Composite material structure, aircraft wing and aircraft fuselage provided with same, and method for manufacturing composite material structure

Abstract

In a composite material structure, which is configured as a fiber-reinforced plastic composite material extending in one direction and having a plurality of holes defined at intervals in a row in the one direction and which is subjected to a tensile load and/or a compressive load in the one direction, a peripheral region around the holes comprises a first area obtained by bending composite material, which is reinforced using continuous fibers that have been made even in a longitudinal direction, so that a center line of a width of the composite material weaves between adjacent holes and zigzags in the one direction. A tensile rigidity and/or a compressive rigidity in the one direction of the peripheral region around the holes is lower than a tensile rigidity and/or a compressive rigidity in the one direction of other regions that surround the peripheral region.

Claims

1. A composite material structure, comprising a fiber-reinforced plastic composite material extending in one direction, wherein the one direction is 0?, and having a plurality of holes defined at intervals in a row in the one direction, that is subjected to a tensile load or a compressive load in the one direction, wherein: a peripheral region around the holes includes a first area obtained by bending a composite material reinforced using continuous fibers made even in a longitudinal direction so that a center line of a width of the composite material weaves between adjacent holes and zigzags in the one direction; a tensile rigidity and/or compressive rigidity in the one direction of the peripheral region is lower than a tensile rigidity and/or compressive rigidity in the one direction of another region that surrounds the peripheral region; the first area includes at least two parallel parts, wherein a first parallel part is positioned on a side and in contact with a hole of the plurality and is connected to a second parallel part on a side and in contact with an adjacent hole of the plurality by a slanted part disposed between the hole and the adjacent hole, such that first parallel part on the side of the hole and the second parallel part on the side of the adjacent hole are on opposite sides; and wherein the parallel part comprises the continuous fibers oriented in a 0? direction, is parallel to a first diameter of its corresponding hole, and includes an extension line of a second diameter of its corresponding hole that is oriented in a ?90? direction, wherein a portion of the parallel part has a length equal to or greater than the first diameter of its corresponding hole.

2. The composite material structure according to claim 1, wherein the slanted part comprises the continuous fibers oriented in a direction greater than or equal to ?30? and less than or equal to ?60?.

3. The composite material structure according to claim 2, wherein the slanted part comprises the continuous fibers oriented in a direction of ?45?.

4. The composite material structure according to claim 1, wherein the portion of the parallel part equal to or greater than the first diameter of its corresponding hole is at an outer edge of the peripheral region.

5. The composite material structure according to claim 1, wherein the slanted part is a first slanted part, and in a case where an orientation of the continuous fibers in the first slanted part is orthogonal to an orientation of continuous fibers to an adjacent second slanted part, the width of the composite material is defined as less than or equal to 1/?2 a distance between centers of adjacent holes.

6. The composite material according to claim 1, wherein the first diameter is a major axis and the second diameter is a minor axis, forming an elongated hole in the 0? direction.

7. The composite material structure according to claim 1, wherein a first layer including a first area in which the composite material reinforced using continuous fibers made even in the longitudinal direction is repeatedly bent so as to define peak areas and valley areas in that order, and a second layer including a first area in which the composite material reinforced using continuous fibers made even in the longitudinal direction is repeatedly bent so as to define valley areas and peak areas in that order, are laminated together so that the peak areas in the first area of the first layer and the valley areas in the first area of the second layer define vertical pairs.

8. The composite material structure according to claim 1, wherein the holes are access holes defined in a lower surface outer plate of an aircraft wing.

9. The composite material structure according to claim 1, wherein the holes are window holes defined in an outer plate of an aircraft fuselage.

