CN106103060B - 复合结构及其制造方法 - Google Patents

复合结构及其制造方法 Download PDF

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Publication number
CN106103060B
CN106103060B CN201580013464.9A CN201580013464A CN106103060B CN 106103060 B CN106103060 B CN 106103060B CN 201580013464 A CN201580013464 A CN 201580013464A CN 106103060 B CN106103060 B CN 106103060B
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China
Prior art keywords
component
slit
enhancing
composite construction
mold
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Expired - Fee Related
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CN201580013464.9A
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English (en)
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CN106103060A (zh
Inventor
山下祐司
近藤清人
泽田义政
河边浩和
稻本好辉
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Aisin Takaoka Co Ltd
Toyota Motor Corp
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Aisin Takaoka Co Ltd
Toyota Motor Corp
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Publication of CN106103060A publication Critical patent/CN106103060A/zh
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—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
    • B29C70/34—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 and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B29C70/345—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 and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using matched moulds
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    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/78—Moulding material on one side only of the preformed part
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    • B29C70/88—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
    • B29C70/882—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced partly or totally electrically conductive, e.g. for EMI shielding
    • B29C70/885—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced partly or totally electrically conductive, e.g. for EMI shielding with incorporated metallic wires, nets, films or plates
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    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/12—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/03—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers with respect to the orientation of features
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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  • Moulding By Coating Moulds (AREA)
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Abstract

本发明提供了一种复合结构，包含由金属材料制成的基础构件和由包含单向排列的增强纤维的纤维增强塑料制成的增强构件，其中在所述增强构件上形成有沿所述增强纤维的取向方向延伸的至少一个狭缝。

Description

复合结构及其制造方法
技术领域
(相关申请的交叉引用)
本申请要求基于2014年3月13日于日本提交的日本专利申请号2014-050751的优先权，其整个公开内容以引用方式并入本文。
本发明涉及一种由金属材料和纤维增强塑料制成的复合结构及其制造方法。
背景技术
已知这些种类的复合结构及其制造方法例如如JP2010-149350A(专利文献1：PTL1)和WO2013-146900A(专利文献2：PTL 2)中所公开。
[PTL 1]
JP2010-149350A
[PTL 2]
WO2013-146900A
发明内容
本发明给出以下分析。
在这些种类的复合结构中，纤维增强塑料部分与金属部分之间的接合位点有着发生应变或层离的问题，特别是由于所述两个部分之间热膨胀系数的差异。本发明鉴于如上文所示例的情况等而作。
考虑到上文所述的情况，在第一个方面，提供了一种复合结构，其包含由金属材料制成的基础构件；和由包含增强纤维的纤维增强塑料制成的增强构件。增强纤维单向排列。在所述增强构件上形成有沿所述增强纤维的取向方向延伸的至少一个狭缝。
在纤维增强塑料中，在增强纤维的取向方向(后文可简称为“取向方向”)和与取向方向相交(通常垂直)的方向之间存在热膨胀量或冷却收缩量的差异。采用单向纤维增强塑料，所谓的“UD(单向)材料”，将产生膨胀或收缩的各向异性，具体取决于取向方向。在UD材料中，在与取向方向垂直相交的方向上的膨胀或收缩量将大于取向方向上的量。这样的各向异性将在接合位点处导致应变或层离。
在根据第一个方面的复合结构中，所述复合结构为接合结构，具有由金属材料制成的基础构件和由UD材料制成的增强构件，所述狭缝形成在增强构件上或增强构件中增强纤维的取向方向上。相应地，增强构件与基础构件之间接合位点的长度可在垂直于取向方向的方向上缩短，并且增强构件的膨胀或收缩量在同一方向上得到抑制。因此，复合结构可取得UD材料在其取向方向上呈现的纤维增强性质，同时抑制基础构件与增强构件之间接合位点中应变或层离的发生。
在一个优选的复合结构中，包含热固性树脂的增强构件与基础构件直接接合。根据这样的优选配置，根据第一个方面的具有上述配置的复合结构可通过容易或简单的制造过程产生。
在第二个方面，提供了具有上述配置的复合结构的制造方法：
(i)准备具有对应于所述至少一个狭缝的至少一个突起的一对模具；
(ii)在所述一对模具之间以增强纤维的取向方向与所述至少一个突起的纵向一致的方式设置基础构件和用以形成增强构件的前体；
(iii)闭合所述一对模具以形成具有基础构件和增强构件前体的层合结构，从而将所述前体成形为预设形状并在其上形成至少一个狭缝；和
(iv)以模具闭合的状态加热所述一对模具中的层合结构。
根据第二个方面，具有上述配置的复合结构可通过容易或简单的制造过程产生。
附图说明
[图1]
图1为示意性平面视图，示出了根据一个示例性实施方案的复合结构的大致配置。
[图2]
图2为沿图1中的线2-2截取的示意性剖视图。
[图3]
图3为示意图，示出了根据一个示例性实施方案的制造方法。
[图4]
