JP2013095112A - Dry preform of composite material and method for manufacturing the same - Google Patents

Dry preform of composite material and method for manufacturing the same Download PDF

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JP2013095112A
JP2013095112A JP2011242384A JP2011242384A JP2013095112A JP 2013095112 A JP2013095112 A JP 2013095112A JP 2011242384 A JP2011242384 A JP 2011242384A JP 2011242384 A JP2011242384 A JP 2011242384A JP 2013095112 A JP2013095112 A JP 2013095112A
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mandrel
reinforcing fiber
dry preform
longitudinal direction
fiber layer
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JP5889604B2 (en
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Tetsuro Hirokawa
哲朗 広川
Shigeru Nishiyama
西山　　茂
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Shikibo Ltd
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Abstract

PROBLEM TO BE SOLVED: To improve yield, to facilitate arrangement of reinforced fiber in the longitudinal direction, and to increase density of the reinforced fiber in the longitudinal direction, when forming a dry preform by winding the reinforced fiber around an outer periphery of a mandrel.SOLUTION: While the long mandrel 2 is sent to one side in the longitudinal direction, the reinforced fiber (a fiber bundle T1) aligned along the longitudinal direction is supplied to the outer periphery of the mandrel 2 to form a longitudinal reinforced fiber layer 11 covering the circumference of the mandrel 2. The reinforced fiber (fiber bundles T2, T3) is spirally wound around the outer periphery of the mandrel 2 to form spiral reinforced fiber layers 12, 13 covering the circumference of the mandrel 2.

Description

本発明は、複合材のドライプリフォーム及びその製造方法に関する。   The present invention relates to a composite dry preform and a method for producing the same.

強化繊維に樹脂を含浸・固化させてなる複合材は、軽量且つ高強度であるため、航空機等に用いられる。特に、複数の強化繊維を引き揃えてなる強化繊維層を積層した複合材は、強化繊維を密に配することができるため強度が非常に高い。このような複合材を筒状に形成する方法として、例えば引抜き成形法やフィラメントワインディング法（以下、ＦＷ法と言う。）が知られている。   A composite material obtained by impregnating and solidifying a resin in a reinforcing fiber is lightweight and has high strength, and thus is used for an aircraft or the like. In particular, a composite material in which a reinforcing fiber layer formed by arranging a plurality of reinforcing fibers is laminated has a very high strength because the reinforcing fibers can be densely arranged. As a method for forming such a composite material into a cylindrical shape, for example, a pultrusion method or a filament winding method (hereinafter referred to as FW method) is known.

引抜き成形法は、樹脂を含浸させた繊維を長尺のマンドレルの外周に沿って引き揃えて配し、この繊維を長手方向に引っ張りながらダイスの内孔を通すことにより所定の断面形状に成形した後、樹脂を加熱して固化させることにより複合材を連続成形するものである（例えば、特許文献１参照）。   In the pultrusion molding method, fibers impregnated with resin are arranged along the outer periphery of a long mandrel, and the fibers are molded into a predetermined cross-sectional shape by passing through the inner hole of the die while pulling the fibers in the longitudinal direction. Thereafter, the composite is continuously formed by heating and solidifying the resin (see, for example, Patent Document 1).

一方、ＦＷ法は、長尺のマンドレルの外周に樹脂を含浸させた強化繊維を、螺旋状に捲回しながら長手方向で往復させることにより、強化繊維層を積層するものである（例えば、特許文献２参照）。   On the other hand, in the FW method, a reinforcing fiber layer is laminated by reciprocating a reinforcing fiber impregnated with resin on the outer periphery of a long mandrel in the longitudinal direction while spirally winding (for example, Patent Documents). 2).

特開平１０−１６６４６７号公報JP-A-10-166467 特開２０１０−０００６９２号公報JP 2010-000692 A

しかし、引抜き成形では、多数のボビンから供給された強化繊維を、ダイスの成形穴を通すことにより成形しているため、断面形状は長手方向で一定とせざるを得ず、成形品の形状が制約される。また、引抜き成形法では、強化繊維が、引抜き装置による張力のみでダイスの成形穴の内周面に押し付けられているに過ぎないため、強化繊維が成形穴の内周面に完全に倣わず、成形品の寸法精度が低下する恐れがある。   However, in pultrusion molding, reinforcing fibers supplied from a large number of bobbins are molded by passing through the molding holes in the die, so the cross-sectional shape must be constant in the longitudinal direction, and the shape of the molded product is restricted. Is done. In the pultrusion method, the reinforcing fibers are merely pressed against the inner peripheral surface of the die forming hole only by the tension from the drawing device, so that the reinforcing fibers do not completely follow the inner peripheral surface of the forming hole. There is a risk that the dimensional accuracy of the molded product is lowered.