10. An aircraft wing comprising the composite material structure according to claim 8.

11. An aircraft fuselage comprising the composite material structure according to claim 9.

12. A method of manufacturing a composite material structure, the composite material structure comprising a fiber-reinforced plastic composite material extending in one direction, wherein the one direction is 0?, and having a plurality of holes defined at intervals in a row in the one direction, that is subjected to a tensile load or a compressive load in the one direction, the method comprising: bending a composite material reinforced using continuous fibers made even in a longitudinal direction in a peripheral region around the holes so that a center line of a width of the composite material weaves between adjacent holes and zigzags in the one direction, thereby obtaining a first area, wherein: a tensile rigidity and/or compressive rigidity in the one direction of the peripheral region is lower than a tensile rigidity and/or compressive rigidity in the one direction of another region that surrounds the peripheral region; the first area includes at least two parallel parts, wherein a first parallel part is positioned on a side and in contact with a hole of the plurality and is connected to a second parallel part on a side and in contact with an adjacent hole of the plurality by a slanted part disposed between the hole and adjacent hole, such that first parallel part on the side of the hole and the second parallel part on the side of the adjacent hole are on opposite sides; and wherein the parallel part comprises the continuous fibers oriented in a 0? direction, is parallel to a first diameter of its corresponding hole, and includes an extension line of a second diameter of its corresponding hole oriented in a ?90? direction, wherein a portion of the parallel part has a length equal to or greater than the first diameter of its corresponding hole.

13. The method of manufacturing a composite material structure according to claim 12, wherein the slanted part comprises the continuous fibers oriented in a direction greater than or equal to ?30? and less than or equal to ?60?.

14. The method of manufacturing a composite material structure according to claim 13, wherein the slanted part comprises the continuous fibers oriented in a direction of ?45?.

15. The method of manufacturing a composite material structure according to claim 12, wherein the portion of the parallel part equal to or greater than the first diameter of its corresponding hole is at an outer edge of the peripheral region.

16. The method of manufacturing a composite material structure according to claim 12, wherein the first diameter is a major axis and the second diameter is a minor axis, forming an elongated hole in the 0? direction.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIGS. 1A and 1B illustrate a lower surface outer plate of a main wing of an aircraft according to an embodiment of a composite material structure of the present invention, where FIG. 1A is a plan view and FIG. 1B is a vertical cross-sectional view taken from A-A in FIG. 1A.

(2) FIG. 2 is a perspective view of a lower surface outer plate and stringers that constitute part of a main wing having a box structure.

(3) FIG. 3 is a horizontal cross-sectional view taken from A-A in FIG. 2.

(4) FIG. 4 is an exploded perspective view illustrating primary elements in a multilayer structure of fiber sheets.

(5) FIG. 5 is a plan view illustrating primary elements in a second layer according to a first embodiment.

(6) FIG. 6 is a plan view illustrating primary elements in a second layer according to a second embodiment.

DESCRIPTION OF EMBODIMENTS

First Embodiment

(7) An embodiment of the present invention will be described below, using FIGS. 1A to 3.

(8) FIG. 1A illustrates a lower surface outer plate 3 of an aircraft main wing 1. The lower surface outer plate 3 is formed as a composite material structure from fiber-reinforced plastic (FRP). A dashed line in FIG. 1A indicates an outline of the main wing 1 including flaps, slats, and the like.

(9) As illustrated in FIGS. 2 and 3, the lower surface outer plate 3, a front spar 20 and a rear spar 22 serving as side surface outer plates erected from both ends of the lower surface outer plate 3 in a width direction thereof, and an upper surface outer plate 24 connecting upper ends of the front spar 20 and the rear spar 22 to each other form a box-shaped torque box, and bear a load of the main wing 1.

(10) A plurality of stringers 26 are provided in a longitudinal direction of the main wing 1. The stringers 26 are formed from the same FRP composite material as the lower surface outer plate 3 and the like. Each stringer 26 is fixed to an inner surface of the lower surface outer plate 3 and the upper surface outer plate 24, and mainly bears a longitudinal direction load of the main wing 1.

(11) Ribs 28 are provided inside the main wing 1 having a box structure so as to divide that interior space into a plurality of segments in the longitudinal direction. The ribs 28 have plate shapes extending across a width direction of the main wing 1 (a direction orthogonal to the longitudinal direction), and a plurality of the ribs 28 are provided at predetermined intervals in the longitudinal direction. As illustrated in FIG. 3, front and rear ends of each rib 28 are fastened to the front spar 20 and the rear spar 22, respectively, by predetermined fasteners 30 such as bolts and nuts.

(12) As illustrated in FIG. 1, a plurality of access holes (holes) 5 used during inspection, assembly, or the like of a fuel tank provided in the main wing 1 are formed in the lower surface outer plate 3 at predetermined intervals in an extension direction of the main wing 1.

(13) The lower surface outer plate 3 is constituted of a peripheral region 3a located in the periphery of the access holes 5 and another region 3b that surrounds the peripheral region 3a, and is formed from a single piece of a composite material.