图4为示意图，示出了根据一个示例性实施方案的制造方法。
[图5]
图5为示意图，示出了根据一个示例性实施方案的制造方法。
[图6]
图6为示意性剖视图，示出了根据一个变型的复合结构的大致配置。
[图7]
图7为示意图，示出了如图6中所示复合结构的一种制造方法。
[图8]
图8为示意图，示出了如图6中所示复合结构的一种制造方法。
[图9]
图9为示意图，示出了如图6中所示复合结构的一种制造方法。
[图10]
图10为示意性平面视图，示出了根据另一个变型的复合结构的大致配置。
具体实施方式
下文将结合附图描述一个示例性实施方案。另外，将在说明书结束处指出变型和/或变体，因为当此类变型和/或变体插入在一个示例性实施方案的描述中时将妨碍对连贯的一个示例性实施方案的描述的理解。
<复合结构的构成>
图1为示意性平面视图，示出了根据一个示例性实施方案的复合结构的大致配置。图2为沿图1中的线2-2截取的示意性剖视图。下文中将结合图1和2描述根据一个示例性实施方案的复合结构10。
以如图2中所示的“帽”形(波纹板形状)形成如图1中所示具有预设纵向(平行于图中的上-下方向)的复合结构10。详细地说，复合结构10具有：凸缘部分10a、10e，第一和第二U-形部分10b、10d，和连接(中间)部分10c。
凸缘部分10a为平面视图中矩形平面形状的一部分，具有平行于上述纵向的纵向。凸缘部分10a布置在复合结构10的宽度方向(垂直于上述纵向或复合结构10的厚度方向)即图中左-右方向上的一个端侧上。第一U-形部分10b为形成为如图2中所示剖视图中大致U-形的部分。第一U-形部分10b具有连接到凸缘部分10a的一端和连接到连接部分10c的另一端。
连接部分10c为平面视图中矩形平面形状的一部分，具有平行于上述纵向的纵向。连接部分10c布置在第一和第二U-形部分10b、10d之间。第二U-形部分10d为形成为剖视图中大致U-形的部分，与第一U-形部分10b相似(大致相同)。第二U-形部分10d具有连接到连接部分10c的一端和连接到凸缘部分10e的另一端。凸缘部分10e为平面视图中矩形平面形状的一部分，具有平行于上述纵向的纵向。凸缘部分10e具有与凸缘部分10a相似(大致相同)的形状。
复合结构10具有由金属材料制成并弯曲形成为上述形状的基础构件11和由CFRP(碳纤维增强塑料)制成并与基础构件11接合的增强构件12。复合结构10具有CFRP和金属材料的层合(接合)结构。特别地，根据本示例性实施方案，增强构件12配置为在与基础构件11的接合位点中包含热固性树脂。在本示例性实施方案中，例如，将浸渍了热固性树脂的增强构件12与基础构件11直接接合而不用另外的粘合剂层。
在本示例性实施方案中，假定复合结构10需要在纵向上具有增强。对于该假定，在本示例性实施方案中，增强构件12仅布置在复合结构10的所需预设强度部分上，即第一和第二U-形部分10b、10d和连接部分10c，而不布置在其它部分上，即凸缘部分10a、10e。增强构件12由包含连续或长碳纤维(所谓的UD材料)的材料制成。为在纵向上增强复合结构，增强构件12中纤维的取向方向与纵向一致(例如，平行于纵向)。
在增强构件12上，狭缝13形成在取向方向上(特别地，大致平行于取向方向)。狭缝13在纵向上于增强构件12的整个长度上延伸。基础构件11具有其上接合增强构件12的内表面，所述内表面在整个狭缝13上部分裸露。本示例性实施方案的狭缝13分别布置在第一和第二U-形部分10b、10d其宽度方向上的中间位置中。
<制造方法>
下文将结合图3-5描述具有上述构成的复合结构10的制造方法。
在下模具20即一对模具的固定模具(外模具)上形成凹形部分，即腔穴21。下模具20具有内壁表面，所述内壁表面能够邻接基础构件11的外表面(布置在上述内表面的相反侧上)。在下模具20内，沿腔穴21的内壁表面布置用于加热的加热器22。
在上模具30即一对模具的可移动模具(内模具)上形成凸形部分31，凸形部分31沿基础构件11的内表面延伸或延长。凸形部分31具有与第一和第二U-形部分10b、10d互补的形状。因此，凸形部分31在垂直于图3的纸页的纵向上延伸。
在凸形部分31的宽度方向(垂直于上述纵向或凸形部分31的突起方向，即图中左右方向)上大致中心的位点形成狭缝形成突起31a。狭缝形成突起31a形成为轨道形状，具有与上述狭缝13大致相等的长度。狭缝形成突起31a平行于凸形部分31的纵向延伸。在上模具30内，沿凸形部分31的外表面布置用于加热的加热器32。
首先，如图3中所示，在下模具20中设置或布置金属组分的基础材料11。在上下模具20、30之间设置或布置板形预浸料41。预浸料41，其为本发明的“增强构件”的前体，由包含固化前的热固性树脂的UD材料制成。以预浸料41中包含的增强纤维(上述连续碳纤维)的取向方向与狭缝形成突起31a的纵向一致(特别地，大致平行于狭缝形成突起31a的纵向)的方式设置预浸料41。
