CN102649316B - 纤维强化树脂与金属的接合构造及接合方法 - Google Patents

纤维强化树脂与金属的接合构造及接合方法 Download PDF

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CN102649316B
CN102649316B CN201210031252.1A CN201210031252A CN102649316B CN 102649316 B CN102649316 B CN 102649316B CN 201210031252 A CN201210031252 A CN 201210031252A CN 102649316 B CN102649316 B CN 102649316B
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reinforced resin
fiber
aforementioned
metal
configuration
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CN102649316A (zh
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滨田圭佑
长田保
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Subaru Corp
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Fuji Heavy Industries Ltd
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Plasma & Fusion (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
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Abstract

本发明提供一种接合构造及接合方法，其使阶梯状接合面多段化，并且即使在很薄的总厚度内，也容易地使经由阶梯状接合面交替地重叠的纤维强化树脂层及金属层多层化，还可以构成具有平面及任意曲面的形状。本接合构造，将由金属材料(11)和纤维强化树脂复合材料(12～15)构成的要素(10)作为一片，以阶梯状构造在厚度方向重叠的方式层叠多片该要素，使金属材料和纤维强化树脂复合材料粘合，并且相邻的要素(10、10)之间在重叠面接合，其中，金属材料的构成阶梯状接合面的端部朝向该端部的端面方向阶梯状地变薄而形成阶梯状构造，纤维强化树脂复合材料利用端部平坦地填充阶梯状构造。金属材(11、11)之间焊接在一起。

