阅读说明：本技术 复合材料、复合材料的制造方法及复合材料的固化方法 (Composite material, method for producing composite material, and method for curing composite material ) 是由 野间一希 秋山浩庸 小佐佐敏生 金升将征 森岛骏一 于 2019-02-26 设计创作，主要内容包括：本发明的目的在于提供一种能够抑制在复合材料固化时蒙皮材料的纤维弯曲而导致强度降低的复合材料。在复合材料(1)中,在蜂窝芯(2)与第1蒙皮材料(4)之间或蜂窝芯(2)与第2蒙皮材料(6)之间或者这双方以重叠于蜂窝芯(2)的端部的末端的方式配置有填料(9)。配置于蜂窝芯(2)与第2蒙皮材料(6)之间的填料(9)在水平观察时重叠于蜂窝芯(2)的端部的末端部分的长度以下的长度露出到复合材料(1)的外侧。(The invention aims to provide a composite material which can inhibit the fiber bending of a skin material when the composite material is cured to reduce the strength. In the composite material (1), a filler (9) is disposed between the honeycomb core (2) and the 1 st skin material (4), between the honeycomb core (2) and the 2 nd skin material (6), or both so as to overlap the end of the honeycomb core (2). The filler (9) disposed between the honeycomb core (2) and the 2 nd skin material (6) is exposed to the outside of the composite material (1) at a length equal to or less than the length of the end portion of the honeycomb core (2) that overlaps the end portion when viewed horizontally.)

1. A composite material, comprising:

a honeycomb core;

a 1 st skin material disposed on one surface of the honeycomb core and bonded to the honeycomb core;

a 2 nd skin material that is disposed on a face on a side opposite to the one face of the honeycomb core and is bonded to the honeycomb core;

a lightning protection mesh disposed on a face of the 2 nd skin material on a side opposite to a face bonded to the honeycomb core; and

a resin material disposed on a surface of the lightning protection mesh opposite to the 2 nd skin material side,

a filler is disposed between the honeycomb core and the 1 st skin material or between the honeycomb core and the 2 nd skin material or both so as to overlap with a tip of an end portion of the honeycomb core.

2. The composite material of claim 1,

the filler arranged between the honeycomb core and the 2 nd skin material is exposed to the outside of the composite material by a length equal to or less than the length of a terminal portion of an end portion of the honeycomb core when viewed horizontally.

3. The composite material according to claim 1 or 2,

a 1 st film adhesive that bonds the 1 st skin material to the honeycomb core is disposed between the 1 st skin material and the honeycomb core,

a 2 nd film adhesive that bonds the 2 nd skin material to the honeycomb core is disposed between the 2 nd skin material and the honeycomb core.

4. The composite material according to any one of claims 1 to 3,

the end of the honeycomb core is chamfered so as to be inclined toward the 2 nd skin material side.

5. A method for producing a composite material, comprising the steps of:

a preparation step of preparing a composite material including a honeycomb core, a 1 st skin material disposed on one surface of the honeycomb core and bonded to the honeycomb core, a 2 nd skin material disposed on a surface of the 2 nd skin material opposite to the surface bonded to the honeycomb core, and a resin material disposed on a surface of the 2 nd skin material opposite to the 2 nd skin material side; and

and a disposing step of disposing a filler so as to overlap a terminal end of an end portion of the honeycomb core between the honeycomb core and the 1 st skin material or between the honeycomb core and the 2 nd skin material, or both.

6. The method for manufacturing a composite material according to claim 5,

in the disposing step, the filler is disposed between the honeycomb core and the 2 nd skin material so as to be exposed to the outside of the composite material by a length equal to or less than a length of a terminal portion overlapping an end portion of the honeycomb core when viewed horizontally.

7. The method for manufacturing a composite material according to claim 5 or 6,

in the preparation step, as the composite material, the following composite material is prepared: a 1 st film adhesive that bonds the 1 st skin material to the honeycomb core is disposed between the 1 st skin material and the honeycomb core, and a 2 nd film adhesive that bonds the 2 nd skin material to the honeycomb core is disposed between the 2 nd skin material and the honeycomb core.