(14) Taking a line that passes through the centers of the access holes 5 and follows the extension direction of the main wing 1 as an axis, the peripheral region 3a is provided spanning a predetermined width d on both sides of that axis. Here, the width d serves as a distance of the peripheral region in a direction orthogonal to the extension direction of the main wing 1.

(15) The other region 3b is located in the periphery of the peripheral region 3a, and is present in a range corresponding to all regions aside from the peripheral region 3a.

(16) The peripheral region 3a and the other region 3b that constitute the lower surface outer plate 3 are a composite material constituted mainly of carbon fiber-reinforced plastic (CFRP). The number of layers of the composite material is determined on the basis of the strength to be borne, and is set to approximately several tens of layers, for example.

(17) Percentages of orientations of the carbon fibers in the other region 3b are set to approximately the normal percentages used in aircraft structures; in the case where the extension direction of the main wing 1 (the longitudinal direction) is taken as 0?, a plurality of fiber sheets having fiber directions of 0?, +45?, ?45?, and 90? are laminated together so that the percentages of (0?, +45?, ?45?, 90?)=(30%, 30%, 30%, 10%), for example.

(18) Percentages of carbon fiber orientations in the peripheral region 3a are different from those in the other region 3b; in the case where the extension direction of the main wing 1 is taken as 0?, the orientation of the carbon fibers is primarily greater than or equal to ?30? and less than or equal to ?60?, and preferably ?45?, between adjacent holes 5. In other words, a plurality of fiber sheets having each of the fiber directions are laminated together so that the percentage of an orientation of greater than or equal to ?30? and less than or equal to ?60?, and preferably ?45?, is greater than in the other region 3b, such that the percentage of an orientation of ?45? is greater than or equal to 70%, for example. Furthermore, the fibers in the 0? direction may be switched from carbon fibers to glass fibers, aramid fibers, or the like in order to reduce tensile rigidity in the 0? direction.

(19) The multilayer structure of the lower surface outer plate 3 having orientation percentages such as those described above will be described with reference to FIG. 4. FIG. 4 is an exploded perspective view illustrating an example of primary elements in the multilayer structure of fiber sheets. The multilayer structure illustrated in FIG. 4 is constituted of a first layer 41 to a fifth layer 45. The locations of the holes 5, the peripheral region 3a, and the other region 3b in the first layer 41 to the fifth layer 45 correspond with each other in a vertical direction. In FIG. 4, the direction in which the holes 5 are arranged (the extension direction of the main wing 1) is taken as 0?.

(20) The first layer 41 is a layer in which the fibers are oriented in the +45? direction. The first layer 41 is formed with a +45? fiber sheet disposed throughout both the peripheral region 3a and the other region 3b.

(21) The second layer 42 is a layer in which the fibers are mainly oriented in the 0? direction. The second layer 42 is formed by disposing a peripheral region composite material in the peripheral region 3a and an other region composite material in the other region 3b. The specific arrangement of the peripheral region composite material and the other region composite material will be described later.

(22) The third layer 43 is a layer in which the fibers are oriented in the 90? direction. The third layer 43 is formed with a 90? fiber sheet disposed throughout both the peripheral region 3a and the other region 3b.

(23) The fourth layer 44 is a layer in which the fibers are mainly oriented in the 0? direction. The fourth layer 44 is formed by disposing the peripheral region composite material in the peripheral region 3a and the other region composite material in the other region 3b.

(24) The fifth layer 45 is, like the first layer 41, a layer in which the fibers are oriented in the +45? direction. The fifth layer 45 is formed with a +45? fiber sheet disposed throughout both the peripheral region 3a and the other region 3b.

(25) The second layer 42 will be described in more detail with reference to FIG. 5. FIG. 5 is a plan view illustrating primary elements of the second layer 42. In FIG. 5, the second layer 42 is constituted of a plurality of the holes 5 formed at intervals along a direction t in which a main load is borne, the peripheral region 3a present around the holes 5, and the other region 3b present on both sides of the peripheral region 3a. The peripheral region 3a includes a first area 10 realized by disposing a first peripheral region composite material and a second area 11 realized by disposing a second peripheral region composite material. The first peripheral region composite material and the second peripheral region composite material are composite materials reinforced using continuous fibers made even in the longitudinal direction (a composite material A). Here, continuous fibers refers to a state in which the peripheral region 3a is not cut in the t direction. The composite material A is a sheet-form prepreg, a partially impregnated prepreg, or the like.