其次，如图4中所示，上下模具20、30彼此闭合。由此，预浸料41被层合在基础构件11上并同时形成为顺应基础构件11的内表面轮廓的帽形。此时，狭缝形成突起31a硬挤入预浸料41中而在预浸料41上或中形成狭缝42，狭缝42具有与狭缝13的形状相对应的形状。
接下来，在如图4中所示的层合态中，预浸料41与基础构件11的层合结构使用加热器22、32在预设温度下加热预设的时间。由此进行预浸料41中包含的热固性树脂的固化反应，使得自预浸料41形成具有狭缝13的增强构件12，并且基础构件11和增强构件12牢固地彼此接合于层合态中。其后，如图5中所示，打开上下模具20、30以能够从模具20、30取出所形成的复合结构10。
<操作和效果>
在根据本示例性实施方案的复合结构10中，所述复合结构为接合结构，具有由金属材料制成的基础构件11和由UD材料制成的增强构件12，狭缝13形成在增强构件12上或增强构件12中增强纤维的取向方向上。相应地，增强构件12与基础构件11之间接合位点的长度可在垂直于取向方向的方向上缩短，并且增强构件12的膨胀或收缩量在同一方向上得到抑制。因此，复合结构10可取得UD材料构件在其取向方向上呈现的纤维增强性质，接合位点处应变或层离的发生被抑制。
特别地，在彼此接合包含热固性树脂的CFRP构件与金属组分的情况下，因制造工艺上的固化反应和因固化后的冷却所致的收缩以及复合结构10的成品在使用环境中的膨胀和收缩均是问题。关于这些问题，根据本示例性实施方案的配置，甚至在接合由包含热固性树脂的CFRP构件形成的增强构件12与由金属组分形成的基础构件11时，接合位点处应变或层离的发生也可得到令人满意的抑制。
在示例性实施方案的复合结构10中，增强构件在与基础构件11的接合位点中包含热固性树脂。例如，将包含热固性树脂的增强构件12与基础构件11直接接合。根据上述配置，基础构件11与增强构件12之间的接合可很好地进行，即便不施加预处理来改善增强构件12向基础构件11上的粘附性(表面处理：例如，电镀、等离子体处理和喷砂等)或在基础构件11与增强构件12之间布置特殊的粘附层(接合层)。另外，具有上述配置的复合结构10可通过容易或简单的制造过程产生。
此外，根据复合结构10及其制造方法，可同时进行基础构件11的形成过程和所形成的基础构件11与增强构件12之间的接合过程，从而有助于减少过程数并由此降低产品成本。
<变型>
接下来示例若干变型。在变型的以下描述中，结构和功能上与上述示例性实施方案的那些相似的组分构件将由与上述示例性实施方案的那些相似的名称和参考号表示。在上面的实施方案描述中出现的组分构件的描述可视情况适用，只要不包含技术不一致之处即可。当然，即便是变型也不限于下文描述的那些。上述示例性实施方案的构成和下文将描述的变型的构成完全或部分适用于适宜的组合中，只要不包含技术不一致之处即可。
本发明不限于上面描述的示例性实施方案的具体配置。例如，复合结构10的形状不限于如上文所提到的帽形。例如，复合结构10可具有大致平板形状。此外，增强构件12不限于由CFRP构件形成。此外，增强构件12的取向方向可根据复合结构10的实际使用中产生的内应力或外应力的方向设置在相对于上述纵向倾斜预设角度的方向上或其它方向上，等等。
如图6中所示，用于形成狭缝13的隆起部111可形成在基础构件11上。在此情况下，在基础构件11的外表面侧上，特别地，在隆起部111的相反侧上，平行于狭缝13形成凹进，即模具突起容纳部分112。模具突起容纳部分112具有与狭缝13大致相同的长度。接下来结合图7-9示例上述变型的复合结构10的制造。
根据本变型，在下模具20的腔穴21中形成对应于狭缝的突起211以向上模具30突出。对应于狭缝的突起211形成在对应于狭缝13的位置中并形成为对应于狭缝13的形状。对应于狭缝的突起211形成为适配到模具突起容纳部分112中。相比之下，上模具30在凸形部分31上不具有如上所述突起(参见如图3中所示的狭缝形成突起31a)。
首先，如图7中所示，在下模具20中以下模具20的对应于狭缝的突起211适配到(容纳于)模具突起容纳部分112中的方式设置或布置基础材料11。在上下模具20、30之间以预浸料41中包含的增强纤维的取向方向与对应于狭缝的突起211的纵向一致(特别地，大致平行于对应于狭缝的突起211的纵向)的方式设置或布置板形预浸料41。
其次，如图8中所示，上下模具20、30彼此闭合。由此，预浸料41被层合在基础构件11上并同时形成为顺应基础构件11的内表面轮廓的帽形。此时，支承在对应于狭缝的突起211上的隆起部111硬挤入预浸料41中而在预浸料41上或中形成狭缝42，狭缝42具有与狭缝13的形状相对应的形状。