Description

纤维强化树脂与金属的接合构造及接合方法
技术领域
本发明涉及纤维强化树脂与金属的接合。
背景技术
当前，纤维强化树脂复合材料(FRP：Fiber Reinforced Plastics)广泛用于飞机、汽车、船舶或一般工程机器的构造用部件。例如，已知一种纤维强化树脂复合材料，其在将炭素纤维或玻璃纤维等无机物系强化纤维纵横地配置而织入的织物中，浸渍硬化环氧树脂等树脂而形成。
但是，不能利用纤维强化树脂复合材料构成整个部件，而必须在一部分中使用金属材料的情况也很多。
因此，纤维强化树脂复合材料与金属材料高强度地接合成为课题。
当前，如专利文献1～3所述，也提出一种技术，其通过将纤维强化树脂复合材料与金属材料直接粘合，去除连结用具而实现轻量化等。
在通过将两个部件粘合而使其接合时，将两个部件的端面对接，在仅将该对接面作为粘合面的情况下，粘合面较小，不能期望高强度的接合构造。
在专利文献1记载的接合构造中采用阶梯状接合面，即，分别在两个部件要接合的端部形成互补的阶梯状构造，在与对接面垂直的阶梯面上确保大面积的接合面。
在专利文献2记载的接合构造中，在管材中采用多段阶梯状接合面。另外，在专利文献2中记载阶梯状接合面重叠为两层的构造(参照该文献第3图)。其是在开口于纤维强化树脂复合材料的端面上且内侧较窄的阶梯状槽中，插入前端较细的阶梯状的金属材料的端部的构造。
在专利文献3记载的接合构造中，在棒材中，通过使轴端倾斜，将纤维强化树脂复合材料与金属材料部分重叠地配置并卷绕，在通过该轴的剖面上使两种材料交替重叠而形成多层。
专利文献1：日本实开昭63-178126号公报
专利文献2：日本实开昭61-009135号公报
专利文献3：日本特开2001-032819号公报
发明内容
但是，根据专利文献3记载的技术，即使可以将两种材料交替重叠地形成多层，也仅能构成轴状的管材，无法构成具有平面或任意曲面的构造。另外，无法形成阶梯状、特别是多段阶梯状接合面。并且，伴随着卷绕，两种材料重叠的区域逐渐偏离轴向，该区域变长。在用于接合的构造部上很难同时形成其他构造。如果用于接合的构造变大，则该部分的设计自由度受到较大限制，或者使用部位受限，因此不优选。
在专利文献1记载的技术中，是由一层纤维强化树脂复合材料和一层金属材料的重叠而形成的接合构造。在专利文献2记载的技术中，金属材料并不是大于或等于两层。
因此，在上述的现有技术中，很难利用将纤维强化树脂复合材料及金属材料分别交替地重叠两层或多于两层的构造，构成具有平面或任意曲面的形状，对于在要求的总厚度内使各层的层厚更薄、更多层化自然产生局限。
因此，本发明的课题在于提供一种接合构造及接合方法，该接合构造是纤维强化树脂复合材料与金属材料的各端部经由阶梯状接合面接合的纤维强化树脂与金属的接合构造，在该构造中，当然使阶梯状接合面多段化，即使在很薄的总厚度内，也容易地使经由阶梯状接合面交替地重叠的纤维强化树脂层及金属层多层化，利用该多层化，可以使接合强度等特性提高，接合强度充分，并且使阶梯状接合面的形成长度缩短，还可以构成具有平面及任意曲面的形状。
用于解决上述课题的技术方案1所述的发明，是一种纤维强化树脂与金属的接合构造，该构造是纤维强化树脂复合材料与金属材料的端部之间经由阶梯状接合面接合而构成，其特征在于，将金属材料和纤维强化树脂复合材料构成的要素作为一片，以阶梯状构造在厚度方向重叠的方式层叠多片该要素，其中，上述金属材料的构成前述阶梯状接合面的端部朝向该端部的端面方向而阶梯状地变薄，从而形成前述阶梯状构造，上述纤维强化树脂复合材料利用端部平坦地填充前述阶梯状构造而进行层叠，
将前述金属材料和纤维强化树脂复合材料粘合，并且相邻的前述要素之间在重叠面处接合。
技术方案2所述的发明，其特征在于，在技术方案1所述的纤维强化树脂与金属的接合构造中，在前述阶梯状构造的形成区域内，在两个外表面上配置前述金属材料。
技术方案3所述的发明，其特征在于，在技术方案1及技术方案2所述的纤维强化树脂与金属的接合构造中，相邻的前述金属材料之间利用焊接接合。
技术方案4所述的发明，其特征在于，在技术方案1至技术方案3中的任一项所述的纤维强化树脂与金属的接合构造中，前述阶梯状构造为多段。
技术方案5所述的发明，其特征在于，在技术方案1至技术方案4中的任一项所述的纤维强化树脂与金属的接合构造中，前述各要素的前述阶梯状构造的两端位置大致一致地配置。
技术方案6所述的发明，提供一种纤维强化树脂与金属的接合方法，该方法是使纤维强化树脂复合材料与金属材料的各端部经由阶梯状接合面而接合，其特征在于，
使构成前述阶梯状接合面的金属材料的端部，形成为朝向该端部的端面方向阶梯状地变薄的阶梯状构造，
层叠纤维强化树脂复合材料，利用其端部平坦地填充前述阶梯状构造，
将由一个前述金属材料、和以填充其阶梯状构造的方式层叠的前述纤维强化树脂复合材料构成的要素作为一片，在以前述阶梯状构造在厚度方向重叠的方式层叠多片该要素的状态下，通过使前述纤维强化树脂复合材料热硬化，从而将前述金属材料和纤维强化树脂复合材料粘合，并且将相邻的前述要素之间在重叠面接合。
技术方案7所述的发明，其特征在于，在技术方案6所述的纤维强化树脂与金属的接合方法中，在前述热硬化后，将相邻的前述金属材料进行焊接。
技术方案8所述的发明，其特征在于，在技术方案7所述的纤维强化树脂与金属的接合方法中，在将前述金属材料焊接后，在由前述金属材料的前述阶梯状构造的相反端构成的端面上焊接金属部件。
发明的效果
根据本发明，由于是将由构成阶梯状接合面的端部形成为朝向该端部的端面方向阶梯状地变薄的阶梯状构造的金属材料和利用端部平坦地填充阶梯状构造而层叠的纤维强化树脂复合材料构成的要素作为一片，并将其层叠的构造及方法，因此，使阶梯状接合面多段化，并且即使在很薄的总厚度内，也容易地使经由阶梯状接合面交替地重叠的纤维强化树脂层及金属层多层化。并且，利用该多层化，确保纤维强化树脂和金属的总粘合面积较大，接合强度等特性提高。因此，可以使接合强度充分，并且使阶梯状接合面的形成长度缩短。另外，可以构成平面，并且通过使一块金属材料形成适合成形的厚度，将由一块金属材料和以填充其阶梯状构造的方式层叠的纤维强化树脂复合材料构成的要素每片进行成型并层叠，还容易地形成任意的曲面。
