CN108394154A - 杆状复合构件 - Google Patents

杆状复合构件 Download PDF

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Publication number
CN108394154A
CN108394154A CN201810041131.2A CN201810041131A CN108394154A CN 108394154 A CN108394154 A CN 108394154A CN 201810041131 A CN201810041131 A CN 201810041131A CN 108394154 A CN108394154 A CN 108394154A
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China
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layer
rod
composite component
shaped composite
reinforced plastic
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山田庸弘
种子田和宏
清本弘
真崎诚二郎
横山淳
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Honda Motor Co Ltd
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Honda Motor Co Ltd
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Abstract

本发明提供一种杆状复合构件，其能够确保弯曲部的期望强度。杆状复合构件(10)将碳纤维(长纤维)的取向方向与杆状复合构件(10)的轴向平行的0°层(16)、配置在该0°层(16)的径向内侧且碳纤维(长纤维)的取向方向与杆状复合构件(10)的轴向斜交的±45°层(18)、夹设于径向外侧的0°层(16)与径向内侧的±45°层(18)之间的内侧玻璃纤维增强塑料层(19)、以及作为最外层配置在作为基底层的0°层(16)的径向外侧且比0°层及±45°层(18)刚性低的外侧玻璃纤维增强塑料层(20)各层层叠起来而构成。外侧玻璃纤维增强塑料层(20)作为加强层及保护层发挥作用。

