CN110545989A - 纤维增强树脂制部件的连接结构和纤维增强树脂制部件的制造方法 - Google Patents

纤维增强树脂制部件的连接结构和纤维增强树脂制部件的制造方法 Download PDF

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Publication number
CN110545989A
CN110545989A CN201780089827.6A CN201780089827A CN110545989A CN 110545989 A CN110545989 A CN 110545989A CN 201780089827 A CN201780089827 A CN 201780089827A CN 110545989 A CN110545989 A CN 110545989A
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Prior art keywords
fiber
reinforced resin
layer
resin
layers
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Granted
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CN201780089827.6A
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CN110545989B (zh
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仓井翔平
大久保洋志
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Renault SAS
Nissan Motor Co Ltd
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Renault SAS
Nissan Motor Co Ltd
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/48—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

纤维增强树脂制部件(1)的连接结构具备：第一部件(2)、和隔着粘接层(9)粘接于第一部件(2)上的第二部件(3)，所述第一部件(2)具有多层的第一纤维层(5)和浸渗于第一纤维层(5)中的基质树脂(6)。纤维增强树脂制部件(1)的连接结构还具备将第一部件(2)和第二部件(3)连接的连接用纤维(4)。第二部件(3)具有多层的第二纤维层(7)和浸渗于第二纤维层(7)中的基质树脂(8)。连接用纤维(4)的一端部(4a)被夹持于第一纤维层(5)间，连接用纤维(4)的另一端部(4b)被夹持于第二纤维层(7)间。