一方、ＦＷ法では、マンドレルの外周に強化繊維を捲回することにより、成形品がマンドレルの外周形状に倣って精度良く成形される。また、マンドレルの形状を変更することで、成形品の形状を自由に設計できる。しかし、ＦＷ法では、強化繊維をマンドレルの外周に螺旋状に捲回しながら長手方向に往復させるため、マンドレルの長手方向両端部で折り返す必要がある。筒状の複合材を成形する場合、通常、この折り返し部分の強化繊維層は廃棄されるため、歩留まりが低下する。また、ＦＷ法では、マンドレルに捲回する方向（螺旋方向）の繊維は供給しやすいが、マンドレルの長手方向に沿った繊維は供給しにくい。このため、例えば、マンドレルの長手方向両端に外径に突出したピンを設け、このピンの間を掛け渡すようにして長手方向の繊維を予め配置する必要がある。この場合、長手方向の強化繊維の配置に非常に手間がかかる。特に、マンドレルが湾曲している場合や、マンドレルの断面形状が長手方向で異なる場合には、マンドレルの外周に長手方向の強化繊維を配置することが極めて困難となる。   On the other hand, in the FW method, the reinforcing fiber is wound around the outer periphery of the mandrel, so that the molded product is accurately molded following the outer peripheral shape of the mandrel. Moreover, the shape of the molded product can be freely designed by changing the shape of the mandrel. However, in the FW method, the reinforcing fiber is reciprocated in the longitudinal direction while spirally wound around the outer periphery of the mandrel, so that it is necessary to fold back at both ends in the longitudinal direction of the mandrel. When a cylindrical composite material is molded, the reinforced fiber layer in the folded portion is usually discarded, so that the yield decreases. In the FW method, fibers in the winding direction (spiral direction) are easy to supply, but fibers along the longitudinal direction of the mandrel are difficult to supply. For this reason, for example, it is necessary to provide pins protruding in the outer diameter at both ends in the longitudinal direction of the mandrel and arrange the fibers in the longitudinal direction in advance so as to span between the pins. In this case, it takes much time to arrange the reinforcing fibers in the longitudinal direction. In particular, when the mandrel is curved or when the cross-sectional shape of the mandrel is different in the longitudinal direction, it is extremely difficult to arrange the reinforcing fibers in the longitudinal direction on the outer periphery of the mandrel.

本発明は、マンドレルの外周に強化繊維を捲回することによりドライプリフォームを成形するにあたり、歩留まりを高めると共に、長手方向の強化繊維の配置を容易化することを目的とする。   An object of the present invention is to increase the yield and facilitate the arrangement of reinforcing fibers in the longitudinal direction when forming a dry preform by winding reinforcing fibers on the outer periphery of a mandrel.

上記の目的を達成するためになされた本発明は、複数の強化繊維層を積層してなる筒状のドライプリフォームを成形するための方法であって、長尺状のマンドレルを長手方向一方に送りながら、長手方向に沿って引き揃えた複数の強化繊維束をマンドレルの外周に供給することによりマンドレルの全周を覆う長手方向強化繊維層を形成すると共に、マンドレルの外周に螺旋状に強化繊維束を捲回することによりマンドレルの全周を覆う螺旋方向強化繊維層を形成するものである。   The present invention made to achieve the above object is a method for forming a cylindrical dry preform formed by laminating a plurality of reinforcing fiber layers, and a long mandrel is fed in one longitudinal direction. However, by supplying a plurality of reinforcing fiber bundles aligned along the longitudinal direction to the outer periphery of the mandrel, a longitudinal reinforcing fiber layer covering the entire periphery of the mandrel is formed, and the reinforcing fiber bundle is spirally formed on the outer periphery of the mandrel. The spiral reinforcing fiber layer covering the entire circumference of the mandrel is formed by winding the wire.

上記の成形方法により、長尺状のマンドレルの外周面で成形された筒状のドライプリフォームであって、長手方向に沿って引き揃えられ、全周に敷き詰められた強化繊維からなる長手方向強化繊維層と、長手方向と交差する方向に沿って引き揃えられ、全周に敷き詰められた強化繊維からなる螺旋方向強化繊維層とを有するドライプリフォームを得ることができる。   A cylindrical dry preform formed on the outer peripheral surface of a long mandrel by the above-described forming method, which is a longitudinal reinforcing fiber composed of reinforcing fibers that are aligned along the longitudinal direction and spread all around the circumference. It is possible to obtain a dry preform having a layer and a spiral direction reinforcing fiber layer made of reinforcing fibers that are aligned along the direction intersecting the longitudinal direction and spread all around.

上記のように、本発明のドライプリフォームの成形方法では、マンドレルを長手方向一方に送りながら、マンドレルの全周を長手方向強化繊維層及び螺旋方向強化繊維で覆う（ラッピングする）ことで、配向方向の異なる複数の強化繊維層を積層している。これにより、ＦＷ法のようにマンドレルの長手方向で強化繊維を往復させる必要がないため、折り返しによる強化繊維の無駄が省かれ、歩留まりが高められる。また、マンドレルを長手方向に送りながら、長手方向に引き揃えた複数の強化繊維束をマンドレルの外周に連続的に供給することで、予めマンドレルの外周に長手方向の強化繊維を配置する場合と比べて、長手方向の強化繊維の配置が容易化される。   As described above, in the dry preform molding method of the present invention, the entire circumference of the mandrel is covered (wrapped) with the longitudinal reinforcing fiber layer and the spiral reinforcing fiber while the mandrel is fed in one longitudinal direction. A plurality of reinforcing fiber layers having different sizes are laminated. This eliminates the need to reciprocate the reinforcing fibers in the longitudinal direction of the mandrel as in the FW method, thereby eliminating waste of reinforcing fibers due to folding and increasing the yield. In addition, by continuously supplying a plurality of reinforcing fiber bundles aligned in the longitudinal direction to the outer periphery of the mandrel while feeding the mandrel in the longitudinal direction, compared to the case where the longitudinal reinforcing fibers are previously arranged on the outer periphery of the mandrel Thus, the arrangement of the reinforcing fibers in the longitudinal direction is facilitated.

