US 11,993,030 B2
Composite material component shaping method and charge
Masahiko Shimizu, Tokyo (JP); Shoya Mano, Tokyo (JP); Toshiki Kitazawa, Tokyo (JP); Homare Yamato, Tokyo (JP); Kenichi Kawamura, Kasugai (JP); and Yoko Taguchi, Nagoya (JP)
Assigned to MITSUBISHI HEAVY INDUSTRIES, LTD., Tokyo (JP)
Appl. No. 17/633,389
Filed by MITSUBISHI HEAVY INDUSTRIES, LTD., Tokyo (JP)
PCT Filed Sep. 26, 2019, PCT No. PCT/JP2019/037774
§ 371(c)(1), (2) Date Feb. 7, 2022,
PCT Pub. No. WO2021/059421, PCT Pub. Date Jan. 4, 2021.
Prior Publication US 2022/0288874 A1, Sep. 15, 2022
Int. Cl. B29C 70/34 (2006.01); B29C 70/16 (2006.01); B29K 307/04 (2006.01); B29K 309/08 (2006.01); B29L 31/30 (2006.01)
CPC B29C 70/345 (2013.01) [B29C 70/16 (2013.01); B29K 2307/04 (2013.01); B29K 2309/08 (2013.01); B29L 2031/3076 (2013.01)] 12 Claims
OG exemplary drawing
 
1. A composite material component shaping method for shaping a charge in which a plurality of reinforced fiber sheets are laminated into a desired shape by using a shaping die, the method comprising:
a lamination step of laminating the plurality of reinforced fiber sheets to manufacture the charge; and
a shaping step of shaping the charge manufactured in the lamination step by pressing the charge in the shaping die,
wherein the charge includes a predetermined angle layer formed of the plurality of reinforced fiber sheets in which fiber directions are aligned in one direction,
the predetermined angle layer has the n-number of forming layers from a first forming layer to an n-th forming layer, each being formed of the plurality of reinforced fiber sheets (n≥2),
the n-th forming layer is laminated on an (n−1)-th forming layer,
each of the plurality of reinforced fiber sheets in each of the forming layers has a split portion in each of the fiber directions at every one location in the predetermined angle layer in a predetermined range along the fiber direction, and
the respective split portions are regularly and repeatedly aligned in each of the forming layers along the fiber direction of the predetermined angle layer so that the split portions are not continuously aligned in a same forming layer in order from one end side in the fiber direction in the predetermined range, and the split portions are aligned not to overlap each other in a lamination direction of the predetermined angle layer when the predetermined angle layer is viewed as a whole.
 
12. A charge in which a plurality of reinforced fiber sheets are laminated, the charge comprising:
a predetermined angle layer formed of the plurality of reinforced fiber sheets in which fiber directions are aligned in one direction,
wherein the predetermined angle layer has the n-number of forming layers from a first forming layer to an n-th forming layer, each being formed of the plurality of reinforced fiber sheets (n≥2),
the n-th forming layer is laminated on an (n−1)-th forming layer,
each of the plurality of reinforced fiber sheets in each of the forming layers has a split portion in each of the fiber directions at every one location in the predetermined angle layer in a predetermined range along the fiber direction, and
the respective split portions are regularly and repeatedly aligned in each of the forming layers along the fiber direction of the predetermined angle layer so that the split portions are not continuously aligned in a same forming layer in order from one end side in the fiber direction in the predetermined range, and the split portions are aligned not to overlap each other in a lamination direction of the predetermined angle layer when the predetermined angle layer is viewed as a whole.