8. The method for manufacturing a composite material according to any one of claims 5 to 7,

in the preparation step, a composite material is prepared in which a chamfer processing is performed on an end portion of the honeycomb core so as to be inclined toward the 2 nd skin material side.

9. A method for curing a composite material, wherein,

curing the composite material of any one of claims 1 to 4 in general.

Technical Field

The present invention relates to a composite material, a method for producing the composite material, and a method for curing the composite material.

Background

In recent years, composite honeycomb sandwich panels that exhibit excellent strength against bending stress, shear stress, and the like have been used as structural materials for aircraft and the like. The composite material honeycomb sandwich board is a sandwich structure in which high-strength skin materials are arranged on the upper surface and the lower surface of a light core material (honeycomb core). A film-like adhesive is sometimes used for bonding these skin materials to the honeycomb core. As an example of such a composite honeycomb sandwich panel, for example, a composite honeycomb sandwich panel described in patent document 1 is reported.

In order to prevent damage due to lightning strikes, in composite honeycomb sandwich panels used in aircraft construction, lightning protection grids are typically installed at the aerodynamic surfaces. Conventionally, in the case of mounting a lightning protection mesh on a composite honeycomb sandwich panel, in the composite honeycomb sandwich panel before curing (hereinafter, simply referred to as "composite material"), the lightning protection mesh and a resin material (for example, a film adhesive (an adhesive for integrating the lightning protection mesh and the composite material) or a surface conditioner) are applied to an aerodynamic surface.

Prior art documents

Patent document

Patent document 1: specification of U.S. Pat. No. 9539769

Disclosure of Invention

Technical problem to be solved by the invention

The following describes a method for manufacturing the composite honeycomb sandwich panel described above with reference to fig. 5 and 6. Fig. 5 is a schematic view for explaining an example (secondary bonding molding) of a conventional method for manufacturing a composite honeycomb sandwich panel. Step (a) of fig. 5 is a diagram showing a state in which a prepreg for forming a skin material is prepared, step (b) of fig. 5 is a diagram showing a state in which the stacked prepregs are cured, and step (c) of fig. 5 is a diagram showing a state in which the composite material is cured.

In the manufacturing method by the two-shot bond molding, first, as shown in step (a) of fig. 5, for example, prepregs 110, which are 3 sheets of materials of two skin materials, one on top of the other, are prepared, and these are laminated. Next, as shown in step (b) of fig. 5, the stacked uncured prepregs 111 are sealed in another autoclave bag 112, and cured by an autoclave. Thus, the prepreg was cured, and two semi-cured sheets 113 after curing were obtained. In this case, although not shown in the drawing, the resin material 108 and the lightning protection mesh 107, which will be described later, are integrally cured on one of the two semi-cured sheets 113 after curing.

Then, the resin material 108, the lightning protection mesh 107, the post-cure cured sheet 113, the 2 nd film adhesive 105, the honeycomb core 102, the 1 st film adhesive 103, and the post-cure sheet 113 are laminated in this order from below to obtain the composite material 101 (step (c) of fig. 5). In addition, although the resin material 108, the lightning protection mesh 107, and the post-cure sheet 113 cured on the lower side of the paper surface in the step (c) of fig. 5 are separately depicted in the step (c) of fig. 5. The obtained composite material 101 was sealed in an autoclave bag 112 and cured by autoclave, whereby a composite material honeycomb sandwich panel could be obtained.

In the manufacture of composite honeycomb sandwich panels, a manufacturing method based on two-shot bonding molding as shown in fig. 5 is currently generally used. However, this production method requires two or more autoclave operations, and has a disadvantage that the cost for curing increases. Therefore, in order to reduce the number of times of operation of the autoclave, one-shot injection molding of manufacturing a composite honeycomb sandwich panel by one-shot autoclave as shown in fig. 6 was attempted. A method for manufacturing a composite honeycomb sandwich panel by such one-shot injection molding will be described below with reference to fig. 6. Step (a) of fig. 6 is a diagram showing a state in which a composite material is prepared, and step (b) of fig. 6 is a diagram showing a state in which the composite material of step (a) of fig. 6 is cured.

