG. 12, the fiber laminate 4 is sandwiched between the upper mold 21 and the lower mold 22 and pressed with a predetermined pressure to form the fiber laminate 4 into a desired shape. As a result, the fiber preform PF having the curved portion B2 which is the second curved portion is formed. Then, the mold is opened and the molded fiber preform PF is taken out from the molding mold 20.

The obtained fiber preform PF is impregnated with resin R by a resin transfer molding method (RTM method), a wet press method, or the like, and is formed into a composite material CM by pressurizing and heating the resin R at a predetermined temperature. Can be done.

In the step of forming the fiber laminate 4, as shown in FIG. 9, an intermediate member 2 is provided between each layer of the portion B2a (hereinafter, referred to as “part B2a”) formed in the curved portion B2 of the fiber laminate 4. Intervene. Specifically, the actual lengths of the fiber base materials F _{1 to} F ₄ in the Xa direction corresponding to the circumferential direction X of the curved portion B2 (see FIG. 12) are formed in the outer layer of the curved portion B2. An intermediate member 2 is interposed between each layer of the portion B2a so that the material becomes longer.

The intermediate member 2 is the sheet-shaped or strip-shaped member 2A (see FIG. 5). When bending the portion B2a of the fiber laminate 4, the intermediate member 2 is heated by pressing the portion B2a against the concave surface 21b and the convex surface 22b of the molded surfaces 21a and 22a, and the intermediate member 2 is gradually melted. Curve.

Hereinafter, the action and effect of the present embodiment will be described.

(5) In the molding method of the present embodiment, in a portion B2a of the fiber laminate 4, the actual length of the Xa direction of the fiber base material F ₁ to F ₄ is shaped into a more outer layer of the curved portion B2 An intermediate member 2 is interposed between each layer of the portion B2a so as to be longer as the fiber base material. Then, the intervening intermediate member 2 is heated and melted to bend the portion B2a. In other words, the intermediate member 2 holds each fiber base material so that the actual length of the portion B2a becomes longer as the fiber base material of the outer layer of the curved portion B2 becomes longer when the portion B2a is not curved, and the portion B2a At the stage after the start of bending, it melts and releases the holding. Therefore, when the portion B2a is curved in the thickness direction, the excess or deficiency of the fibers caused by the difference in the peripheral length of each layer can be suppressed as compared with the case where the intermediate member 2 is not interposed. As a result, buckling due to excess fibers in the inner layer and pulling of fibers inward in the radial direction of the curved portion B2 due to insufficient fiber length in the outer layer can be suppressed, and the appearance of the fiber preform PF and eventually the appearance of the fiber preform PF can be suppressed. , The appearance of the composite material CM which is a molded product can be improved.

(6) Further, according to this method, unlike the technique of Patent Document 1, it is not necessary to form a notch or add a member, and the composite material CM, which is a molded product, is curved while suppressing an increase in cost. The strength of the part can be maintained high.

(7) Further, according to this method, the thermoplastic resin of the molten intermediate member 2 permeates into the layers or layers of the curved portion B2, so that cracks occur in the curved portion of the composite material CM which is a molded product. The growth of generated cracks can be suppressed.

Further, since the intermediate member 2 is a sheet-shaped or strip-shaped member 2A made of a thermoplastic resin, it is possible to obtain the same action and effect as the above-mentioned action and effect of (4).

<Modification example>
The intermediate member 2 is interposed between each layer of the portion B2a (when the number of layers is n, all n-1 layers), but the present invention is not limited to this. For example, an intermediate member 2 is interposed any one or more n-1 less than the interlayer, the actual length in the Xa direction, the fiber substrate to be formed on the outermost layer than the fiber base material F ₁ which is molded into at least the innermost layer it may be longer in the F _4. According to this modification, when the portion B2a is curved, the excess or deficiency of fibers caused by the difference in peripheral length between the innermost layer and the outermost layer can be suppressed by a smaller number of intermediate members 2. As a result, buckling due to excess fibers in the innermost layer and pulling of fibers inward in the radial direction of the curved portion B2 due to insufficient fiber length in the outermost layer can be suppressed, and the appearance of the molded product can be improved. Can be done.

Further, the intermediate member 2 may be the thread-like member 2D made of the thermoplastic resin. In this case, the thread-like members 2D may previously fixed on the fiber base material _F 1 to F ₄ parts B2a. For example, as shown in FIG. 13, if the fiber base material F ₁ is composed of non-crimp fabric material formed into a sheet by knitting a plurality of fiber bundles arranged in one direction in the knitting yarn 5, the thread-like members 2D it may incorporate utilizing the knitting yarn 5 in the fiber base material F _1. Although not shown, the thread-like member 2D may be woven into the fiber base materials F _{1 to} F ₄ made of a woven fabric as a part of warp or weft. Further, the threadlike members 2D may be sewn in the stitch yarn at any position of the fiber base material F ₁ to F _4, or may be fixed with an adhesive. By pre-fixing filamentous member 2D in the fiber base material F ₁ to F _4, it improves the efficiency of the process by laminating the fibrous base material F ₁ to F ₄ to form a fiber laminate 4, a portion B2a It is possible to prevent the intermediate member 2 from being displaced when it is curved. The diameter of the thread-like member 2D is not particularly limited, but is such that the thread-like member 2D protrudes from the surface of the portion B2a by about 0.1 [mm] when fixed to the portion B2a. Is preferable.

