Composite material structure and method of manufacturing composite material structure

Patent metadata

Field	Value
Publication number	US-9931809-B2
Application number	US-201615259109-A
Country	US
Kind code	B2
Filing date	Sep 8, 2016
Priority date	Sep 9, 2015
Publication date	Apr 3, 2018
Grant date	Apr 3, 2018

Abstract

According to one implementation, a composite material structure includes a first member and a second member. The first member has at least one first bonded surface. The second member has at least one second bonded surface to be bonded to the at least one first bonded surface. The second member is made of a composite material. At least one surface formed by fibers forming the composite material is used as the at least one second bonded surface by disposing end portions of the fibers, in the first member side, inside the composite material.

First claim

What is claimed is:

1. A composite material structure comprising:
a first member having at least one first bonded surface including a surface of a projecting convex portion, a section of the convex portion being a wedge shape; and
a second member having at least one second bonded surface to be bonded to the at least one first bonded surface, the second member being made of a composite material,
wherein end portions of sheet-like fibers forming the composite material are disposed inside the composite material by spreading a part of the sheet-like fibers in a V-shape corresponding to the convex portion and laminating the spread part of the sheet-like fibers on the at least one second bonded surface in directions perpendicular to the at least one second bonded surface, the end portions of the sheet-like fibers being formed on a side of the first member.

2. The composite material structure according to claim 1 ,
wherein lengths of the sheet-like fibers forming the composite material are changed, and a lamination direction of a part of the sheet-like fibers forming the composite material is perpendicular to the at least one second bonded surface while a lamination direction of another part of the sheet-like fibers forming the composite material is a thickness direction of the second member, and the part of the sheet-like fibers being formed on a side of the first member and on the at least one second bonded surface, and the another part of the sheet-like fibers being formed on a side of the first member and separated from the at least one second bonded surface, the first member and the second member being platy.

3. A composite material structure comprising:
a first member having at least one first bonded surface, the first member being made of a metal; and
a second member having at least one second bonded surface to be bonded to the at least one first bonded surface, the second member being made of a composite material,
wherein end portions of sheet-like fibers forming the composite material are disposed inside the composite material by laminating a part of the sheet-like fibers on the at least one second bonded surface in a direction perpendicular to the at least one second bonded surface, the end portions of the sheet-like fibers being formed on a side of the first member.

4. The composite material structure according to claim 3 ,
wherein the first member is jointed to the second member by a scarf joint.

5. The composite material structure according to claim 4 ,
wherein the at least one first bonded surface includes a surface of a projecting convex portion, a section of the convex portion being a wedge shape; and
the second member includes two sheets of sheet-like fibers, the two sheets being spread in a V-shape corresponding to the convex portion.

6. The composite material structure according to claim 3 ,
wherein the at least one first bonded surface includes a surface of a projecting convex portion, a section of the convex portion being a wedge shape; and
the second member includes two sheets of sheet-like fibers, the two sheets being spread in a V-shape corresponding to the convex portion.

7. The composite material structure according to claim 3 ,
wherein lengths of the sheet-like fibers forming the composite material are changed, and a lamination direction of a part of the sheet-like fibers forming the composite material is perpendicular to the at least one second bonded surface while a lamination direction of another part of the sheet-like fibers forming the composite material is a thickness direction of the second member, the part of the sheet-like fibers being formed on a side of the first member and on the at least one second bonded surface, and the another part of the sheet-like fibers being formed on a side of the first member and separated from the at least one second bonded surface, the first member and the second member being platy.

8. A method of manufacturing a composite material structure comprising:
producing a platy laminated body of first prepregs, of which lengths are not same, by laminating the first prepregs to make at least one ends of the first prepregs become inside, the laminated body of the first prepregs having a surface to be bonded formed by a surface of one of the first prepregs, the surface to be bonded formed by the surface of the one of the first prepregs inclining to a thickness direction of the laminated body of the first prepregs;
producing a platy laminated body of second prepregs, of which lengths are not same, by laminating the second prepregs to make at least one ends of the second prepregs become inside, the laminated body of the second prepregs having a surface to be bonded formed by a surface of one of the second prepregs, the surface to be bonded formed by the surface of the one of the second prepregs inclining to a thickness direction of the laminated body of the second prepregs; and
heating and curing an object part to be bonded having two surfaces to be bonded, the laminated body of the first prepregs, and the laminated body of the second prepregs, which have been combined in a state where the thickness direction of the laminated body of the first prepregs is same as the thickness direction of the laminated body of the second prepregs, the surface to be bonded formed on the laminated body of the first prepregs is matched to one of the two surfaces of the object part and the surface to be bonded formed on the laminated body of the second prepregs is matched to another of the two surfaces of the object part, the two surfaces of the object part being surfaces of a projecting convex portion of which section is a wedge shape,
wherein the object to be bonded constitutes a first member;
wherein the platy laminated body of first prepregs and the platy laminated body of second prepregs constitute a second member being made of a composite material, and
wherein the first and second prepregs comprise sheet-like fibers, and end portions of the sheet-like fibers form the composite material and are disposed inside the composite material by spreading a part of the sheet-like fibers in a V-shape corresponding to the convex portion and laminating the spread part of the sheet-like fibers on the two surfaces to be bonded in directions perpendicular to the two surfaces to be bonded, the end portions of the sheet-like fibers being formed on a side of the first member.

9. A method of manufacturing a composite material structure comprising:
producing a platy laminated body of first prepregs, of which lengths are not same, by laminating the first prepregs to make at least one ends of the first prepregs become inside, the laminated body of the first prepregs having a surface to be bonded formed by a surface of one of the first prepregs, the surface to be bonded formed by the surface of the one of the first prepregs inclining to a thickness direction of the laminated body of the first prepregs;
producing a platy laminated body of second prepregs, of which lengths are not same, by laminating the second prepregs to make at least one ends of the second prepregs become inside, the laminated body of the second prepregs having a surface to be bonded formed by a surface of one of the second prepregs, the surface to be bonded formed by the surface of the one of the second prepregs inclining to a thickness direction of the laminated body of the second prepregs;
producing a platy first composite component and a platy second composite component by heating and curing the laminated body of the first prepregs and the laminated body of the second prepregs simultaneously or individually, the first composite component having a first surface to be bonded, the second composite component having a second surface to be bonded;

Assignees

• Fuji Heavy Ind Ltd
• Subaru Corp

Inventors

• Kosugi Yoshikazu
• Abe Masakatsu
• Yasunaga Yuichiro

Classifications

• B29C65/00

  Joining {or sealing} of preformed parts {, e.g. welding of plastics materials}; Apparatus therefor {(general aspects of processes or apparatus for joining preformed parts B29C66/00; using porous material formed by internal pressure generated therein for joining preformed parts B29C44/1228, B29C44/326)} · CPC title

• B29C70/34

  and shaping or impregnating by compression {, i.e. combined with compressing after the lay-up operation} · CPC title

• B29C70/00

  Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts · CPC title

• B32B5/02 Primary

  characterised by structural features of a {fibrous or filamentary} layer {(layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02)} · CPC title

• B29C70/304 Primary

  In-plane lamination by juxtaposing or interleaving of plies, e.g. scarf joining · CPC title