In the one-shot molding, as shown in step (a) of fig. 6, a composite material in which the semi-cured sheet 113 after curing is replaced with the uncured semi-cured sheet 111 in the composite material 101 of step (c) of fig. 5 is prepared as a composite material 101'. Next, as shown in step (b) of fig. 6, the composite material 101' is sealed in an autoclave bag 112 and cured by an autoclave. Thereby, the composite material honeycomb sandwich panel can be manufactured by a single autoclave. Therefore, if the injection molding is performed once, not only the running cost of the autoclave can be reduced, but also the molding cost can be reduced because the operation of the curing bag is performed once. In addition, finishing work and jig cleaning work after curing of the skin, which are required in secondary bonding molding, are not required.

Here, in order to reduce core crush (core crush) caused by pressure applied to the side surface of the honeycomb core when the composite honeycomb sandwich panel is molded, chamfer (chamfer) processing of cutting off the end portion of the honeycomb core to be inclined by about 30 ° is generally performed. Fig. 7 is a view showing a case where a composite material including a honeycomb core subjected to such chamfering is injection-molded at a time.

Fig. 7 is a vertical cross-sectional view showing a state in the vicinity of the end portion of the honeycomb core when the composite material 101' of step (b) of fig. 6 is cured. As shown in fig. 7, when the end portion of the honeycomb core 102 is chamfered, the end portion has an inclined shape, and therefore, the uncured prepreg 111 is more difficult to be adapted to the shape of the end portion of the honeycomb core 102 as it goes toward the end of the end portion of the honeycomb core 102. Further, since the end portion of the honeycomb core 102 has an inclined shape, a portion where it is relatively difficult to apply the pressure of the autoclave is generated at the end of the end portion. When such a composite material 101' is injection-molded at one time, the resin material 108 disposed at the outermost layer may accumulate (adhesive accumulation 114 may occur) at a position where the autoclave pressure is relatively difficult to apply at the end of the honeycomb core 102. If the adhesive accumulation 114 occurs, the fibers of the skin material (uncured prepreg 111 on the lower side of the paper in fig. 7) are bent (wrinkled) due to the adhesive accumulation 114, and there is a problem that the strength of the obtained composite honeycomb sandwich panel is reduced.

The present invention has been made in view of such circumstances, and an object thereof is to provide a composite material and a method for manufacturing the composite material, which can suppress a decrease in strength due to bending of fibers of a skin material when the composite material is cured.

Means for solving the technical problem

In order to solve the above problems, the present invention adopts the following method.

The present invention provides a composite material, which comprises: a honeycomb core; a 1 st skin material disposed on one surface of the honeycomb core and bonded to the honeycomb core; a 2 nd skin material that is disposed on a face on a side opposite to the one face of the honeycomb core and is bonded to the honeycomb core; a lightning protection mesh disposed on a face of the 2 nd skin material on a side opposite to a face bonded to the honeycomb core; and a resin material disposed on a surface of the lightning protection mesh opposite to the 2 nd skin material side, wherein a filler is disposed between the honeycomb core and the 1 st skin material, between the honeycomb core and the 2 nd skin material, or both so as to overlap with a terminal end of an end portion of the honeycomb core.

In the composite material of the present invention, a filler is disposed between the honeycomb core and the 1 st skin material or between the honeycomb core and the 2 nd skin material or both so as to overlap with the end of the end portion of the honeycomb core. In composite materials used in aircraft construction, lightning protection meshes and resin materials are typically applied to the aerodynamic surfaces. In the composite material, particularly when chamfering is performed on the end portion of the honeycomb core, a portion where it is relatively difficult to apply the pressure of the autoclave is generated at the end of the end portion. When the composite material is cured in this state, the resin material (for example, a film adhesive or a surface conditioner) disposed at the outermost layer may accumulate (adhesive accumulation may occur) at that portion. If the adhesive build-up occurs, the fibers of the skin material may be bent (wrinkled), possibly resulting in a decrease in strength. Here, if the filler is disposed between the honeycomb core and the 1 st skin material (the upper portion of the end portion of the honeycomb core) as in the present invention, the pressure of the autoclave is easily transmitted to the portion where the adhesive is accumulated via the filler, and therefore the adhesive accumulation can be suppressed. If the filler is disposed between the honeycomb core and the 2 nd skin material (lower portion of the end portion of the honeycomb core), the effect of suppressing the adhesive accumulation can be obtained by the rigidity of the filler, and therefore, the bending of the skin material can be suppressed. When the filler is disposed in the composite material in this manner, it is possible to suppress a decrease in strength due to bending of the fibers of the skin material when the composite material is cured. Therefore, the composite material of the present invention can be suitably used for an aircraft structure.

