Composite material molding method
A composite material molding method for molding a composite material by integrating a first fiber base material which is formed in a plate shape and a second fiber base material. The method includes installing, in a recess in a first molding surface of a molding tool, the second fiber base material formed in a shape corresponding to the recess; fixing a first fiber-reinforced portion which is a part of a plurality of fiber reinforced sheets included in the first fiber base material to the first molding surface to cover the recess in which the second fiber base material is installed by the installation step; laying up a second fiber-reinforced portion on the first fiber-reinforced portion fixed by the fixing step; and molding the composite material by integrating and curing the first fiber base material and the second fiber base material installed in the recess using a resin material.
1 . A composite material molding method for molding a composite material by integrating a first fiber base material which is formed in a plate shape and a second fiber base material, the method comprising:
an installation step of installing, in a recess formed in a first molding surface of a molding tool having the first molding surface extending along a longitudinal direction, the second fiber base material formed in a shape corresponding to the recess, a core portion or a bladder being inserted into a hollow portion of the second fiber base material;
a fixing step of fixing a pair of end portions of a first fiber-reinforced portion in a width direction orthogonal to the longitudinal direction to the first molding surface to cover the recess in which the second fiber base material and either the core portion or the bladder are installed by the installation step, the first fiber-reinforced portion being a part of a plurality of fiber reinforced sheets included in the first fiber base material, and a pair of end portions of the second fiber base material being included between the pair of end portions of the first fiber-reinforced portion in the width direction;
a lay-up step of laying up a second fiber-reinforced portion, which is the other part of the plurality of fiber reinforced sheets included in the first fiber base material, on the first fiber-reinforced portion fixed by the fixing step, the second fiber-reinforced portion having a larger number of layers than the fiber reinforced sheets included in the first fiber-reinforced portion, and the pair of end portions of the second fiber base material being included between the pair of end portions of the second fiber-reinforced portion in the width direction; and
a molding step of molding the composite material by integrating and curing the first fiber base material and the second fiber base material installed in the recess using a resin material, wherein
in the fixing step, the pair of end portions of the first fiber-reinforced portion is positioned on an outer side of the pair of end portions of the second fiber base material along the width direction to prevent the second fiber base material from contacting other members and moving in the lay-up step.
2 . The composite material molding method according to claim 1 , wherein
in the fixing step, the first fiber-reinforced portion is fixed to the first molding surface in a state in which a sheet material is sandwiched between the first fiber-reinforced portion and the first molding surface.
3 . The composite material molding method according to claim 2 , wherein
the molding tool includes a curved portion provided at an end portion of the first molding surface in the width direction,
the composite material molding method further comprises a shaping step of shaping the second fiber-reinforced portion formed in a flat shape into a shape corresponding to the curved portion by using a forming die having a shape corresponding to the curved portion, and
in the lay-up step, the second fiber-reinforced portion shaped into a shape corresponding to the curved portion by the shaping step is laid up on the first fiber-reinforced portion.
4 . The composite material molding method according to claim 2 , wherein
the molding tool includes a curved portion provided at an end portion of the first molding surface in the width direction, and
the composite material molding method further comprises a shaping step of pressing an end portion in the width direction of the second fiber-reinforced portion formed in a flat shape against the curved portion to shape the second fiber-reinforced portion.
5 . The composite material molding method according to claim 1 , wherein
the molding tool includes a curved portion provided at an end portion of the first molding surface in the width direction,
the composite material molding method further comprises a shaping step of shaping the second fiber-reinforced portion formed in a flat shape into a shape corresponding to the curved portion by using a forming die having a shape corresponding to the curved portion, and
in the lay-up step, the second fiber-reinforced portion shaped into a shape corresponding to the curved portion by the shaping step is laid up on the first fiber-reinforced portion.
6 . The composite material molding method according to claim 1 , wherein
the molding tool includes a curved portion provided at an end portion of the first molding surface in the width direction, and
the composite material molding method further comprises a shaping step of pressing an end portion in the width direction of the second fiber-reinforced portion formed in a flat shape against the curved portion to shape the second fiber-reinforced portion.
7 . The composite material molding method according to claim 1 , wherein
the first fiber-reinforced portion is fixed to the first molding surface formed in a flat shape in the fixing step, and
the second fiber-reinforced portion formed in a flat shape is laid up on the first fiber-reinforced portion in the lay-up step.