(26) The first area 10 is realized by disposing the composite material A in a bending zigzag shape so that a center line of a width W of the composite material A weaves between adjacent holes 5. It is preferable that the composite material A zigzag symmetrically using a line passing through the centers of the plurality of holes 5 as an axis. The composite material A may achieve the width W by aligning a plurality of thin prepregs.

(27) It is preferable that the width W be set to a length at which the space between adjacent holes 5 is filled by the composite material A when the composite material A is arranged in the zigzag shape. The width W is a length of the composite material in a direction orthogonal to the orientation of the continuous fibers. The width W of the composite material A can be determined on the basis of a distance L between the centers of adjacent holes 5. For example, in the case where the orientation of the fibers in one slanted part is orthogonal to the orientation of the fibers in the next slanted part (?=90?), as indicated in FIG. 5, it is preferable that the width W be set to less than or equal to 1/?2 the distance L between the centers of adjacent holes 5.

(28) The first area 10 includes slanted parts 12 and parallel parts 13. The slanted parts 12 and the parallel parts 13 are disposed alternately. In FIG. 5, the composite material A bends when changing from the slanted part 12 to the parallel part 13 so that the fiber orientation switches at a predetermined angle, but may instead bend so that the fiber orientation changes gradually so as to trace a curve.

(29) The slanted parts 12 are located between adjacent holes 5, with the continuous fibers in the composite material A being oriented in a direction greater than or equal to ?30? and less than or equal to ?60?, and preferably ?45?.

(30) The parallel parts 13 are disposed in positions including an extension line of the minor axis of the holes 5 (a diameter oriented in the ?90? direction). It is preferable that the parallel parts 13 also be disposed in locations including outer edges 13a of the first area 10 in regions parallel to the major axis of the holes 5 (the diameter of the holes 5 in the 0? direction). The parallel parts 13 are at least partially in contact with the holes 5.

(31) The second area 11 is a valley area corresponding to a part where the zigzagging first area bends. The second area 11 is realized by disposing the second peripheral region composite material in the valley area so that the fiber orientation is in the 0? direction.

(32) The fourth layer 44 has the same configuration as the second layer 42. However, it is preferable that the first area in the fourth layer 44 have a zigzag shape in which the peak and valley areas are inverted with respect to those in the first area of the second layer 42. Specifically, the first area 10 in the second layer 42 has a zigzag shape in which the composite material A repeatedly bends so as to form peak areas and valley areas in that order, whereas the first area in the fourth layer 44 has a zigzag shape in which the composite material A repeatedly bends so as to form valley areas and peak areas in that order. When the second layer 42 and the fourth layer 44 having such first areas are laminated together, the peak areas in the first area of the second layer 42 and the valley areas in the first area of the fourth layer 44 form vertical pairs.

(33) By repeating the first layer 41 to the fifth layer 45 described above or combining those layers as desired (see FIG. 5), the peripheral region 3a can primarily have an orientation percentage of greater than or equal to ?30? and less than or equal to ?60?, and preferably ?45?, as compared to the other region 3b.

(34) Effects obtained when using the main wing 1 configured as described above will be described next.

(35) During flight, a load that causes a tip of the main wing 1 to deform upward acts on the main wing 1. Accordingly, a tensile load in the extension direction (0? direction) of the lower surface outer plate 3 of the main wing 1 acts on the lower surface outer plate 3. The tensile load in the 0? direction is primarily borne not by the peripheral region 3a, but rather by the other region 3b of the lower surface outer plate 3. This is because compared to the other region 3b, the peripheral region 3a is primarily formed from fibers oriented in a direction greater than or equal to ?30? and less than or equal to ?60?, and preferably ?45?, and is therefore a region having a low rigidity with respect to a tensile load in the 0? direction. Accordingly, compared to the other region 3b, only a small tensile load acts on the peripheral region 3a, and thus less strength is required for the peripheral region 3a. In other words, it is not necessary to provide a reinforcing laminated body for increased thickness around the holes. FIG. 1B indicates a reinforcing laminated body 104 as well to facilitate understanding. As such, the reinforcing laminated body 104 is unnecessary, and thus the weight can be reduced by that amount.