In the composite material, the following is preferred: the filler arranged between the honeycomb core and the 2 nd skin material is exposed to the outside of the composite material by a length equal to or less than the length of a terminal portion of an end portion of the honeycomb core when viewed horizontally.

As described above, if the filler is disposed between the honeycomb core and the 2 nd skin material, the bending of the skin material can be sufficiently suppressed. Since the filler can be set to an appropriate size, the composite material can be prevented from becoming excessively heavy.

In the composite material, the following is preferred: a 1 st film adhesive that bonds the 1 st skin material to the honeycomb core is disposed between the 1 st skin material and the honeycomb core, and a 2 nd film adhesive that bonds the 2 nd skin material to the honeycomb core is disposed between the 2 nd skin material and the honeycomb core.

As described above, in the present invention, two skin materials can be bonded to the honeycomb core using a film adhesive.

In the composite material, the following is preferred: the end of the honeycomb core is chamfered so as to be inclined toward the 2 nd skin material side.

As described above, in the present invention, the end portion of the honeycomb core can be chamfered.

The present invention provides a method for producing a composite material, comprising the steps of: a preparation step of preparing a composite material including a honeycomb core, a 1 st skin material disposed on one surface of the honeycomb core and bonded to the honeycomb core, a 2 nd skin material disposed on a surface of the 2 nd skin material opposite to the surface bonded to the honeycomb core, and a resin material disposed on a surface of the 2 nd skin material opposite to the 2 nd skin material side; and disposing a filler between the honeycomb core and the 1 st skin material, between the honeycomb core and the 2 nd skin material, or both so as to overlap with a terminal end of an end portion of the honeycomb core.

In the method for producing a composite material according to the present invention, in the disposing step, the filler is disposed so as to overlap the end of the end portion of the honeycomb core between the honeycomb core and the 1 st skin material or between the honeycomb core and the 2 nd skin material, or both. In composite materials used in aircraft construction, lightning protection meshes and resin materials are typically applied to the aerodynamic surfaces. In the composite material, particularly when chamfering is performed on the end portion of the honeycomb core, a portion where it is relatively difficult to apply the pressure of the autoclave is generated at the end of the end portion. When the composite material is cured in this state, the resin material (for example, a film adhesive or a surface conditioner) disposed at the outermost layer may accumulate (adhesive accumulation may occur) at that portion. If the adhesive build-up occurs, the fibers of the skin material may be bent (wrinkled), possibly resulting in a decrease in strength. Here, if the filler is disposed between the honeycomb core and the 1 st skin material (the upper portion of the end portion of the honeycomb core) as in the present invention, the pressure of the autoclave is easily transmitted to the portion where the adhesive is accumulated via the filler, and therefore the adhesive accumulation can be suppressed. If the filler is disposed between the honeycomb core and the 2 nd skin material (lower portion of the end portion of the honeycomb core), the effect of suppressing the adhesive accumulation can be obtained by the rigidity of the filler, and therefore, the bending of the skin material can be suppressed. When the filler is disposed in the composite material in this manner, it is possible to suppress a decrease in strength due to bending of the fibers of the skin material when the composite material is cured. Therefore, the method for producing a composite material of the present invention can be suitably used for an aircraft structure.

In the disposing step, it is preferable that: the filler is disposed between the honeycomb core and the 2 nd skin material in such a manner that a length of a tip portion overlapping an end of the honeycomb core when viewed horizontally is less than a length of the tip portion is exposed to an outside of the composite material.