上記のドライプリフォームの形成方法において、強化繊維束が捲回されたボビンを、マンドレルの外周を周方向一方に周回させることにより、第１の螺旋方向強化繊維層を形成すると共に、上記のボビンと長手方向に離隔した箇所で、強化繊維束が捲回された他のボビンを、マンドレルの外周を周方向他方に周回させることにより、第２の螺旋方向強化繊維層を形成すれば、配向方向の異なる複数の強化繊維層を連続的に積層することができる。   In the dry preform forming method, the bobbin on which the reinforcing fiber bundle is wound is rotated around the outer periphery of the mandrel in one circumferential direction, thereby forming the first spiral reinforcing fiber layer, and the bobbin and If the second spiral direction reinforcing fiber layer is formed by rotating the outer periphery of the mandrel in the other circumferential direction by rotating the other bobbin around which the reinforcing fiber bundle is wound at a place separated in the longitudinal direction, A plurality of different reinforcing fiber layers can be continuously laminated.

長手方向強化繊維層をマンドレルの外周に形成した後、この長手方向強化繊維層をマンドレルの外周に仮固定すれば、マンドレルが湾曲した場合や、マンドレルの断面形状が長手方向で異なる場合であっても、マンドレルの外周面形状に沿って長手方向強化繊維層を配置することができる。尚、「仮固定」とは、強化繊維層に樹脂を含浸・固化して完全に固定する工程とは別に設けられるものであり、強化繊維層をマンドレルの外周に倣わせるために暫定的に固定するものである。また、長手方向強化繊維層のマンドレルへの仮固定は、マンドレルの外周面に長手方向強化繊維層を直接仮固定する場合だけでなく、マンドレルの外周に形成した他の強化繊維層の外周に長手方向強化繊維層を仮固定する場合も含む。   After the longitudinal reinforcing fiber layer is formed on the outer periphery of the mandrel, if this longitudinal reinforcing fiber layer is temporarily fixed to the outer periphery of the mandrel, the mandrel may be curved or the cross-sectional shape of the mandrel may be different in the longitudinal direction. Moreover, a longitudinal direction reinforcing fiber layer can be arrange | positioned along the outer peripheral surface shape of a mandrel. “Temporary fixing” is provided separately from the step of impregnating and solidifying the resin in the reinforcing fiber layer and completely fixing it, and it is provisionally set so that the reinforcing fiber layer follows the outer periphery of the mandrel. It is to be fixed. In addition, the temporary fixing of the longitudinal reinforcing fiber layer to the mandrel is not limited to the case where the longitudinal reinforcing fiber layer is temporarily fixed directly on the outer peripheral surface of the mandrel, but is also extended to the outer periphery of another reinforcing fiber layer formed on the outer periphery of the mandrel. This includes the case where the direction reinforcing fiber layer is temporarily fixed.

上記のドライプリフォーム連続成形方法により筒状のドライプリフォームを成形する工程と、このドライプリフォームに樹脂を含浸固化させる工程とを経ることにより、筒状の複合材を製造することができる。   A cylindrical composite material can be manufactured through a step of forming a cylindrical dry preform by the dry preform continuous molding method and a step of impregnating and solidifying the resin into the dry preform.

以上のように、本発明によれば、マンドレルの外周に強化繊維を捲回することによりドライプリフォームを成形するにあたり、歩留まりを高めると共に、長手方向の強化繊維の配置を容易化することができる。   As described above, according to the present invention, when forming a dry preform by winding reinforcing fibers on the outer periphery of a mandrel, the yield can be increased and the arrangement of reinforcing fibers in the longitudinal direction can be facilitated.

本発明の一実施形態に係るドライプリフォームの成形方法に用いる成形装置の側面図である。It is a side view of the shaping | molding apparatus used for the shaping | molding method of the dry preform which concerns on one Embodiment of this invention. 図１のＸ−Ｘ線から矢印方向に見た断面図である。It is sectional drawing seen from the XX line | wire of FIG. 1 in the arrow direction. 図１のＹ−Ｙ線から矢印方向に見た断面図である。It is sectional drawing seen from the YY line | wire of FIG. 1 in the arrow direction. ドライプリフォームの一部を切り欠いた側面図である。It is the side view which notched a part of dry preform. 他の実施形態に係るドライプリフォームの成形方法に用いる成形装置の側面図である。It is a side view of the shaping | molding apparatus used for the shaping | molding method of the dry preform which concerns on other embodiment. 他の実施形態に係るドライプリフォームの成形方法に用いる成形装置の側面図である。It is a side view of the shaping | molding apparatus used for the shaping | molding method of the dry preform which concerns on other embodiment. マンドレルの外周に補強部材を配置した様子を示す側面図である。It is a side view which shows a mode that the reinforcement member was arrange | positioned on the outer periphery of the mandrel. 補強部材の外周から強化繊維を捲回した様子を示す側面図である。It is a side view which shows a mode that the reinforced fiber was wound from the outer periphery of the reinforcement member. 他の実施形態に係るドライプリフォームの成形方法を示す側面図である。It is a side view which shows the shaping | molding method of the dry preform which concerns on other embodiment.