附图说明
图1是本发明的一个实施方式涉及的纤维强化树脂与金属的接合构造的剖面图。
图2是本发明的一个实施方式涉及的纤维强化树脂与金属的接合构造的一片要素的剖面图。
图3是表示本发明的一个实施方式涉及的纤维强化树脂与金属的接合构造中的层间焊接的形态的剖面图。
图4是表示本发明的一个实施方式涉及的纤维强化树脂与金属的接合构造中的端面焊接的形态的剖面图。
具体实施方式
下面，参照附图对本发明的一个实施方式进行说明。下面是本发明的一个实施方式，并不是限定本发明。
如图1所示，本实施方式的纤维强化树脂与金属的接合构造1，是将在图2中以单体表示的一片要素10层叠多片而构成的。
一片要素10由金属箔11和纤维强化树脂复合材料12～15构成。金属箔11和纤维强化树脂复合材料12～15经由阶梯状接合面粘合，各要素10、10之间在其重叠面接合。
在这里，按照制造过程进行说明。
首先，如图2所示，使金属箔11的端部11a，形成为沿其端面方向阶梯状地变薄的阶梯状构造。
然后，在金属箔11的阶梯状构造的端部11a上，依次层叠在强化纤维中浸渍基体树脂而成的预浸渍体状态的纤维强化树脂复合材料12～15。
纤维强化树脂复合材料12～15，在与端部11a的各段相对应的部分简单地分开。纤维强化树脂复合材料12～15，分别由一片或多片预浸渍体构成。
在层叠时，首先，使纤维强化树脂复合材料12与端部11a的端面对接。将纤维强化树脂复合材料13的端部配置在与纤维强化树脂复合材料12的端部相比向金属箔11的最厚部11b侧偏移的位置上，利用纤维强化树脂复合材料13的端部，平坦地填充第1阶梯面11c而进行层叠。相同地，将纤维强化树脂复合材料14的端部配置在与纤维强化树脂复合材料13的端部相比向金属箔11的最厚部11b侧偏移的位置上，利用纤维强化树脂复合材料14的端部，平坦地填充第2阶梯面11d而进行层叠。相同地，将纤维强化树脂复合材料15的端部配置在与纤维强化树脂复合材料14的端部相比向金属箔11的最厚部11b侧偏移的位置上，利用纤维强化树脂复合材料15的端部，平坦地填充第3阶梯面11e而进行层叠。此外，也可以在与纤维强化树脂复合材料12～15接触的金属箔11的阶梯状构造的表面上涂敷胶状粘合剂或层叠片状粘合剂，之后层叠纤维强化树脂复合材料12～15。
将上述的要素10如图1所示，使阶梯状构造在厚度方向上重叠，得到层叠多片的状态。另外，也可以将要素10制作必要片数，如图1所示使阶梯状构造在厚度方向上重叠，得到层叠多片的状态。
在图1中示出了阶梯状接合面的形成长度L。
在将要素10进行层叠时，也可以适当改变要素10的正反面，但优选如图1所示，在阶梯状构造的形成区域内，将金属箔11、11配置在整体的正反、即两个外表面上。将金属面作为外表面是为了较强地抵抗来自外部的冲击。
另外，优选配置为使各要素10、10、10…的阶梯状构造的两端位置一致。这是为了可以使阶梯状接合面的形成长度L缩短。
在将要素10层叠多片的状态下，使各要素10的纤维强化树脂复合材料12～15热硬化。
由此，金属箔11和纤维强化树脂复合材料12～15接合在一起，并且所有的纤维强化树脂复合材料12～15成为一体。
然后，如图3所示，对相邻的金属箔11、11进行焊接。在此过程中，如箭头16所示，使激光等焊接热源从端面朝向金属箔11、11的接合面，与接合面平行地入射直至每个接合面上很深的位置，形成熔接部17。
根据需要，在利用研磨等将形成熔接部17的端面进行整形后，如图4所示，使金属部件18的端面与该整形的端面对齐，利用焊接进行接合。此时，如箭头19所示，也使激光等焊接热源朝向金属箔11和金属部件18的接合面，与接合面平行地入射，直至很深的位置，形成熔接部20。
从上述的制造过程可知，本实施方式的纤维强化树脂与金属的接合构造1，是纤维强化树脂复合材料与金属材料的各端部经由阶梯状接合面接合的纤维强化树脂与金属的接合构造，其构成为，将由金属箔11和纤维强化树脂复合材料12～15构成的要素10作为一片，以阶梯状构造在厚度方向重叠的方式层叠多片要素10，将金属箔11和纤维强化树脂复合材料12～15粘合，并且相邻的要素10、10之间在重叠面接合，其中，金属箔11构成阶梯状接合面的端部朝向该端部的端面方向阶梯状地变薄而形成阶梯状构造，纤维强化树脂复合材料12～15利用端部平坦地填充该阶梯状构造而进行层叠。
在上述的实施方式中，使各阶梯状构造形成3段，但这仅是一个例子。优选阶梯状构造形成大于或等于2段的多段。这是因为，在经由阶梯状接合面的接合构造中，应力会集中在各阶梯的端部。通过使阶梯状构造形成更多段数，可以使应力集中分散，减小最大应力。
在上述的实施方式中，使要素10的层叠片数为5片。但这仅是一个例子。优选利用大于或等于3片，如上所述，在两个外表面配置金属面。
通过使要素10的层叠片数增多，纤维强化树脂复合材料和金属材料的粘合面积扩大，即使将阶梯状接合面的形成长度L缩短，也可以确保充分的接合强度。如图4所示，在100％金属的端部的尺寸L1因上述焊接等原因而仅具有一定距离即可的情况下，通过缩短阶梯状接合面的形成长度L，可以提高纤维强化树脂复合材料的容积占有率，从而可以追求轻量化等。
另外，由于纤维强化树脂复合材料和金属材料的粘合面积扩大，因此纤维强化树脂复合材料和金属材料之间的导电性也提高。
在现有的具有阶梯状接合面的接合构造中，由于阶梯状接合面为1层或2层，因此，如果受到冲击载荷或拉伸·压缩、弯曲等重复载荷，在1层阶梯状接合面上产生剥离，则会完全分裂或剥离至大致一半而破坏。
与此相对，如果利用本接合构造1，则成为多层化，粘合面积扩大，由于从距外表面较浅的位置至较深的位置，分散地配置由与外表面平行的阶梯面形成的粘合面，因此即使在相同载荷条件下也不会产生剥离，或者可以仅为外表面的一部分剥离。因此，优选使要素10为3层、4层、5层…，将其层叠数增多。
关于适用的纤维强化树脂复合材料，可以例举炭素纤维强化树脂复合材料，玻璃纤维强化树脂复合材料等，但不限制其种类。
关于适用的金属材料的材质，可以例举Ti合金、Al合金、Mg合金等，但也不限制其种类。关于适用的树脂，只要是热硬化树脂即可，也不限制其种类。