As described above, if the filler is disposed between the honeycomb core and the 2 nd skin material, the bending of the skin material can be sufficiently suppressed. Since the filler can be set to an appropriate size, the composite material to be produced can be prevented from becoming excessively heavy.

The following are preferred: in the preparation step, as the composite material, the following composite material is prepared: a 1 st film adhesive that bonds the 1 st skin material to the honeycomb core is disposed between the 1 st skin material and the honeycomb core, and a 2 nd film adhesive that bonds the 2 nd skin material to the honeycomb core is disposed between the 2 nd skin material and the honeycomb core.

As described above, in the present invention, two skin materials can be bonded to the honeycomb core using a film adhesive.

The following are preferred: in the composite step, a composite material is prepared in which an end portion of the honeycomb core is chamfered so as to be inclined toward the 2 nd skin material side.

As described above, in the present invention, the end portion of the honeycomb core can be chamfered.

The invention provides a curing method of a composite material, wherein the composite material is cured in a batch manner.

The composite material of the present invention can suppress a decrease in strength due to bending of fibers of the skin material when the composite material is cured, even if the composite material is molded by all-round curing (one-shot injection molding). Therefore, by performing the injection molding once, not only the running cost of the autoclave can be reduced, but also the molding cost can be reduced because the work of curing by the curing bag becomes one time. The finishing work and the clamp cleaning work after the skin material is solidified, which are required in the secondary bonding molding, are not required, so that the method is simple and convenient.

Effects of the invention

The composite material and the method for manufacturing the composite material according to the present invention can suppress the reduction in strength due to the bending of the fibers of the skin material when the composite material is cured.

Drawings

Fig. 1 is a vertical cross-sectional view showing a state in the vicinity of the end of an end portion of a honeycomb core when a composite material according to embodiment 1 of the present invention is cured.

Fig. 2 is a vertical cross-sectional view showing a state in the vicinity of the end of the honeycomb core when the composite material according to embodiment 2 of the present invention is cured.

Fig. 3 is a vertical cross-sectional view showing a state in the vicinity of the end of the honeycomb core when the composite material according to embodiment 3 of the present invention is cured.

Fig. 4 is a perspective view for explaining the structure of the composite material according to embodiment 1 of the present invention.

Fig. 5 is a schematic diagram for explaining an example of a conventional method for manufacturing a composite honeycomb sandwich panel, where step (a) is a diagram showing a state in which a prepreg for forming a skin material is prepared, step (b) is a diagram showing a state in which the laminated prepregs are cured, and step (c) is a diagram showing a state in which a composite material is cured.

Fig. 6 is a schematic view for explaining another example of a conventional method for producing a composite honeycomb sandwich panel, where step (a) is a view showing a state in which a composite material is prepared, and step (b) is a view showing a state in which the composite material in step (a) of fig. 6 is cured.

Fig. 7 is a vertical cross-sectional view showing a state in the vicinity of the end of the honeycomb core when the composite material of step (b) of fig. 6 is cured.

Detailed Description

Hereinafter, an embodiment of a composite material and a method for producing a composite material according to the present invention will be described with reference to the drawings.

[ composite Material ]

[ 1 st embodiment ]

Hereinafter, a composite material according to embodiment 1 of the present invention will be described with reference to fig. 1 and 4.

Fig. 4 is a perspective view for explaining the structure of the composite material according to the present embodiment.

As shown in fig. 4, the composite material 1 according to the present embodiment includes a honeycomb core 2, a 1 st film adhesive 3, a 1 st skin material 4, a 2 nd film adhesive 5, a 2 nd skin material 6, a lightning protection mesh 7, and a resin material 8. Specifically, the 1 st film adhesive 3 is disposed on one surface (upper surface) of the honeycomb core 2, and the 1 st skin material 4 is bonded to the honeycomb core 2 via the 1 st film adhesive 3. On the other hand, the 2 nd film adhesive 5 is disposed on the surface (lower surface) opposite to the one surface of the honeycomb core 2, and the 2 nd skin material 6 is bonded to the honeycomb core 2 via the 2 nd film adhesive 5. The lightning protection mesh 7 is disposed on the surface of the 2 nd skin material 6 opposite to the surface bonded to the honeycomb core 2, and the resin material 8 is disposed on the surface of the lightning protection mesh 7 opposite to the 2 nd skin material 6. Examples of the resin material 8 include a film adhesive and a surface conditioner.