本発明の一実施形態に係るドライプリフォームは、図１に示す成形装置１を用いて成形される。この成形装置１は、長尺状のマンドレル２と、マンドレル２を長手方向一方（図１の右側）に送る駆動部（図示省略）と、長手方向の強化繊維を供給する長手方向繊維供給部（図示省略）と、螺旋方向の強化繊維を供給する螺旋方向繊維供給部３と、切断部４とを有する。強化繊維としては、例えば炭素繊維やガラス繊維が使用される。尚、以下では、マンドレル２の長手方向一方側（図１の右側）を前方、その反対側を後方と言う。   A dry preform according to an embodiment of the present invention is molded using a molding apparatus 1 shown in FIG. The molding apparatus 1 includes a long mandrel 2, a drive unit (not shown) that sends the mandrel 2 to one side in the longitudinal direction (right side in FIG. 1), and a longitudinal fiber supply unit that supplies reinforcing fibers in the longitudinal direction ( (Not shown), a spiral direction fiber supply unit 3 for supplying reinforcing fibers in the spiral direction, and a cutting unit 4. For example, carbon fiber or glass fiber is used as the reinforcing fiber. In the following, one side of the mandrel 2 in the longitudinal direction (the right side in FIG. 1) is referred to as the front, and the opposite side is referred to as the rear.

マンドレル２は、例えば金属、樹脂、複合材、あるいは水等の溶剤により溶解可能な材料で長尺状に形成される。本実施形態のマンドレル２は、直線状に延び、長手方向で断面形状が一定であり、図示例では断面矩形（正方形）を成している（図２参照）。マンドレル２は、図示しない駆動部で前方に搬送され、後方端部には別のマンドレル２’の前方端部が当接している。   The mandrel 2 is formed in a long shape from a material that can be dissolved by a solvent such as metal, resin, composite, or water. The mandrel 2 of the present embodiment extends linearly and has a constant cross-sectional shape in the longitudinal direction, and forms a rectangular cross section (square) in the illustrated example (see FIG. 2). The mandrel 2 is conveyed forward by a driving unit (not shown), and the front end of another mandrel 2 'is in contact with the rear end.

長手方向繊維供給部は、複数の強化繊維を引き揃えて樹脂で一体化された帯状の繊維束Ｔ１が捲回された複数のボビン（図示省略）を有する。各ボビンから引き出された複数の繊維束Ｔ１は、ガイド５に案内されてマンドレル２の全周に均一に配置され、これによりマンドレル２の全周を覆う長手方向強化繊維層１１が形成される。   The longitudinal fiber supply unit has a plurality of bobbins (not shown) around which a strip-shaped fiber bundle T1 formed by aligning a plurality of reinforcing fibers and integrated with a resin is wound. The plurality of fiber bundles T1 drawn from each bobbin are guided by the guide 5 and are uniformly disposed on the entire circumference of the mandrel 2, thereby forming the longitudinal reinforcing fiber layer 11 covering the entire circumference of the mandrel 2.

螺旋方向繊維供給部３は、複数の強化繊維を引き揃えて樹脂で一体化された帯状の繊維束Ｔ２、Ｔ３がそれぞれ捲回され、長手方向に離隔して配置された複数（本実施形態では２つ）のボビン６、７からなる。図示例では、複数の繊維束Ｔ２、Ｔ３が、シート状に引き揃えた状態でボビン６、７に捲回されている。後方側のボビン６は、図２に示すように、マンドレル２の外周を周方向一方（図中時計回り方向）に周回する。これにより、マンドレル２の外周に形成された長手方向強化繊維層１１の外周に繊維束Ｔ２が螺旋状に捲回され、第１の螺旋方向強化繊維層１２が形成される（図４参照）。また、前方側のボビン７は、図３に示すように、マンドレル２の外周を周方向他方（図中反時計回り方向）に周回し、これにより第１の螺旋方向強化繊維層１２の外周に繊維束Ｔ３が螺旋状に捲回され、第２の螺旋方向強化繊維層１３が形成される（図４参照）。このとき、繊維束Ｔ２、Ｔ３がマンドレル２の外周を一周する間に、マンドレル２が繊維束Ｔ２、Ｔ３の幅の分だけ前方に搬送される。これにより、繊維束Ｔ２、Ｔ３がマンドレル２の外周に隙間なく敷き詰められ、螺旋方向強化繊維層１２、１３がそれぞれマンドレル２の全周を覆うように形成される。図示例では、第１の螺旋方向強化繊維層１２及び第２の螺旋方向強化繊維層１３の配向方向が、長手方向に対して対称となっている。例えば、第１の螺旋方向強化繊維層１２の配向方向が長手方向に対して＋４５°、第２の螺旋方向強化繊維層１３の配向方向が長手方向に対して−４５°となっている（図４参照）。   The spiral-direction fiber supply unit 3 includes a plurality of (in the present embodiment, a plurality of strip-like fiber bundles T2 and T3, which are formed by aligning a plurality of reinforcing fibers and integrated with a resin, and are spaced apart in the longitudinal direction. 2) bobbins 6 and 7. In the illustrated example, a plurality of fiber bundles T2 and T3 are wound around bobbins 6 and 7 in a state of being aligned in a sheet shape. As shown in FIG. 2, the rear bobbin 6 circulates around the outer periphery of the mandrel 2 in one circumferential direction (clockwise direction in the figure). Thereby, the fiber bundle T2 is spirally wound on the outer periphery of the longitudinal reinforcing fiber layer 11 formed on the outer periphery of the mandrel 2, and the first spiral reinforcing fiber layer 12 is formed (see FIG. 4). Further, as shown in FIG. 3, the bobbin 7 on the front side circulates the outer periphery of the mandrel 2 in the other circumferential direction (counterclockwise direction in the figure), and thereby on the outer periphery of the first spiral direction reinforcing fiber layer 12. The fiber bundle T3 is spirally wound to form the second spiral direction reinforcing fiber layer 13 (see FIG. 4). At this time, while the fiber bundles T2 and T3 make one round of the outer periphery of the mandrel 2, the mandrel 2 is conveyed forward by the width of the fiber bundles T2 and T3. Thereby, the fiber bundles T2 and T3 are spread on the outer periphery of the mandrel 2 without a gap, and the spiral direction reinforcing fiber layers 12 and 13 are formed so as to cover the entire periphery of the mandrel 2, respectively. In the illustrated example, the orientation directions of the first spiral direction reinforcing fiber layer 12 and the second spiral direction reinforcing fiber layer 13 are symmetric with respect to the longitudinal direction. For example, the orientation direction of the first spiral direction reinforcing fiber layer 12 is + 45 ° with respect to the longitudinal direction, and the orientation direction of the second spiral direction reinforcing fiber layer 13 is −45 ° with respect to the longitudinal direction (FIG. 4).