Claims (8)

1.一种纤维强化树脂与金属的接合构造，该构造是纤维强化树脂复合材料与金属材料的端部之间经由阶梯状接合面接合而构成，其特征在于，
将金属材料和纤维强化树脂复合材料构成的要素作为一片，以阶梯状构造在厚度方向重叠的方式层叠多片该要素，其中，上述金属材料的构成前述阶梯状接合面的端部朝向该端部的端面方向而阶梯状地变薄，从而形成前述阶梯状构造，上述纤维强化树脂复合材料利用端部平坦地填充前述阶梯状构造而进行层叠，
将前述金属材料和纤维强化树脂复合材料粘合，并且相邻的前述要素之间在重叠面处接合。
2.根据权利要求1所述的纤维强化树脂与金属的接合构造，其特征在于，
在前述阶梯状构造的形成区域内，在层叠要素整体的两个外表面上配置前述金属材料。
3.根据权利要求1所述的纤维强化树脂与金属的接合构造，其特征在于，
相邻的前述金属材料之间利用焊接接合。
4.根据权利要求1所述的纤维强化树脂与金属的接合构造，其特征在于，
前述阶梯状构造为多段。
5.根据权利要求1至4中的任一项所述的纤维强化树脂与金属的接合构造，其特征在于，
前述各要素的前述阶梯状构造的两端位置大致一致地配置。
6.一种纤维强化树脂与金属的接合方法，该方法是使纤维强化树脂复合材料与金属材料的各端部经由阶梯状接合面而接合，其特征在于，
使构成前述阶梯状接合面的金属材料的端部，形成为朝向该端部的端面方向阶梯状地变薄的阶梯状构造，
层叠纤维强化树脂复合材料，利用其端部平坦地填充前述阶梯状构造，
将由一个前述金属材料、和以填充其阶梯状构造的方式层叠的前述纤维强化树脂复合材料构成的要素作为一片，在以前述阶梯状构造在厚度方向重叠的方式层叠多片该要素的状态下，通过使前述纤维强化树脂复合材料热硬化，从而将前述金属材料和纤维强化树脂复合材料粘合，并且将相邻的前述要素之间在重叠面接合。
7.根据权利要求6所述的纤维强化树脂与金属的接合方法，其特征在于，
在前述热硬化后，将相邻要素的前述金属材料进行焊接。
8.根据权利要求7所述的纤维强化树脂与金属的接合方法，其特征在于，
在将前述金属材料焊接后，在由前述金属材料的前述阶梯状构造的相反端构成的端面上焊接金属部件。
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