# US 11,993,030 B2 · Composite material component shaping method and charge > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,993,030 B2 - Document ID: US11993030B2 - Status: Granted - Kind: B2 - Application number: 17/633,389 - Filed: 2019-09-26 - Published: 2022-09-15 - Granted: 2024-05-28 - Earliest claimed: 2019-09-26 - Assignees: Mitsubishi Heavy Industries, Ltd. - Applicants: Mitsubishi Heavy Industries, Ltd. - Inventors: Masahiko Shimizu; Shoya Mano; Toshiki Kitazawa; Homare Yamato; Kenichi Kawamura; Yoko Taguchi - Web page: https://patentgrep.com/patent/US11993030B2 ## CPC - B29C 70/345: {using matched moulds} - B29C 70/16: using fibres of substantial or continuous length {(non-woven fabrics per se D04H3/00)} - B29C 70/30: Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core - B29C 70/46: using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs - B29C 70/545: {Perforating, cutting or machining during or after moulding} - B29K 2307/04: Carbon - B29K 2309/08: Glass - B29L 2031/3076: {Aircrafts (blades, propellers B29L2031/08)} - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES ## Abstract A method includes laminating a plurality of fiber reinforced sheets to create a charge; and shaping, by pressing, the charge created in the lamination step into a shaping mold. The charge has a predetermined angle layer including the plurality of fiber reinforced sheets, the fiber direction of which is aligned in a single direction. The predetermined angle layer has n-number of constitutional layers (n≥2) ranging from a first constitutional layer to an n-th constitutional layer each including the plurality of fiber reinforced sheets, wherein the n-th constitutional layer is laminated on an (n−1)-th constitutional layer, the plurality of fiber reinforced sheets in each of the constitutional layers have dividing portions which are along the fiber direction and which are disposed one by one at respective positions within a predetermined range along the fiber direction in the predetermined angle layer. ## Claims ### Claim 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. ### Claim 2 (depends on 1) The composite material component shaping method according to claim 1, wherein in each of the forming layers, the split portions of two sheets of the reinforced fiber sheets adjacent to each other in the lamination direction are adjacent to each other in the fiber direction. ### Claim 3 (depends on 1) The composite material component shaping method according to claim 1, wherein an interval between the split portions adjacent to each other in the fiber direction in the predetermined angle layer is 1/n of an interval between the split portions adjacent to each other in the fiber direction in each of the forming layers. ### Claim 4 (depends on 2) The composite material component shaping method according to claim 2, wherein n=2 is defined, the split portion of the reinforced fiber sheet facing a second forming layer of each of the reinforced fiber sheets of the first forming layer is located on the one end side in the predetermined range in the fiber direction, and the split portion of the reinforced fiber sheet facing the first forming layer of each of the reinforced fiber sheets of the second forming layer is located on the one end side in the predetermined range in the fiber direction. ### Claim 5 (depends on 2) The composite material component shaping method according to claim 2, wherein n=2 is defined, the split portion of the reinforced fiber sheet facing the first forming layer of each of the reinforced fiber sheets of the second forming layer is located on the one end side in the predetermined range in the fiber direction, and the split portion of the reinforced fiber sheet facing the second forming layer of each of the reinforced fiber sheets of the first forming layer is located on the other end side in the predetermined range in the fiber direction. ### Claim 6 (depends on 2) The composite material component shaping method according to claim 2, wherein n=4 is defined, the split portion of the reinforced fiber sheet facing the first forming layer of each of the reinforced fiber sheets of the second forming layer is located on the one end side in the predetermined range in the fiber direction, the split portion of the reinforced fiber sheet facing the second forming layer of each of the reinforced fiber sheets of the first forming layer is located on the other end side in the predetermined range in the fiber direction, the split portion of the reinforced fiber sheet facing the second forming layer of each of the reinforced fiber sheets of the third forming layer is located on the one end side in the predetermined range in the fiber direction, the split portion of the reinforced fiber sheet facing the third forming layer of each of the reinforced fiber sheets of the second forming layer is located on the other end side in the predetermined range in the fiber direction, the split portion of the reinforced fiber sheet facing the third forming layer of each of the reinforced fiber sheets of the fourth forming layer is located on the one end side in the predetermined range in the fiber direction, and the split portion of the reinforced fiber sheet facing the fourth forming layer of each of the reinforced fiber sheets of the third forming layer is located on the other end side in the predetermined range in the fiber direction. ### Claim 7 (depends on 1) The composite material component shaping method according to claim 1, wherein the respective split portions are separated and aligned at an equal interval along the fiber direction of the predetermined angle layer. ### Claim 8 (depends on 1) The composite material component shaping method according to claim 1, wherein the predetermined angle layer is divided into a plurality of sections in a direction orthogonal to the fiber direction and the lamination direction, and the respective split portions in each of the sections are aligned not to overlap each other in a direction in which the predetermined angle layer is divided. ### Claim 9 (depends on 1) The composite material component shaping method according to claim 1, wherein in the charge, another reinforced fiber sheet having the fiber direction different from that of each of the reinforced fiber sheets forming the predetermined angle layer is interposed between the respective reinforced fiber sheets of the predetermined angle layer. ### Claim 10 (depends on 1) The composite material component shaping method according to claim 1, wherein the shaping die has a first surface on which a curved surface is formed and a second surface that intersects with the first surface, and the lamination step includes a first surface alignment step of aligning the reinforced fiber sheet on the first surface, a second surface alignment step of aligning the reinforced fiber sheet on the second surface, and a splitting step of providing the split portion in the reinforced fiber sheet. ### Claim 11 (depends on 10) The composite material component shaping method according to claim 10, wherein each of the split portions is folded toward the second surface to be provided only in a range of the reinforced fiber sheet aligned on the second surface. ### Claim 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.