Description

纤维增强树脂制部件的连接结构和纤维增强树脂制部件的制 造方法
技术领域
本发明涉及一种纤维增强树脂制部件的连接结构和纤维增强树脂制部件的制造方法。
背景技术
一直以来，公知的是用于在纤维增强树脂制的第一部件上安装第二部件的结构(例如，参照专利文献1)。
专利文献1中记载有利用结合机构将碳纤维增强树脂材料和被结合构件结合而成的碳纤维增强树脂材料的结合结构。该结合结构中，碳纤维增强树脂材料通过重叠第一层叠部、和被设为与第一层叠部的碳纤维面方向正交的碳纤维面方向的第二层叠部，由此使由温度变化导致的重合方向的线性膨胀量减小。另外，专利文献1所述的纤维增强树脂材料的结合结构中，用螺栓和螺母将被结合构件紧固在碳纤维增强树脂材料上。
现有技术文献
专利文献
专利文献1：日本特开2007-292106号公报
发明内容
发明要解决的问题
在前述的结构中，由于第一部件和第二部件利用螺栓和螺母紧固，所以因向第一部件或第二部件输入比较大的载荷而使第一部件与第二部件的连接(利用螺栓和螺母的紧固)被解除的可能性较低。利用螺栓和螺母的紧固由于操作性低、可成为成本上升的要因，因此研究从利用螺栓和螺母的紧固变更为利用粘接剂的粘接。然而，仅利用粘接剂粘接第一部件和第二部件时，担心因向第一部件或第二部件输入比较大的载荷而使第一部件与第二部件的连接(利用粘接剂的粘接)被解除，并且第一部件与第二部件发生分离。
因此，本发明的目的在于即使是在因向第一部件或第二部件输入比较大的载荷而解除了第一部件与第二部件的连接(利用粘接剂的粘接)的情况下，也能够抑制第一部件与第二部件发生分离。
用于解决课题的手段
本发明的第一方案是一种纤维增强树脂制部件的连接结构，其具备：纤维增强树脂制的第一部件、粘接于第一部件的纤维增强树脂制的第二部件、和连接第一部件与第二部件的连接用纤维。连接用纤维的一端部被夹持于第一部件的第一纤维层间，且连接用纤维的另一端部被夹持于第二部件的第二纤维层间。
本发明的第二方案是纤维增强树脂制部件的制造方法。该制造方法具备如下工序：通过将连接用纤维的一端部夹入到第一纤维层间，并将连接用纤维的另一端部夹入到第二纤维层间，从而使连接用纤维中的一端部与另一端部之间的中间部从第一纤维层和第二纤维层露出。另外，前述的制造方法还具备如下工序：使基质树脂浸渗到第一纤维层和第二纤维层中，而不使基质树脂浸渗到连接用纤维的中间部的工序。
发明的效果
根据本发明，即使在因向第一部件或第二部件输入比较大的载荷而解除了第一部件与第二部件的连接(利用粘接剂的粘接)的情况下，也能够抑制第一部件与第二部件发生分离。
附图说明
图1是示出本发明的实施方式的纤维增强树脂制部件的连接结构的侧视图。
图2是示出图1的A-A线截面的概略截面图。
图3是示出本发明的实施方式的纤维增强树脂制部件的连接结构的粘接前的状态的部分放大侧视图。
图4A是本发明的实施方式的纤维增强树脂制部件的制造方法的说明图。
图4B是本发明的实施方式的纤维增强树脂制部件的制造方法的说明图。
图4C是本发明的实施方式的纤维增强树脂制部件的制造方法的说明图。
图5A是本发明的实施方式的纤维增强树脂制部件的制造方法的说明图。
图5B是本发明的实施方式的纤维增强树脂制部件的制造方法的说明图。
图5C是本发明的实施方式的纤维增强树脂制部件的制造方法的说明图。
图6A是本发明的实施方式的纤维增强树脂制部件的制造方法的说明图。
图6B是本发明的实施方式的纤维增强树脂制部件的制造方法的说明图。
图6C是本发明的实施方式的纤维增强树脂制部件的制造方法的说明图。
具体实施方式
以下与附图一起详述本发明的实施方式。
基于图1～图3说明本发明的实施方式的纤维增强树脂制部件1的连接结构。
纤维增强树脂制部件1能够应用于例如车盖(引擎罩)、门板、保险杠、后行李箱盖、后栏板、挡泥板、侧车身板、顶板等车辆用构成构件。另外，纤维增强树脂制部件1不限定于车辆用构成构件，可应用于各种构成构件。
如图1～图3所示，纤维增强树脂制部件1主要由第一部件2、第二部件3和连接用纤维4构成。
第一部件2是具有多层的第一纤维层5、浸渗于第一纤维层5中的基质树脂(第一树脂)6而构成的纤维增强树脂制的部件(参照图4C)。本实施方式的第一部件2是未图示的车辆的外板面板(挡泥板)。第一部件2具有部件主体部(面板主体部)2a、和粘接并安装第二部件3的第一部件侧粘接部2b而构成。