Description

杆状复合构件
技术领域
本发明涉及杆状复合构件。
背景技术
近年来，对于汽车，为了提高燃油效率而期望使各种构件轻量化、高强度化，例如利用碳材质等的纤维增强树脂。作为利用了纤维增强树脂的例子，例如，在专利文献1中公开了一种使用旋转工作台(rolling table)在碳纤维增强铝管(金属杆状构件)的外表面卷绕设置碳纤维增强层(纤维增强层)的技术思想。
另外，在专利文献2中公开了一种从内向外层叠具有不同取向角度的多个碳纤维而形成的纤维增强复合材料制的高尔夫俱乐部用球棒。
现有技术文献
专利文献
专利文献1：日本特开平3－166937号公报
专利文献2：日本特开2007－528号公报
可是，例如，在对像汽车的框架构造体所使用的杆状复合构件这样具有弯曲部等曲率较高的形状的杆状复合构件应用了纤维增强树脂材的情况下，难以在该弯曲部缠上纤维增强树脂材料来确保框架构造体的刚性。其原因在于，例如，在将专利文献1所公开的碳纤维增强层缠绕于直线状的芯棒，然后对该芯棒进行弯曲成形而使其弯曲变形为规定曲率的情况下，当芯棒的弯曲部的曲率增大时，可能会因弯曲部的内侧与外侧的周长差的不同，而导致缠绕于弯曲部内侧的碳纤维增强层起皱。
因此，为了避免所述弯曲部的内侧起皱，可以考虑采用这样的应对技术：沿杆状复合构件的轴向并排设置由碳纤维增强塑料(CFRP)形成的UD材(单向增强材料)(所谓的0°层)，从而消除弯曲部的内侧与外侧的周长差，以使得曲率较高的弯曲部不起皱。但是，当对并排设置有UD材的弯曲部作用扭转变形力(扭转载荷)时，在弯曲部作用有朝向径向外侧方向的面外力，从而表面层的0°层向径向外侧方向变形。结果可能会成为弯曲部在强度上的弱点。
发明内容
本发明是鉴于上述问题而做成的，其目的在于提供一种能够确保弯曲部的期望强度的杆状复合构件。
为了达到所述目的，本发明提供一种杆状复合构件，其具有弯曲部，该杆状复合构件的特征在于，所述弯曲部包括：0°层，其由碳纤维增强塑料形成，碳纤维的取向方向与所述杆状复合构件的轴向平行；以及玻璃纤维增强塑料层，其配置在所述0°层的外表面，刚性比所述碳纤维增强塑料的刚性低。
发明效果
采用本发明，能够获得能够确保弯曲部的期望强度的杆状复合构件。
附图说明
图1是本发明的实施方式的杆状复合构件的立体图。
图2是图1的沿II－II线的剖视图。
图3的(a)～(g)是表示制造本实施方式的杆状复合构件的制造工序的示意图。
图4是对没有加强层的比较例的杆状复合构件和具有加强层的本实施方式的杆状复合构件的耐久性进行比较的说明图。
附图标记说明
10 杆状复合构件
14 弯曲部
16 0°层
18 ±45°层
20 外侧玻璃纤维增强塑料层(玻璃纤维增强塑料层；GFRP)
具体实施方式
接着，参照适当的附图对本发明的实施方式详细进行说明。
图1是本发明的实施方式的杆状复合构件的立体图，图2是图1的沿II－II线的剖视图。
本实施方式的杆状复合构件10能够用作车辆的零件例如方向盘、悬挂加强杆(suspension tower bar)、悬挂臂及稳定器(stabilizer)。另外，还能够用作体育休闲用品、自行车的车把、以及婴儿车的零件等。
如图1所示，杆状复合构件10由其一部分具有大致L字形状的中空的管体形成，杆状复合构件10形成为由呈直线或者大致直线状延伸的直线部12和非直线状的弯曲部14组合而成的复合形状。
杆状复合构件10(直线部12及弯曲部14)沿径向层叠有四层，该四层均形成为沿周向连续。如图2所示，杆状复合构件10构成为从径向内侧朝向径向外侧去依次层叠±45°层18、内侧玻璃纤维增强塑料层19、0°层16、以及外侧玻璃纤维增强塑料层20。
详细而言，将0°层16、±45°层18、内侧玻璃纤维增强塑料层19以及外侧玻璃纤维增强塑料层20各层层叠起来而构成了杆状复合构件10，其中，0°层16是基底层，碳纤维(长纤维)的取向方向与杆状复合构件10的轴向平行，±45°层18配置在该0°层16的径向内侧，碳纤维(长纤维)的取向方向与杆状复合构件10的轴向斜交，内侧玻璃纤维增强塑料层19夹设于径向外侧的0°层16与径向内侧的±45°层18之间，作为应力缓和层发挥作用，外侧玻璃纤维增强塑料层20作为最外层配置在作为基底层的0°层16的径向外侧。其中，如后述那样，外侧玻璃纤维增强塑料层20作为加强层及保护层发挥作用。
0°层16由使取向方向朝向与杆状复合构件10的轴向平行的一个方向地拉齐了纤维的UD(Uni－Directional：单向)材形成，由碳纤维增强树脂塑料(CFRP)形成。