以上のようにして、図４に示すように、マンドレル２の外周に、長手方向強化繊維層１１及び螺旋方向強化繊維層１２、１３が積層されてなる長尺筒状のドライプリフォーム１０が形成される。長尺筒状のドライプリフォーム１０の内周面は、マンドレル２の外周面と密着し、マンドレル２の外周面の形状に倣って成形される。   As described above, as shown in FIG. 4, the long cylindrical dry preform 10 in which the longitudinal direction reinforcing fiber layer 11 and the spiral direction reinforcing fiber layers 12 and 13 are laminated is formed on the outer periphery of the mandrel 2. The The inner peripheral surface of the long cylindrical dry preform 10 is in close contact with the outer peripheral surface of the mandrel 2, and is molded following the shape of the outer peripheral surface of the mandrel 2.

このように、マンドレル２を長手方向一方に送りながら、長手方向強化繊維層１１及び螺旋方向強化繊維層１２、１３が積層されるため、ＦＷ法のように強化繊維を折り返す必要が無く、歩留まりが高められる。特に、本実施形態のように、マンドレル２、２’・・・を連続的に成形装置１に供給することにより、長手方向の強化繊維（繊維束Ｔ１）及び螺旋方向の強化繊維（繊維束Ｔ２、Ｔ３）を途切れなく連続的に供給できるため、歩留まりがさらに高められる。   Thus, since the longitudinal direction reinforcing fiber layer 11 and the spiral direction reinforcing fiber layers 12 and 13 are laminated while feeding the mandrel 2 in one longitudinal direction, there is no need to fold up the reinforcing fibers as in the FW method, and the yield is increased. Enhanced. In particular, as in this embodiment, by continuously supplying the mandrels 2, 2 ′, etc. to the molding apparatus 1, longitudinal reinforcing fibers (fiber bundle T1) and spiral reinforcing fibers (fiber bundle T2). , T3) can be continuously supplied without interruption, so that the yield is further increased.

その後、切断部４により、長尺筒状のドライプリフォーム１０が所定の長さで切断され、マンドレル２及びドライプリフォーム１０’の一体品が得られる（図１参照）。そして、マンドレル２とドライプリフォーム１０’とを分離し、ドライプリフォーム１０’に樹脂を含浸・固化させることにより、複合材が完成する。このように、ドライプリフォーム１０’に樹脂を含浸・固化させる前に、ドライプリフォーム１０’からマンドレル２を分離することで、容易に分離することができる。尚、分離に問題が無ければ、ドライプリフォーム１０’に樹脂を含浸・固化させて複合材を形成した後、この複合材の内周からマンドレル２を分離してもよい。   Thereafter, the long cylindrical dry preform 10 is cut to a predetermined length by the cutting portion 4 to obtain an integrated product of the mandrel 2 and the dry preform 10 '(see FIG. 1). Then, the mandrel 2 and the dry preform 10 'are separated, and the dry preform 10' is impregnated with a resin and solidified to complete the composite material. Thus, before the dry preform 10 ′ is impregnated and solidified with the resin, the mandrel 2 can be separated easily from the dry preform 10 ′. If there is no problem in separation, the mandrel 2 may be separated from the inner periphery of the composite material after the dry preform 10 'is impregnated and solidified with resin to form a composite material.

本発明は上記の実施形態に限られない。以下、本発明の他の実施形態を説明するが、上記の実施形態と同様の機能を有する箇所には同一の符号を付して、重複説明を省略する。   The present invention is not limited to the above embodiment. Hereinafter, although other embodiment of this invention is described, the same code | symbol is attached | subjected to the location which has the same function as said embodiment, and duplication description is abbreviate | omitted.