Further, when forming the fiber laminate 4, as in the modification shown in FIG. 8 of the first embodiment, by laminating the fiber base material F ₁ to F ₄ on the recess formed surface fibers The laminated body 4 may be formed. Specifically, the fiber base material F ₁ to be molded as the outermost layer, on the surface where recesses are formed, placed in alignment so that the recesses and portions B2a faces, its fiber base The fiber base materials F _{2 to} F ₄ formed in a layer inside the outermost layer may be sequentially laminated on F ₁ . The portion B2a of the fiber laminate 4 formed by this method is curved in the opposite direction to the curved portion B2 due to the convex surface and the concave surface (not shown) in which the directions of the convex surface 22b and the concave surface 21b and the uneven surface are opposite to each other. It can be molded into a curved portion (not shown). Further, according to this modification, when the fiber base material is placed on the surface on which the recess is formed, at least the central portion of the fiber base material portion B2a in the Xa direction is dented by its own weight, and thus the first embodiment. It is possible to obtain the same effect as that of the modified example shown in FIG.

The first and second embodiments and their modifications may be applied in combination of any two or more. In the embodiment relating to the combination, the effect of each of the combined elements can be obtained.

The above embodiments and modifications are merely examples described for facilitating the understanding of the invention. The technical scope of the invention is not limited to the specific technical matters disclosed in the above-described embodiments and modifications, but also includes various modifications, modifications, and alternative techniques that can be easily derived from the specific technical matters.

The molding method according to the above-described embodiment and modification can be applied as a method for pre-molding or main molding of a fiber-reinforced composite material or a fiber preform thereof. Further, these molding methods can be applied as a molding method of a fiber reinforced composite material such as a pillar, a side sill, a suspension member, a bumper, a fender panel, etc., which constitutes a vehicle such as an automobile, or a fiber preform thereof.

CM Fiber Reinforced Composite 1 Laminated Body P _{1 to} P ₄ Prepreg F Reinforced Fiber (Continuous Fiber)
R resin B1 curved part (first curved part)
B1a Part molded into the curved part PF Fiber preform 4 Fiber laminate F _{1 to} F ₄ Fiber base material B2 Curved part (second curved part)
B2a Part formed into the curved part X Circumferential direction of the curved part Xa Direction corresponding to the circumferential direction 2 Intermediate member 2A Sheet-shaped or strip-shaped member (intermediate member)
2B, 2D thread-like member (intermediate member)
2C granular member (intermediate member)
3 Degassing path 15 Recess

Claims (11)

A process of laminating a plurality of sheet-shaped prepregs formed by impregnating continuous fibers with resin to form a laminate, and
A step of bending at least a part of the laminated body to form a first curved portion,
Including
In the portion of the laminated body formed on the first curved portion, the actual length of the prepreg in the direction corresponding to the circumferential direction of the first curved portion is the prepreg formed on the innermost layer of the first curved portion. An intermediate member made of a thermoplastic resin is interposed between at least one or more layers of the portion so as to be longer in the prepreg formed in the outermost layer of the first curved portion.
A method for forming a fiber-reinforced composite material, which comprises bending the portion while heating and melting the intermediate member. The fiber reinforcement according to claim 1, wherein the intermediate member is interposed between each layer of the portion so that the actual length becomes longer as the prepreg is formed in the outer layer of the first curved portion. Method of molding composite material. The method for molding a fiber-reinforced composite material according to claim 1 or 2, wherein the intermediate member includes a sheet-shaped or strip-shaped member made of a thermoplastic resin. The intermediate member includes a plurality of thread-like members made of a thermoplastic resin.
Any one of claims 1 to 3, wherein the plurality of filamentous members are arranged side by side so as to extend in one direction, and a degassing path along the filamentous member is formed between the layers. The method for molding a fiber-reinforced composite material according to. The method for molding a fiber-reinforced composite material according to any one of claims 1 to 4, wherein the intermediate member includes a granular member made of a thermoplastic resin. Any of claims 1 to 5, wherein the step of forming the laminate includes a step of placing the prepreg on a surface on which the recess is formed so that the recess and the portion face each other. The method for forming a fiber-reinforced composite material according to item 1. A process of laminating a plurality of sheet-shaped fiber base materials made of continuous fibers to form a fiber laminate, and
A step of bending at least a part of the fiber laminate to form a second curved portion,
Including
In the portion of the fiber laminate that is molded into the second curved portion, the actual length of the fiber base material in the direction corresponding to the circumferential direction of the second curved portion is molded into the innermost layer of the second curved portion. An intermediate member made of a thermoplastic resin is interposed between at least one or more layers of the portion so that the fibrous substrate formed in the outermost layer of the second curved portion is longer than the fiber substrate to be formed.
A method for forming a fiber preform, which comprises bending the portion while heating and melting the intermediate member. The seventh aspect of claim 7, wherein the intermediate member is interposed between each layer of the portion so that the fiber base material formed in the outer layer of the second curved portion has a longer actual length. How to mold fiber preform. The method for molding a fiber preform according to claim 7 or 8, wherein the intermediate member includes a sheet-shaped or strip-shaped member made of a thermoplastic resin. The intermediate member includes a thread-like member made of a thermoplastic resin.
The method for molding a fiber preform according to any one of claims 7 to 9, further comprising a step of fixing the filamentous member to the portion. 7. To claim 7, wherein the step of forming the fiber laminate includes a step of placing the fiber base material on a surface on which the recess is formed so that the recess and the portion face each other. The method for molding a fiber preform according to any one of 10.

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