Method for manufacturing composite structure and method for manufacturing integrated composite structure

Patent metadata

Field	Value
Publication number	US-11072098-B2
Application number	US-201716471228-A
Country	US
Kind code	B2
Filing date	Dec 20, 2017
Priority date	Dec 22, 2016
Publication date	Jul 27, 2021
Grant date	Jul 27, 2021

Abstract

A method for manufacturing a composite structure in which a first member and a structure material as a second member are integrated, the method including: an arrangement step of arranging a structure precursor including a resin and reinforced fibers in a mold made of the first member; a heating step of heating the structure precursor to equal to or higher than a temperature at which a storage elastic modulus (G′) of the structure precursor is less than 1.2×108 Pa; a shaping step of expanding the structure precursor by heating to form a structure material as a second member, and bringing the structure material into close contact with the first member to obtain a composite structure; and a cooling step of cooling the composite structure.

First claim

The invention claimed is:

1. A method for manufacturing a composite structure in which a first member and a structure material as a second member are integrated, the method comprising:
an arrangement step of arranging a structure precursor comprising a resin and reinforced fibers in a mold comprising the first member;
a heating step of heating the structure precursor to equal to or higher than a temperature at which a storage elastic modulus (G′) of the structure precursor is less than 1.2×10 8 Pa;
a shaping step of expanding the structure precursor during the heating step to form a structure material as a second member, and bringing the structure material into close contact with the first member to obtain a composite structure; and
a cooling step of cooling the composite structure,
the first member having a bending modulus of 5 GPa or more at a temperature of the heating step,
the structure material as the second member comprising a resin, reinforced fibers and voids.

2. The method for manufacturing a composite structure according to claim 1 , which further comprises a molding step of molding the composite structure by pressurization, after the shaping step.

3. The method for manufacturing a composite structure according to claim 1 , which further comprises a deformation step of locally applying pressure to deform the composite structure, after the shaping step.

4. The method for manufacturing a composite structure according to claim 3 , wherein at least a part of a portion to be deformed is heated in the deformation step.

5. The method for manufacturing a composite structure according to claim 1 , wherein a linear expansion coefficient of the first member is 50×10 −6 /° C. or less.

6. The method for manufacturing a composite structure according to claim 1 , wherein the first member is a member selected from the group consisting of a fiber reinforced thermosetting resin member, a fiber reinforced thermoplastic resin member, a metal member, and a ceramic member.

7. The method for manufacturing a composite structure according to claim 1 , wherein a thickness of the first member is 0.1 mm or more.

8. The method for manufacturing a composite structure according to claim 1 , wherein the structure material as the second member satisfies the following (1) to (3):
(1) a volume content of the resin is 2.5 to 85% by volume;
(2) a volume content of the reinforced fibers is 0.5 to 55% by volume; and
(3) a volume content of the voids is 10 to 97% by volume.

9. The method for manufacturing a composite structure according to claim 1 , wherein the structure precursor satisfies the following (4) to (6):
(4) a volume content of the resin is 2.5 to 95% by volume;
(5) a volume content of the reinforced fibers is 0.5 to 85% by volume; and
(6) a volume content of the voids is 0 to 30% by volume.

10. The method for manufacturing a composite structure according to claim 1 , wherein a density (ρ) of the structure material as the second member is 0.9 g/cm 3 or less.

11. The method for manufacturing a composite structure according to claim 1 , wherein the reinforced fibers in the structure material as the second member are discontinuous, and dispersed in a nearly monofilament form and in a random manner.

12. A method for manufacturing an integrated composite structure, the method comprising further integrating another member with at least a part of a surface of the composite structure obtained by the method according to claim 1 .

Assignees

• Toray Industries

Inventors

• Fujioka Takashi
• Takebe Yoshiki
• Honma Masato

Classifications

• B29C39/24

  Feeding the material into the mould · CPC title

• B29C70/68 Primary

  by incorporating or moulding on preformed parts, e.g. inserts or layers {, e.g. foam blocks (mould constructions therefor B29C33/12; joining preformed parts by moulding B29C65/70)} · CPC title

• B29C70/681

  Component parts, details or accessories; Auxiliary operations · CPC title

• B29C44/14

  the preformed part being a lining {(B29C44/1209 takes precedence)} · CPC title

• B29C43/006

  Pressing and sintering powders, granules or fibres · CPC title