上記の実施形態では、マンドレル２が直線状である場合を示したが、これに限らず、例えば図５に示すように湾曲したマンドレル２を使用することもできる。また、上記の実施系形態では、マンドレル２の断面形状が長手方向で一定である場合を示したが、これに限らず、断面形状を長手方向で異ならせてもよい。例えば図６に示す例では、マンドレル２が、大径部２ａと、小径部２ｃと、これらを連続するテーパ部２ｂとを有している。また、マンドレル２の断面形状は矩形に限らず、円形や楕円形、あるいは多角形であってもよい。これらの場合、ボビン６、７に捲回されたシート状の強化繊維は独立した複数の繊維束Ｔ２、Ｔ３からなるため、各繊維束Ｔ２、Ｔ３がマンドレル２の外周面形状に沿って配置され、ドライプリフォーム１０を高精度に成形することができる。尚、マンドレル２を溶解可能な材料で形成すれば、マンドレル２及びドライプリフォーム１０が引抜き不可能なアンダーカット形状である場合であっても、マンドレル２を水等の溶剤により溶解させてドライプリフォーム１０の内周からマンドレル２を除去することにより、中空筒状のドライプリフォーム１０を得ることができる。   In the above embodiment, the case where the mandrel 2 is linear has been described. However, the present invention is not limited to this, and for example, a curved mandrel 2 as shown in FIG. 5 can be used. In the above embodiment, the case where the cross-sectional shape of the mandrel 2 is constant in the longitudinal direction has been described. However, the present invention is not limited thereto, and the cross-sectional shape may be varied in the longitudinal direction. For example, in the example shown in FIG. 6, the mandrel 2 has a large diameter portion 2a, a small diameter portion 2c, and a tapered portion 2b that continues these. Further, the cross-sectional shape of the mandrel 2 is not limited to a rectangle, but may be a circle, an ellipse, or a polygon. In these cases, since the sheet-like reinforcing fibers wound around the bobbins 6 and 7 are composed of a plurality of independent fiber bundles T2 and T3, the fiber bundles T2 and T3 are arranged along the outer peripheral surface shape of the mandrel 2. The dry preform 10 can be molded with high accuracy. If the mandrel 2 is formed of a soluble material, the dry preform 10 is prepared by dissolving the mandrel 2 with a solvent such as water, even when the mandrel 2 and the dry preform 10 have an undercut shape that cannot be pulled out. By removing the mandrel 2 from the inner periphery, a hollow cylindrical dry preform 10 can be obtained.

また、特に補強したい箇所がある場合は、強化繊維層の間に補強部材を挟みこんでもよい。例えば、図７に示すように、長手方向強化繊維層１１の外周に、平板状の補強部材２０を配置する。補強部材２０は、複合材や金属板、繊維織物などからなり、矩形、円形、楕円形など、補強する箇所に応じた形状とされる。そして、図８に示すように、長手方向強化繊維層１１及び補強部材２０の外周から繊維束Ｔ２を捲回することにより、長手方向強化繊維層１１と第１の螺旋方向強化繊維層１２との間に補強部材２０が保持される。このとき、補強部材２０により、繊維束Ｔ２の周方向長さが部分的に異なるが、独立した複数の繊維束Ｔ２が、それぞれ補強部材２０による周方向長さの変化に追従するため、補強部材２０の外周及びその前後を繊維束Ｔ２で滑らかに捲回することができる。   In addition, when there is a portion to be reinforced, a reinforcing member may be sandwiched between the reinforcing fiber layers. For example, as shown in FIG. 7, a flat reinforcing member 20 is disposed on the outer periphery of the longitudinal reinforcing fiber layer 11. The reinforcing member 20 is made of a composite material, a metal plate, a fiber fabric, or the like, and has a shape corresponding to a location to be reinforced, such as a rectangle, a circle, or an ellipse. And as shown in FIG. 8, by winding the fiber bundle T2 from the outer periphery of the longitudinal direction reinforcing fiber layer 11 and the reinforcing member 20, the longitudinal direction reinforcing fiber layer 11 and the first spiral direction reinforcing fiber layer 12 are formed. The reinforcing member 20 is held therebetween. At this time, although the circumferential length of the fiber bundle T2 is partially different depending on the reinforcing member 20, the plurality of independent fiber bundles T2 follow changes in the circumferential length by the reinforcing member 20, respectively. The outer periphery of 20 and the front and back thereof can be smoothly wound with the fiber bundle T2.

また、上記の実施形態では、一つのボビン６にシート状に引き揃えた繊維束Ｔ２、Ｔ３が捲回されているが、複数の繊維束Ｔ２、Ｔ３ごとにボビンを設けてもよい。これにより、マンドレル２が湾曲したり（図５参照）、マンドレル２の断面形状が軸方向で異なったり（図６参照）、あるいはマンドレル２の外周に補強部材２０を配置したとき（図７及び図８参照）に、各繊維束Ｔ２、Ｔ３の引き出し長さを異ならせることができるため、繊維束Ｔ２をマンドレル２や補強部材２０により一層追従させやすくなる。この場合、マンドレルの送り速度、ボビンの周回速度、及びマンドレルに対する繊維束の入射角度（長手方向に対するボビン周回方向の傾斜角度）等のパラメータを調整することにより、マンドレルの断面変化に対して繊維束を追従させることができる。   In the above embodiment, the fiber bundles T2 and T3 aligned in a sheet shape are wound around one bobbin 6, but a bobbin may be provided for each of the plurality of fiber bundles T2 and T3. As a result, the mandrel 2 is curved (see FIG. 5), the cross-sectional shape of the mandrel 2 is different in the axial direction (see FIG. 6), or the reinforcing member 20 is disposed on the outer periphery of the mandrel 2 (FIGS. 7 and 7). 8), the drawing lengths of the fiber bundles T2 and T3 can be made different, so that the fiber bundle T2 can be more easily followed by the mandrel 2 and the reinforcing member 20. In this case, by adjusting parameters such as the mandrel feed speed, the bobbin revolving speed, and the incident angle of the fiber bundle with respect to the mandrel (inclination angle in the bobbin revolving direction with respect to the longitudinal direction), the fiber bundle against the mandrel cross-sectional change Can be made to follow.