接下来，在如图8中所示的层合态中，预浸料41与基础构件11的层合结构使用加热器22、32在预设温度下加热预设的时间。由此进行预浸料41的热固性树脂的固化反应，使得自预浸料41形成具有狭缝13的增强构件12，并且基础构件11和增强构件12牢固地彼此接合于层合态中。其后，如图9中所示，打开上下模具20、30以能够从模具20、30取出所形成的复合结构10。
预浸料41可对应于增强构件12预成型。成型的预浸料41可在闭合上下模具20、30之前与基础构件一起设置在下模具20中。有时候，不是如图3中所示将基础构件11设置在下模具20中，而是可在预浸料41与下模具20之间插入用以形成基础构件11的金属坯料。在这种情况下，其后的闭模和加热(参见图4)可导致基础构件11和增强构件12的形成及同时两个构件11、12的接合。
基础构件11的内表面可经过上述预处理，尤其是如果增强构件12由热塑性纤维增强塑料制成的话。使用由热塑性纤维增强塑料制成的增强构件12，可在基础构件11与增强构件12之间插入由固化前的热固性树脂制成的板(热固性树脂前体板)。在这种情况下，增强构件12可经由由热固性树脂制成的粘合剂层与基础构件11接合。根据所述配置和制造方法，基础构件11与由热塑性FRP制成的增强构件12之间的接合可很好地进行，即便没有在基础构件11的内表面上的上述预处理。
狭缝13的数量和位置不受特别限制。例如，狭缝13可如图10中所示形成在连接部分10c中或上。
在这种情况下，布置在连接部分10c中的狭缝13可设置在增强构件12宽度方向上大致中心部分中。在第一U-形部分10b中，与第一U-形部分10b的大致中心部分的一侧相比，狭缝13可朝向连接部分10c的一侧设置。类似地，在第二U-形部分10d中，与第二U-形部分10d的大致中心部分的一侧相比，狭缝13可朝向连接部分10c的一侧设置。
根据如图10中所示的配置，增强构件12被分成四个块。所述四个块可具有大致相同的与基础构件的接合位点长度。相应地，接合位点处应变和层离可得到进一步抑制。
当然，未特别提及的那些变型也涵盖在本发明的技术范围内，只要本发明没有被实质性改变即可。部分地构成用以解决本发明待解决的问题的措施及在操作上或功能上表达的那些部件，不仅包括上面在上述示例性实施方案和变型的描述中公开的特定结构和其等价物，而且包括可实施所述部件的操作或功能的任何其它结构。
上述专利文献的整个公开内容以引用方式并入本文。在本发明的整体公开内容(包括权利要求书)的范围内并基于本发明的基本技术概念，示例性实施方案的变型和调节是可能的。在本发明的范围内，各种所公开要素(包括每一权利要求的每一要素、每一示例性实施方案的每一要素、每一附图的每一要素等)的各种组合和选择是可能的。即，本发明当然包括本领域技术人员根据包括权利要求书和技术概念在内的整体公开内容可作的各种改变和修改。特别地，本文中公开的任何数值范围应理解为落在所公开范围内的任何中间值或子范围也被具体地公开，即便其没有被明确地述及。
参考符号列表
10 复合(混合)结构
11 基础构件(层)
111 突起
12 增强构件(层)
13 狭缝
20 下模具
21 腔穴
211 对应于狭缝的突起
22 加热器
30 上模具
31a 狭缝形成突起
32 加热器
41 预浸料

Claims (3)

1.一种复合结构，包含：
由金属材料制成的基础构件，和
由包含沿所述基础构件的纵向单向排列的增强纤维的纤维增强塑料制成的增强构件，其中
在所述增强构件上形成有在所述纵向上于所述增强构件的整个长度上延伸的至少一个狭缝；并且
所述增强构件层合并连接于所述基础构件。
2.根据权利要求1所述的复合结构，其中
所述增强构件包含热固性树脂，并与所述基础构件直接接合。
3.一种复合结构的制造方法，其中
所述复合结构包含：
由金属材料制成的基础构件，和
由包含沿所述基础构件的纵向单向排列的增强纤维的纤维增强塑料制成的增强构件，
在所述增强构件上形成有在所述纵向上于所述增强构件的整个长度上延伸的至少一个狭缝；以及
所述制造方法包括：
准备具有对应于所述至少一个狭缝的至少一个突起的一对模具；
在所述一对模具之间以所述增强纤维的取向方向与所述至少一个突起的纵向一致的方式设置所述基础构件和用以形成所述增强构件的前体；
闭合所述一对模具以形成具有所述基础构件和所述增强构件的前体的层合结构，从而将所述前体成形为预设形状并在其上形成所述至少一个狭缝；和
以模具闭合的状态加热所述一对模具中的所述层合结构。
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