(36) The peripheral region 3a is primarily formed from fibers oriented in a direction greater than or equal to ?30? and less than or equal to ?60?, and preferably ?45?, and is therefore strengthened with respect to rigidity in a shear direction, or in other words, torsional rigidity. Accordingly, the peripheral region 3a bears a torsional load, and does not bear an axial force (a tensile load).

(37) The peripheral region 3a includes the first area 10 realized by causing the composite material A, which is reinforced using continuous fibers made even in the longitudinal direction, to zigzag. Because the composite material A contains the continuous fibers, the fibers hold their continuous state even when bent. By making the fibers continuous, the strength in the 0? direction can be increased as compared to a case where short fibers are used. By using a composite material reinforced using continuous fibers, there is no worry of gaps arising at borders in the first area where the fiber orientation changes. This results in a composite material structure that is more precise than in the past.

(38) The first area 10 can be formed around the plurality of holes collectively by making the composite material A zigzag so as to weave between the holes 5, which makes it possible to dispose the composite material A using a machine and manufacture the composite material A efficiently.

(39) Disposing the slanted parts 12 between the holes 5 makes it possible to realize a region in which the tensile rigidity in the 0? direction (one direction) is reduced and extension in a tensile direction (and/or a compression direction) is permitted. In the slanted parts 12, the fibers are oriented in a direction greater than or equal to ?30? and less than or equal to ?60?, and preferably ?45?, which increases the strength in the shear direction (a direction orthogonal to the one direction, or in other words, the ?90? direction) and makes it possible to increase the torsional rigidity.

(40) Providing the parallel parts on the extension line of the diameter of the holes 5 oriented in the ?90? direction makes it possible to alleviate concentrations of stress on the peripheral region 3a of the holes 5 without causing a drop in strength at locations that break easily. This results in a composite material structure having a high substantial strength.

(41) By disposing the parallel parts 13 in the peripheral region 3a serving as a border, the orientation of the fibers in the peripheral region 3a can be matched to the orientation of the fibers in the adjacent other region 3b. This makes it possible to suppress a drop in strength in the ?90? direction at the borders between the peripheral region 3a and the other region 3b.

(42) When laminating the fiber sheets, making a pair of a peak area in a first area A of one layer and a valley area in a first area B of another layer makes it possible to stagger the borders of the fiber sheets in the vertical direction. This makes it possible to alleviate the risk of a drop in strength in the ?90? direction.

Second Embodiment

(43) A composite material structure according to the present embodiment has the same configuration as that of the first embodiment aside from a range in which the parallel parts are provided.

(44) FIG. 6 is a plan view illustrating primary elements of a second layer 52 according to the present embodiment. In the present embodiment, the parallel parts 13 are disposed throughout a region parallel to the major axis of the holes 5 (the diameter in the 0? direction). The length of the parallel parts is the same as that of the major axis of the holes 5.

(45) By using the entirety of the regions parallel to the holes 5 as the parallel parts, the strength around the holes with respect to the 0? direction can be increased. Because there are no longer any borders where the direction of the fibers switch in the ?90? direction of the holes, the strength around the holes with respect to the ?90? direction can be increased.

(46) Although the above embodiments described apply to the present invention in the lower surface outer plate 3 of the main wing 1, the present invention is not limited thereto, and can be broadly applied in any composite material structure having holes.

(47) For example, the same configuration as that of the lower surface outer plate 3 may be applied in the upper surface outer plate that forms the torque box along with the lower surface outer plate 3. The present embodiment can also be applied in a tail assembly or the like.

(48) The above embodiments can also be applied in an aircraft fuselage in which window holes are formed. Furthermore, the composite material structure according to the present invention is not limited to aircraft, and can also be applied in ships, vehicles, and the like, for example.

(49) Although the above embodiments describe primarily using carbon fiber-reinforced plastic (CFRP), the present invention is not limited thereto, and glass fiber-reinforced plastic, aramid fiber-reinforced plastic, or the like may be used as well, for example.

REFERENCE SIGNS LIST

(50) 1 Main wing 3 Lower surface outer plate (composite material structure) 3a Peripheral region 3b Other region 5 Access hole (hole) 10 First area 11 Second area 12 Slanted part 13 Parallel part 13a Outer edge (of parallel part) 20 Front spar 22 Rear spar 24 Upper surface outer plate 26 Stringer 28 Rib 30 Fastener 41 First layer 42 Second layer 43 Third layer 44 Fourth layer 45 Fifth layer 104 Reinforcing laminated body