また、長手方向強化繊維層１１をマンドレル２の外周に仮固定してもよい。例えば図９に示すように、ガイド５を通して繊維束Ｔ１を長手方向に引き揃え、マンドレル２の外周に長手方向強化繊維層１１を形成した直後に、長手方向強化繊維層１１の外周から仮固定繊維３１を螺旋方向（略フープ方向）に捲回することで、長手方向強化繊維層１１がマンドレル２に仮固定される。具体的には、仮固定繊維３１が捲回されたボビン３０を、マンドレル２の外周を周回させることにより、長手方向強化繊維層１１の外周に仮固定繊維３１を捲回し、長手方向強化繊維層１１がマンドレル２の外周に仮固定される。仮固定繊維３１は、例えば熱融着性樹脂繊維や強化繊維、あるいはこれらを混在させたものを使用することができる。仮固定繊維３１は、必ずしも長手方向で隙間なく捲回する必要はなく、図示のように所定の間隔で螺旋状に捲回してもよい。尚、仮固定の方法は上記に限らず、例えば、繊維束に融点の低い熱融着性繊維を混在させ、この繊維束で形成した強化繊維層を加熱して熱融着生繊維を溶融・固化することで仮固定を行うこともできる。あるいは、強化繊維層に熱融着性樹脂からなるパウダーや液体を付着させ、この強化繊維層を加熱して熱融着性樹脂を溶融・固化することで仮固定を行うこともできる。また、図示例では、長手方向強化繊維１１がマンドレル２の外周に直接仮固定されているが、これに限らず、長手方向強化繊維層１１が他の強化繊維層の外周に配される場合は、長手方向強化繊維層１１が他の強化繊維層の外周に仮固定される。   Further, the longitudinal reinforcing fiber layer 11 may be temporarily fixed to the outer periphery of the mandrel 2. For example, as shown in FIG. 9, the fiber bundle T <b> 1 is aligned in the longitudinal direction through the guide 5, and immediately after the longitudinal reinforcing fiber layer 11 is formed on the outer periphery of the mandrel 2, temporarily fixed fibers are formed from the outer periphery of the longitudinal reinforcing fiber layer 11. The longitudinal reinforcing fiber layer 11 is temporarily fixed to the mandrel 2 by winding 31 in a spiral direction (substantially hoop direction). Specifically, the bobbin 30 around which the temporarily fixed fiber 31 is wound is wound around the outer periphery of the mandrel 2, whereby the temporarily fixed fiber 31 is wound around the outer periphery of the longitudinal reinforcing fiber layer 11. 11 is temporarily fixed to the outer periphery of the mandrel 2. As the temporarily fixed fiber 31, for example, a heat-fusible resin fiber, a reinforcing fiber, or a mixture of these can be used. The temporarily fixed fiber 31 does not necessarily have to be wound in the longitudinal direction without a gap, and may be wound spirally at a predetermined interval as illustrated. The method of temporary fixing is not limited to the above. For example, a heat-fusible fiber having a low melting point is mixed in the fiber bundle, and the reinforcing fiber layer formed by the fiber bundle is heated to melt the heat-bonded raw fiber. Temporary fixing can also be performed by solidifying. Alternatively, temporary fixing can be performed by attaching powder or liquid made of a heat-fusible resin to the reinforcing fiber layer and heating and heating the reinforcing fiber layer to melt and solidify the heat-fusible resin. Further, in the illustrated example, the longitudinal reinforcing fibers 11 are temporarily fixed directly on the outer periphery of the mandrel 2, but not limited to this, when the longitudinal reinforcing fiber layer 11 is disposed on the outer periphery of another reinforcing fiber layer. The longitudinal reinforcing fiber layer 11 is temporarily fixed to the outer periphery of another reinforcing fiber layer.

また、上記の実施形態では、マンドレル２、２’・・・を連続的に供給し、ドライプリフォーム１０を連続成形する場合を示したが、これに限らず、マンドレル１本ごとに分割してドライプリフォームを成形してもよい。   In the above embodiment, the case where the mandrels 2, 2 ′, etc. are continuously supplied and the dry preform 10 is continuously formed has been shown. However, the present invention is not limited to this. A reform may be formed.

また、上記の実施形態では、マンドレル２をドライプリフォーム１０’から分離した場合を示したが、マンドレルとドライプリフォームとを一体化したまま樹脂を含浸・固化し、マンドレルを含む複合材としてもよい。   In the above embodiment, the case where the mandrel 2 is separated from the dry preform 10 ′ has been described. However, the mandrel and the dry preform may be integrated and impregnated and solidified to form a composite material including the mandrel.