As described later, the end portion of the honeycomb core 2 is chamfered so as to be inclined toward the 2 nd skin material 6 side. The 1 st skin material 4 and the 2 nd skin material 6 are formed by laminating a plurality of uncured prepregs, for example.

Next, referring to fig. 1, a structure near the end of the honeycomb core 2 in the composite material 1 according to the present embodiment will be specifically described. Fig. 1 is a vertical cross-sectional view showing a state in the vicinity of the end of an end portion of a honeycomb core 2 when a composite material 1 according to the present embodiment is cured. As shown in fig. 1, the end portion of the honeycomb core 2 is chamfered, for example, by 30 ° to the 2 nd skin material 6 side. Further, a filler 9 is disposed between the 2 nd film adhesive 5 and the 2 nd skin material 6 so as to overlap the end of the chamfered end portion of the honeycomb core 2. Specifically, the filler 9 disposed between the 2 nd film adhesive 5 and the 2 nd skin material 6 is exposed to the outside of the composite material 1 (particularly, the end of the honeycomb core 2) at a length equal to or less than the length of the end portion overlapping the end of the honeycomb core 2 when viewed horizontally.

The material of the filler 9 is not particularly limited, and examples thereof include composite materials (e.g., CFRP (carbon Fiber reinforced Plastics), GFRP (Glass Fiber reinforced Plastics), etc.), film adhesives, resin materials, and the like. The cured state of the filler 9 may be a cured state or an uncured state. The number of stacked packings 9 (number of ply) may be determined according to the expected height of adhesive accumulation, but when the thickness of the packing 9 is 0.3mm/ply or less, it is preferably about 1 to 3 ply. When the packing 9 is applied by overlapping a plurality of sheets, the length of each ply may be the same or different.

According to the present embodiment, the following operational effects are exhibited by the above-described configuration.

In the composite material 1 of the present embodiment, the filler 9 is disposed between the honeycomb core 2 and the 2 nd skin material 6 so as to overlap the end of the end portion of the honeycomb core 2. As in the present embodiment, if the filler 9 is disposed between the honeycomb core 2 and the 2 nd skin material 6 (lower portion of the end portion of the honeycomb core 2), the effect of suppressing the adhesive accumulation can be obtained by the rigidity of the filler 9, and therefore the skin material (the 2 nd skin material 6) can be suppressed from being bent. If the filler 9 is disposed in the composite material 1 in this manner, it is possible to suppress the fiber bending of the 2 nd skin material 6 and the strength reduction at the time of curing the composite material 1. Therefore, the composite material 1 according to the present embodiment can be suitably used for an aircraft structure.

In the present embodiment, the filler 9 is exposed to the outside of the composite material 1 by a length equal to or less than the length of the end portion overlapping the end portion of the honeycomb core 2 when viewed horizontally. If the filler 9 is disposed in this manner, the bending of the 2 nd skin material 6 can be sufficiently suppressed. Since the size of the filler 9 can be set to an appropriate size, the composite material 1 can be prevented from becoming excessively heavy.

In embodiment 1 described above, the case where the filler 9 is exposed to the outside of the composite material 1 by a length equal to or less than the length of the end portion of the honeycomb core 2 overlapping the end portion when viewed horizontally is exemplified, but the present invention is not limited thereto. Specifically, the length of the filler 9 is not particularly limited as long as it overlaps the vicinity of the end of the honeycomb core 2 where adhesive accumulation occurs.

[ 2 nd embodiment ]

Next, embodiment 2 of the present invention will be described with reference to fig. 2.

The basic configuration of the present embodiment is basically the same as that of embodiment 1, but differs from embodiment 1 in that a filler 9' is disposed between the 1 st film adhesive 3 and the 1 st skin material 4 instead of the filler 9. Therefore, in the present embodiment, the different portions will be described, and description of other overlapping matters will be omitted.