±45°层18由碳纤维的取向方向与杆状复合构件10的轴向斜交的预浸料(优选为丝束预浸料(tow prepreg))形成。丝束预浸料由成为粘结剂的树脂浸渗于成为增强材料的碳纤维而成的许多单丝构成。作为树脂，例如可以使用环氧树脂、不饱和聚酯树脂、聚氨酯树脂、邻苯二甲酸二烯丙酯树脂、酚醛树脂、聚酰亚胺树脂等热固化性树脂。
形成内侧玻璃纤维增强塑料层19及外侧玻璃纤维增强塑料层20的预浸料分别由刚性比作为0°层16的碳纤维增强塑料(CFRP)低的玻璃纤维增强塑料(GFRP)形成。优选使用该玻璃纤维增强塑料(GFRP)在0°层16与±45°层18之间以及在0°层16的外表面形成比0°层16及±45°层18刚性低的短切玻璃纤维层(短纤维)。另外，对于内侧玻璃纤维增强塑料层19及外侧玻璃纤维增强塑料层20，不局限于短纤维(短切玻璃纤维层)，也可以使用刚性比0°层16及±45°层18低的长纤维。
如图2所示，关于四层的沿径向的厚度尺寸，0°层16与±45°层18设定为相同或者大致相同的尺寸，内侧玻璃纤维增强塑料层19与外侧玻璃纤维增强塑料层20设定为比0°层16及±45°层18小的尺寸。另外，内侧玻璃纤维增强塑料层19和外侧玻璃纤维增强塑料层20设定为彼此相同或者大致相同的厚度尺寸。
另外，在本实施方式中，由从杆状复合构件10的径向内侧朝向径向外侧依次为±45°层18、内侧玻璃纤维增强塑料层19、0°层16以及外侧玻璃纤维增强塑料层20的四层构造分别形成直线部12及弯曲部14，但是不局限于此。
即，对于杆状复合构件10，至少弯曲部14由包含外侧玻璃纤维增强塑料层20的四层构造形成即可。另外，直线部12也可以由去除了外侧玻璃纤维增强塑料层20的包括0°层16、内侧玻璃纤维增强塑料层19及±45°层18的三层构成。进而，直线部12还可以由仅包括0°层16及±45°层18的两层构成。
在本实施方式中，例如，针对作用于杆状复合构件10的弯曲部14的弯曲载荷，位于径向外侧的0°层16具有刚性(抗弯刚性较高)，并且，针对扭转载荷，位于径向内侧的±45°层18具有刚性(扭转刚性较高)。此时，由于弯曲部14的各层的刚性各不相同，所以在各层变形的方式不同。其中，在弯曲部14的表层侧的0°层16作用有朝向径向外侧方向的面外力，由此，该部分有可能会成为强度上的弱点。
因此，在本实施方式中，将形成为抗弯刚性比0°层16低且扭转刚性比±45°层18低的外侧玻璃纤维增强塑料层20设于最靠径向外侧的0°层的外表面。对于该点，在后面详细进行说明。
接着，对制造杆状复合构件10的制造方法进行说明。
图3的(a)～图3的(g)是表示制造本实施方式的杆状复合构件的制造工序的示意图。
准备一对模具32a、32b(参照图3的(f))。模具32a、32b形成有由截面为半圆状的槽部构成的模腔34，该模腔34从上方观察(俯视观察)时为形状与杆状复合构件10相对应的大致L字形状(参照图3的(a))。另外，一模具32a与另一模具32b以槽部形状对称的方式形成。
首先，在各模具32a(32b)的模腔34内铺设由玻璃纤维增强塑料(GFRP)形成的片状的预浸料36a(外侧玻璃纤维增强塑料材)(参照图3的(a))。
接下来，在铺设于模腔34内的预浸料36a之上，沿模腔34的轴向并列地铺设作为0°层的多个UD材38(参照图3的(b))。之后，在铺设好的UD材38的上表面铺设由玻璃纤维增强塑料(GFRP)形成的作为片状体的预浸料36b(内侧玻璃纤维增强塑料材)(参照图3的(c))，在模腔34内构成层叠体。
其中，预浸料36b(内侧玻璃纤维增强塑料材)也可以与后述的预浸料40(±45°材)一起利用片材卷绕(SW：sheet winding)法来缠绕成形。
另外，使用未图示的夹具将片状的预浸料40(优选为丝束预浸料)(±45°材)利用片材卷绕(SW)法卷绕在树脂芯(芯棒)42的外表面上成形(参照图3的(d))。该片状的预浸料40由将树脂浸渗于碳纤维而成的较薄的片状体形成，由+45°的碳纤维与-45°的碳纤维事先编织而构成的片状体构成。自卷绕好的预浸料40拔出树脂芯(芯棒)42后，向拔出树脂芯42后形成的卷绕体的贯通孔内插入例如橡胶制的管状气囊(充气囊)44。
另外，在本实施方式中，利用片材卷绕法卷绕预浸料(±45°材)，但是，例如也可以利用单丝卷绕法卷绕单丝。
接着，在形成于模具32a的层叠体(外侧玻璃纤维增强塑料材、UD材以及内侧玻璃纤维增强塑料材)的内周侧嵌入卷绕好的预浸料40(±45°材)(参照图3的(e))，将一对模具32a、32b合模。在将一对模具32a、32b合模后，在管状气囊44的两端部安装未图示的栓构件。从未图示的气体供给源向管状气囊44的中空部内供给例如大约0.6MPa的气体(参照图3的(f))。