また、長手方向強化繊維層や螺旋方向強化繊維層の数は上記に限らず、例えば長手方向強化繊維層を複数設けたり、螺旋方向強化繊維層を１層、あるいは３層以上設けてもよい。この場合、各繊維層の数に応じて、長手方向繊維供給部や螺旋方向繊維供給部の数及び設置場所を設定すればよい。   Further, the number of longitudinal direction reinforcing fiber layers and spiral direction reinforcing fiber layers is not limited to the above, and for example, a plurality of longitudinal direction reinforcing fiber layers may be provided, or one or more spiral direction reinforcing fiber layers may be provided. In this case, what is necessary is just to set the number and installation place of a longitudinal direction fiber supply part or a spiral direction fiber supply part according to the number of each fiber layers.

１ 成形装置
２ マンドレル
３ 螺旋方向繊維供給部
４ 切断部
５ ガイド
６、７ ボビン
１０ ドライプリフォーム
１１ 長手方向強化繊維層
１２ 第１の螺旋方向強化繊維層
１３ 第２の螺旋方向強化繊維層
Ｔ１ 繊維束（長手方向の強化繊維）
Ｔ２、Ｔ３ 繊維束（螺旋方向の強化繊維） DESCRIPTION OF SYMBOLS 1 Molding apparatus 2 Mandrel 3 Spiral direction fiber supply part 4 Cutting part 5 Guide 6, 7 Bobbin 10 Dry preform 11 Longitudinal direction reinforcing fiber layer 12 First spiral direction reinforcing fiber layer 13 Second spiral direction reinforcing fiber layer T1 Fiber bundle (Longitudinal reinforcing fiber)
T2, T3 fiber bundle (reinforced fiber in spiral direction)

Claims (6)

複数の強化繊維層を積層してなる筒状のドライプリフォームを成形するための方法であって、
長尺状のマンドレルを長手方向一方に送りながら、長手方向に沿って引き揃えた複数の強化繊維束を前記マンドレルの外周に供給することにより前記マンドレルの全周を覆う長手方向強化繊維層を形成すると共に、前記マンドレルの外周に螺旋状に強化繊維束を捲回することにより前記マンドレルの全周を覆う螺旋方向強化繊維層を形成するドライプリフォームの成形方法。 A method for forming a cylindrical dry preform formed by laminating a plurality of reinforcing fiber layers,
Forming a longitudinal reinforcing fiber layer covering the entire circumference of the mandrel by feeding a plurality of reinforcing fiber bundles aligned along the longitudinal direction to the outer circumference of the mandrel while feeding a long mandrel in one longitudinal direction And forming a spiral reinforcing fiber layer covering the entire circumference of the mandrel by winding a reinforcing fiber bundle in a spiral shape on the outer periphery of the mandrel. 強化繊維束が捲回されたボビンを、マンドレルの外周を周方向一方に周回させることにより、第１の螺旋方向強化繊維層を形成すると共に、前記ボビンと長手方向に離隔した箇所で、強化繊維束が捲回された他のボビンを、マンドレルの外周を周方向他方に周回させることにより、第２の螺旋方向強化繊維層を形成する請求項１記載のドライプリフォームの成形方法。   The bobbin around which the reinforcing fiber bundle is wound is rotated around the outer periphery of the mandrel in one circumferential direction to form a first reinforcing fiber layer in the spiral direction, and at a location separated from the bobbin in the longitudinal direction, the reinforcing fiber The method for molding a dry preform according to claim 1, wherein the second spiral direction reinforcing fiber layer is formed by rotating another bobbin wound with a bundle around the outer periphery of the mandrel in the other circumferential direction. 長手方向強化繊維層を、マンドレルの外周に仮固定する請求項１又は２記載のドライプリフォームの成形方法。   The method for molding a dry preform according to claim 1 or 2, wherein the longitudinal reinforcing fiber layer is temporarily fixed to the outer periphery of the mandrel. 請求項１〜３の何れかに記載のドライプリフォーム成形方法により筒状のドライプリフォームを成形する工程と、前記ドライプリフォームに樹脂を含浸固化させる工程とを有する筒状複合材の製造方法。   The manufacturing method of a cylindrical composite material which has the process of shape | molding a cylindrical dry preform with the dry preform shaping | molding method in any one of Claims 1-3, and the process of impregnating and solidifying resin to the said dry preform. 長尺状のマンドレルの外周面で成形された筒状のドライプリフォームであって、
長手方向に沿って引き揃えられ、全周に敷き詰められた強化繊維からなる長手方向強化繊維層と、長手方向と交差する方向に沿って引き揃えられ、全周に敷き詰められた強化繊維からなる螺旋方向強化繊維層とを有するドライプリフォーム。 A cylindrical dry preform formed on the outer peripheral surface of a long mandrel,
A longitudinal reinforcing fiber layer composed of reinforcing fibers arranged along the longitudinal direction and spread all around the periphery, and a spiral composed of reinforcing fibers arranged along the entire circumference and arranged along the direction intersecting the longitudinal direction A dry preform having a direction reinforcing fiber layer. 請求項５記載のドライプリフォームに樹脂を含浸・固化させてなる複合材。   A composite material obtained by impregnating and solidifying a resin to the dry preform according to claim 5.
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