The same components as those in embodiment 1 are denoted by the same reference numerals, and redundant description thereof is omitted.

Fig. 2 is a vertical cross-sectional view showing a state in the vicinity of the end of the honeycomb core 2 when the composite material 21 according to the present embodiment is cured. In the composite material 21 according to the present embodiment, the filler 9' is disposed between the 1 st film adhesive 3 and the 1 st skin material 4 so as to overlap the end of the chamfered end portion of the honeycomb core 2. The filler 9' may be the same as the filler 9 in embodiment 1.

According to the present embodiment, the following operational effects are exhibited by the above-described configuration.

In the composite material 21 of the present embodiment, the filler 9' is disposed between the honeycomb core 2 and the 1 st skin material 4 so as to overlap the end of the end portion of the honeycomb core 2. As in the present embodiment, when the filler 9 'is disposed between the honeycomb core 2 and the 1 st skin material 4 (the upper portion of the end portion of the honeycomb core 2), the pressure of the autoclave is easily transmitted to the portion where the adhesive is accumulated via the filler 9'. This can suppress the occurrence of adhesive accumulation. If the filler 9' is disposed in the composite material 21 in this manner, it is possible to suppress the fiber bending of the 2 nd skin material 6 and the strength reduction caused when the composite material 21 is cured. Therefore, the composite material 21 of the present embodiment can be suitably used for an aircraft structure.

[ 3 rd embodiment ]

Next, embodiment 3 of the present invention will be described with reference to fig. 3.

The basic configuration of the present embodiment is basically the same as that of embodiment 1, but differs from embodiment 1 in that a filler 9' of embodiment 2 is disposed in addition to the filler 9. Therefore, in the present embodiment, the different portions will be described, and description of other overlapping matters will be omitted.

The same components as those in embodiments 1 and 2 are denoted by the same reference numerals, and redundant description thereof is omitted.

Fig. 3 is a vertical cross-sectional view showing a state in the vicinity of the end of the honeycomb core 2 when the composite material 31 according to the present embodiment is cured. In the composite material 31 according to the present embodiment, the filler 9 is disposed between the 1 st film adhesive 3 and the 1 st skin material 4, and the filler 9 is disposed between the 2 nd film adhesive 5 and the 2 nd skin material 6.

According to the present embodiment, the following operational effects are exhibited by the above-described configuration.

In the composite material 31 of the present embodiment, the filler 9' is disposed between the honeycomb core 2 and the 1 st skin material 4 so as to overlap the tip of the end portion of the honeycomb core 2, and the filler 9 is disposed between the honeycomb core 2 and the 2 nd skin material 6. As in the present embodiment, if the filler 9 is disposed between the honeycomb core 2 and the 1 st skin material 4 (upper portion of the end portion of the honeycomb core 2), the pressure of the autoclave is easily transmitted to the portion where the adhesive is accumulated via the filler 9. This can suppress the occurrence of adhesive accumulation. If the filler 9 'is disposed between the honeycomb core 2 and the 2 nd skin material 6 (lower portion of the end portion of the honeycomb core 2), an effect of suppressing the adhesive accumulation can be obtained by the rigidity of the filler 9', and thus the 2 nd skin material 6 can be suppressed from being bent. If the fillers 9 and 9' are disposed in the composite material 31 in this manner, it is possible to suppress a decrease in strength due to bending of the fibers of the 2 nd skin material 6 when the composite material 31 is cured. Therefore, the composite material 31 of the present embodiment can be suitably used for an aircraft structure.

The composite material of the present invention as described above can be cured in general. In the composite material of the present invention, even if the composite material is molded by all-round curing (one-shot injection molding), it is possible to suppress a decrease in strength due to bending of fibers of the skin material when the composite material is cured. Therefore, by performing the injection molding once, not only the running cost of the autoclave can be reduced, but also the molding cost can be reduced because the work of curing by the curing bag becomes one time. The finishing work and the clamp cleaning work after the skin material is solidified, which are required in the secondary bonding molding, are not required, so that the method is simple and convenient.

