Mold for manufacturing composite material molded product, and method for manufacturing composite material molded product

Abstract

A composite material molded product has a hollow portion, a bent portion, or a curved portion in a transverse section thereof. When the composite material molded product has, for example, a bent portion, a surface on an inside of the bent portion is a pressed surface. A mold includes a pressing body that is thermally expandable and has an outer surface shape corresponding to a shape of a pressed surface, and a mold main body including a cavity accommodating the laminate and the pressing body inside, the cavity including an inner surface shape corresponding to a shape other than the pressed surface. The cavity is sealed in a state that the pressing body is disposed in the cavity. The laminate is accommodated in a molding space formed between an inner surface of the cavity and an outer surface of the pressing body.

1 . A mold for manufacturing a composite material molded product having a cross-sectional shape including at least one of a hollow, a bent portion, and a curved portion in a transverse section thereof, the mold further for heat curing a laminate of prepregs obtained by impregnating a fiber material with a thermosetting resin composition and half curing the thermosetting resin composition, wherein a surface on an inside or outside of the hollow side, the bent portion, or the curved portion in the transverse section is a pressed surface, the mold comprising:
 a pressing body that has a pressure molding surface, the pressure molding surface having a shape corresponding to a shape of the pressed surface and the pressing body thermally expanding to press the laminate; and   a mold main body having a cavity to accommodate the laminate and the pressing body, the cavity including an inner surface shape corresponding to a shape other than the pressed surface, wherein   in the mold main body, in a state that the pressing body is disposed in the cavity, the laminate is accommodated in a molding space formed between an inner surface of the cavity and an inner surface of the pressing body.   
     
     
         2 . The mold according to  claim 1 , wherein the pressing body includes:
 an expansion core that thermally expands due to heating; and   a pressure distributor that is provided on a side of the composite material molded product with respect to the expansion core and distributes pressing force by the expansion core to the entire pressed surface.   
     
     
         3 . The mold according to  claim 2 , wherein the expansion core has a concavo-convex structure that adjusts pressing force due to thermal expansion. 
     
     
         4 . The mold according to  claim 2 , wherein a thermal expansion coefficient of the expansion core is larger than a thermal expansion coefficient of the pressure distributor. 
     
     
         5 . The mold according to  claim 1 , wherein the pressing body comprises a hollow box located inside the pressing body and is deformable inward accompanying thermal expansion of the pressing body. 
     
     
         6 . The mold according to  claim 1 , wherein the mold main body comprises:
 a female mold portion provided with the cavity; and   a lid mold portion that seals the cavity in a state that the laminate and the pressing body are disposed in the cavity of the female mold portion.   
     
     
         7 . The mold according to  claim 1 , wherein the mold main body comprises:
 a first mold portion having the inner surface shape; and   a second mold portion having a recessed space in which the first mold portion is fitted, wherein   by fitting the first mold portion and the second mold portion, the cavity is formed therebetween, and   the pressing body is disposed in the recessed space of the second mold portion so that the pressure molding surface of the pressing body opposes the first mold portion.   
     
     
         8 . The mold according to  claim 1 , wherein
 a cross section of the composite material molded product is a shape having a plate-shaped main body portion and two flange portions bent in a same direction from both edges of the main body portion, and   the pressing body has an outer surface shape corresponding to a shape of the pressed surface between the two flange portions and the main body portion.   
     
     
         9 . The mold according to  claim 1 , wherein the mold main body comprises a heater that heats the mold main body. 
     
     
         10 . A mold for manufacturing a composite material molded product having a cross-sectional shape including at least one of a hollow side, a bent portion, and a curved portion in a transverse section thereof, the mold further for heat curing a laminate of prepregs obtained by impregnating a fiber material with a thermosetting resin composition and half curing the thermosetting resin composition, the mold comprising:
 a pressing body including
 an expansion core that expands itself, and 
 a pressure distributor that is provided on a side of the composite material molded product with respect to the expansion core and that distributes pressing force by the expansion core to an entire pressed surface, wherein
 in a case that a surface on an inside or outside of the hollow side, the bent portion, or the curved portion in the transverse section is a pressed surface, the pressing body has a pressure molding surface having a shape corresponding to a shape of the pressed surface; and 
 
   a mold main body having a cavity to accommodate the laminate and the pressing body inside, the cavity including an inner surface shape corresponding to a shape other than the pressed surface, wherein   in the mold main body, in a state that the pressing body is disposed in the cavity, the laminate is accommodated in a molding space formed between an inner surface of the cavity and an inner surface of the pressing body.   
     
     
         11 . The mold for manufacturing the composite material molded product according to  claim 10 , wherein the pressing body further comprises a pressure hole communicating with an outside of the mold main body and blowing compressed air into an internal space of the pressing body. 
     
     
         12 . A method for manufacturing a composite material molded product having a cross-sectional shape including at least one of a hollow, a bent portion, and a curved portion in a transverse section thereof, the method comprising:
 disposing a laminate of prepregs and a pressing body in a cavity of a mold main body so that a surface on an inside or outside of the hollow, the bent portion, or the curved portion in the transverse section is a pressed surface;   fixing the mold main body so as to seal the cavity; and   heating the pressing body and the mold main body without pressing, so as to cure the laminate.   
     
     
         13 . A method for manufacturing a composite material molded product having a cross-sectional shape including at least one of a hollow, a bent portion, and a curved portion in a transverse section thereof, the method comprising:
 disposing a laminate of prepregs and a pressing body in a cavity of a mold main body so that a surface on an inside or outside of the hollow, the bent portion, or the curved portion in the transverse section is a pressed surface;   fixing the mold main body so as to seal the cavity; and   blowing compressed air into the pressing body to press the pressed surface, and heating the mold main body without pressing, so as to cure the laminate.   
     
     
         14 . The mold according to  claim 2 , wherein the pressing body comprises a hollow box located inside the pressing body and is deformable inward accompanying thermal expansion of the pressing body. 
     
     
         15 . The mold according to  claim 2 , wherein the mold main body comprises:
 a female mold portion provided with the cavity; and   a lid mold portion that seals the cavity in a state that the laminate and the pressing body are disposed in the cavity of the female mold portion.   
     
     
         16 . The mold according to  claim 2 , wherein the mold main body comprises:
 a first mold portion having the inner surface shape; and   a second mold portion having a recessed space in which the first mold portion is fitted, wherein   by fitting the first mold portion and the second mold portion, the cavity is formed therebetween, and   the pressing body is disposed in the recessed space of the second mold portion so that the pressure molding surface of the pressing body opposes the first mold portion.   
     
     
         17 . The mold according to  claim 2 , wherein
 a cross section of the composite material molded product is a shape having a plate-shaped main body portion and two flange portions bent in a same direction from both edges of the main body portion, and   the pressing body has an outer surface shape corresponding to a shape of the pressed surface between the two flange portions and the main body portion.   
     
     
         18 . The mold according to  claim 2 , wherein the mold main body comprises a heater that heats the mold main body.