然后，使用未图示的加热手段进行规定温度的热处理，使树脂热固化，然后开模，取出作为成形品的杆状复合构件10(参照图3的(g))。
通过实施这样的制造方法，能够简单地得到由位于径向内侧的±45°层18、位于径向外侧的UD材38(0°层16)、夹设于±45°层18和0°层16之间的内侧玻璃纤维增强塑料层19(GFRP)、以及在0°层16的外表面成为最外层的外侧玻璃纤维增强塑料层20(GFRP)构成的杆状复合构件10。另外，在该制造方法中，通过使用一对模具32a、32b，能够吸收弯曲部14的内外周差(内侧与外侧之间的周长差)，避免起皱，并且能够提高弯曲部14的强度。
接着，对本实施方式的杆状复合构件10的作用效果进行说明。
在本实施方式中，在0°层16的外表面且是最外层设置了外侧玻璃纤维增强塑料层20，外侧玻璃纤维增强塑料层20形成得抗弯刚性比0°层16低且扭转刚性比±45°层18低。由此，在本实施方式中，在对弯曲部14施加有弯曲载荷及扭转载荷时，能够抑制在0°层16的外表面产生的朝向径向外侧方向的面外力，提高外表面的强度(尤其是，反复受力的疲劳强度)。结果，采用本实施方式，能够确保弯曲部14的期望的强度，提高耐久性。
图4是对没有加强层的比较例的杆状复合构件和具有加强层的本实施方式的杆状复合构件的耐久性进行比较的说明图。
如图4所示，将没有外侧玻璃纤维增强塑料层20(加强层)的比较例的杆状复合构件的耐久试验次数，和具有外侧玻璃纤维增强塑料层20(加强层)的本实施方式的杆状复合构件10的耐久试验次数进行比较，可知其耐久性提高了大约2.5倍。
另外，在本实施方式中，作为加强层发挥作用的外侧玻璃纤维增强塑料层20本身没有提高刚性的作用，因此能够维持刚性地提高疲劳强度。
此外，采用本实施方式，能够在避免主要层(0°层16及±45°层18)厚度过大的同时抑制面外力，因此能够尽量减少杆状复合构件10的重量增加，实现强度提高。
另外，采用本实施方式，具有随着0°层16产生裂纹而表层侧的外侧玻璃纤维增强塑料层20变成白色的作用。由此，能够容易地利用肉眼观察到对弯曲部14造成的损伤状态。结果能够提高维护性，容易预测新杆状复合构件10的更换时期。
通常，对于会被施加复合载荷(例如弯曲载荷、扭转载荷等)的纤维增强塑料管(杆状复合构件10)，从性能出发，优选具有承受各载荷且纤维取向角不同的多个层，但基于制法上的要求，使表层侧为抗弯曲载荷较强的取向角0°层16。
采用这样的构造，各层的刚性(例如抗弯刚性、扭转刚性等)不同，因此各层的变形方式不同。此时，表层侧的0°层16会作用有朝向径向外侧方向的面外力，因而该部分有可能成为强度上的弱点。
在本实施方式中，针对上述技术问题，在有可能成为强度上的弱点的0°层16的外侧，设置刚性比0°层16及±45°层18低的加强层(外侧玻璃纤维增强塑料层20)，从而能够抑制面外变形，进一步提高强度(尤其是疲劳强度)。
另外，位于表层侧的外侧玻璃纤维增强塑料层20与杆状复合构件10的中心之间的分开距离最大，因此负担的应力较高，但是，通过以能够适当抑制面外变形的低刚性的层来形成外侧玻璃纤维增强塑料层20，能够减小加强层(外侧玻璃纤维增强塑料层20)本身的应力负担，加强层自身能够发挥其功能而不会比内侧的其他层(0°层16、±45°层18)先破坏。
另外，作为提高强度的常用途径，有通过增加厚度和增加重量(＝增加刚性)来提高强度的方法。但是，采用本实施方式，能够通过相对较少的重量增加在不提高刚性的情况下提高强度。由此，能够高效地制造例如轻量化且设定了刚性目标的零件。
另外，该加强层(外侧玻璃纤维增强塑料层20)兼具作为针对碎屑等的保护层的功能。另外，因在0°层16产生的裂纹，与该部位邻接的加强层(外侧玻璃纤维增强塑料层20)会变白，因此具有能够使损伤状态容易地可视化(肉眼能够观察到)的优点。

Claims (2)

1.一种杆状复合构件，具有弯曲部，该杆状复合构件的特征在于，
所述弯曲部包括：
0°层，其由碳纤维增强塑料形成，碳纤维的取向方向与所述杆状复合构件的轴向平行；以及
玻璃纤维增强塑料层，其配置在所述0°层的外表面，刚性比所述碳纤维增强塑料的刚性低。
2.根据权利要求1所述的杆状复合构件，其特征在于，
所述弯曲部为稳定器的弯曲部。
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