The composite material of the present invention described above can be suitably used for products requiring a lightweight/high-rigidity composite honeycomb sandwich panel, such as a control surface structure for a future civil aircraft, a panel for a future helicopter/space flight vehicle, a floor material for an aircraft, a floor material/bracket material for new transportation and railway vehicles, and the like.

[ method for producing composite Material ]

Next, an embodiment of the method for producing a composite material of the present invention will be described.

The method for producing a composite material of the present invention includes a preparation step and a placement step. In the preparation step, the composite material of the present invention is prepared. In the disposing step, the filler is disposed so as to overlap the end of the end portion of the honeycomb core between the honeycomb core and the 1 st skin material or between the honeycomb core and the 2 nd skin material, or both.

In the following, a case will be described where the method for producing a composite material of the present invention is applied to the production of the composite material 1 shown in fig. 1 and 4 as an example, but the present invention is not limited thereto.

(preparation Process)

In the preparation step, the composite material 1 according to embodiment 1 is prepared. Here, as an example, the composite material 1 shown in fig. 4 is prepared and the following steps are performed.

(preparation Process)

In the disposing step, as shown in fig. 1, the filler 9 is disposed between the 2 nd film adhesive 5 and the 2 nd skin material 6 so as to overlap the end of the chamfered end portion of the honeycomb core 2.

In this disposing step, specifically, as shown in fig. 1, the filler 9 is disposed between the 2 nd film adhesive 5 and the 2 nd skin material 6 so as to be exposed to the outside of the composite material 1 by a length equal to or less than the length of the end portion overlapping the end portion of the honeycomb core 2 when viewed horizontally.

According to the present embodiment, the following operational effects are exhibited by the above-described configuration.

In the method for manufacturing the composite material 1 of the present embodiment, in the arranging step, the filler 9 is arranged between the honeycomb core 2 and the 2 nd skin material 6 so as to overlap with the end of the end portion of the honeycomb core 2. As in the present embodiment, when the filler 9 is disposed between the honeycomb core 2 and the 2 nd skin material 6 (lower portion of the end portion of the honeycomb core 2), the effect of suppressing the adhesive accumulation can be obtained by the rigidity of the filler 9, and therefore, the skin material (the 2 nd skin material 6) can be suppressed from being bent. By disposing the filler 9 in the composite material 1 in this manner, it is possible to suppress the fiber bending of the 2 nd skin material 6 and the strength reduction caused when the composite material 1 is cured. Therefore, the method for producing the composite material 1 according to the present embodiment can be suitably used for an aircraft structure.

In the above-described embodiment of the method for manufacturing a composite material according to the present invention, the case where the filler 9 is provided only between the 2 nd film adhesive 5 and the 2 nd skin material 6 is exemplified, but the present invention is not limited thereto. As shown in fig. 2, the filler 9 'may be provided only between the 1 st film adhesive 3 and the 1 st skin material 4, or as shown in fig. 3, the filler 9' may be provided between the 1 st film adhesive 3 and the 1 st skin material 4, and the filler 9 may be provided between the 2 nd film adhesive 5 and the 2 nd skin material 6. The present invention is not limited to these embodiments.

In the above-described embodiment of the composite material and the method for producing the composite material according to the present invention, the case where the 1 st film adhesive 3 and the 2 nd film adhesive 5 are used has been described as an example, but the two film adhesives may not be used. With such a configuration, the film adhesive is not required, and thus the cost can be reduced. Further, even in the case of the system not using the above-described two types of film adhesives, molding can be performed by one-shot injection molding. At this time, two skin materials (uncured prepregs) were directly bonded to the honeycomb core.

In the composite material and the method for manufacturing the composite material according to the embodiment of the present invention described above, the case where the end portion of the honeycomb core 2 is chamfered has been described as an example, but the chamfering may not be performed. The adhesive accumulation as described above is expected to occur even without chamfering the honeycomb core, but if the filler is provided as in the present invention, the adhesive accumulation can be suppressed.

Description of the symbols

1. 21, 31-composite material, 2-honeycomb core, 3-1 st film adhesive, 4-1 st skin material, 5-2 nd film adhesive, 6-2 nd skin material, 7-lightning protection grid, 8-resin material and 9, 9' -filler.