构成第一纤维层5的纤维没有特别限定，能够使用碳纤维、芳族聚酰胺纤维、玻璃纤维等各种纤维。另外，作为第一纤维层5，能够使用例如NCF(Non Crimp Fabric：无褶皱织物)、织物(织布)、无纺物(无纺织布)。此外，基质树脂6没有特别限定，能够使用例如环氧树脂、酚醛树脂、聚酰胺树脂等各种热固化性树脂。予以说明，作为基质树脂6，并不限定于热固化性树脂，也可以使用各种热塑性树脂。
第二部件3是具有多层的第二纤维层7、和浸渗于第二纤维层7中的基质树脂(第二树脂)8而构成的纤维增强树脂制的部件(参照图4C)。第二部件3隔着粘接层9粘接于第一部件2上(参照图2)。即，本实施方式中，第一部件2与第二部件3的连接不使用利用螺栓和螺母的结合，而是使用利用粘接剂的粘接。本实施方式的第二部件3是用于将车辆的外板面板(第一部件2)安装到未图示的车辆的车体上的支架。第二部件3具有粘接并安装于第一部件2上的第二部件侧粘接部3a、安装于车辆的车体上的车体安装部3b、和配设于第二部件侧粘接部3a与车体安装部3b之间的连结部3c而构成。
构成第二纤维层7的纤维没有特别限定，能够使用碳纤维、芳族聚酰胺纤维、玻璃纤维等各种纤维。另外，作为第二纤维层7，能够使用例如NCF(Non Crimp Fabric：无褶皱织物)、织物(织布)、无纺物(无纺织布)。此外，基质树脂8没有特别限定，能够使用例如环氧树脂、酚醛树脂、聚酰胺树脂等各种热固化性树脂。予以说明，作为基质树脂8，并不限定于热固化性树脂，也可以使用各种热塑性树脂。
构成粘接层9的粘接剂只要能够得到充分的粘接强度即可，能够使用例如环氧树脂系粘接剂、聚氨酯树脂系粘接剂。另外，该粘接剂可以是热固化性的粘接剂，也可以是热塑性的粘接剂。
连接用纤维4连接第一部件2与第二部件3。具体而言，连接用纤维4的一端部4a(图3中带有点影线的部位)被夹持于第一部件2的第一纤维层5间，连接用纤维4的另一端部4b(图3中带有点影线的部位)被夹持于第二部件3的第二纤维层7间。并且，连接用纤维4中的一端部4a与另一端部4b之间的中间部4c从第一部件2的第一纤维层5和第二部件3的第二纤维层7露出，基质树脂6、8并未浸渗到连接用纤维4的中间部4c中。
本实施方式中，连接用纤维4的一端部(第一部件连接部)4a配置于第一纤维层5的中间层(厚度方向的中央层)，连接用纤维4的另一端部(第二部件连接部)4b配置于第二纤维层7的中间层(厚度方向的中央层)(参照图4A)。并不限定于此，也可以连接用纤维4的第一部件连接部4a配置于比第一纤维层5中的中间层更外侧的外层，连接用纤维4的第二部件连接部4b配置于比第二纤维层7中的中间层更外侧的外层。
本实施方式中，连接用纤维4的第一部件连接部4a未配置于第一部件2的整体，而是仅配置于第一部件2的一部分(第一部件侧粘接部2b)(参照图3)。另外，连接用纤维4的第二部件连接部4b未配置于第二部件3的整体，而是仅配置于第二部件3的一部分(第二部件侧粘接部3a)(参照图3)。进而，连接用纤维4的中间部4c未配置于第一部件连接部4a和第二部件连接部4b的宽度方向的整个区域，而是仅配置于第一部件连接部4a和第二部件连接部4b的宽度方向的一部分区域(宽度方向的两端区域)。
在借助粘接层9粘接第一部件2与第二部件3的状态下，例如，连接用纤维4被嵌入到粘接层9中。并不限定于此，在借助粘接层9粘接第一部件2与第二部件3的状态下，连接用纤维4可以在粘接层9中迂回地配置。
构成连接用纤维4的纤维没有特别限定，能够使用碳纤维、芳族聚酰胺纤维等各种纤维。另外，作为连接用纤维4，能够使用NCF(Non Crimp Fabric：无褶皱织物)、织物(织布)。因此，通过使连接用纤维4的第一部件连接部4a被夹持于第一部件2的第一纤维层5间，从而第一部件连接部4a构成与第一纤维层5共通的织物层(即，第一纤维层5的一部分)。另一方面，通过使连接用纤维4的第二部件连接部4b被夹持于第二部件3的第二纤维层7间，从而第二部件连接部4b构成与第二纤维层7共通的织物层(即，第二纤维层7的一部分)。
接着，对本实施方式的纤维增强树脂制部件1的制造方法的一例进行说明。
制造纤维增强树脂制部件1的方法能够使用例如RTM(Resin Transfer Molding：树脂传递模塑)成形。
[RTM成形的情形]
1.层叠
首先，如图4A所示，层叠多层的第一纤维层5，并且层叠多层的第二纤维层7。此时，将连接用纤维4的第一部件连接部4a夹入到第一纤维层5间，并将连接用纤维4的第二部件连接部4b夹入到第二纤维层7间。通过如此操作，使连接用纤维4中的第一部件连接部4a与第二部件连接部4b之间的中间部4c从第一纤维层5和第二纤维层7上露出。
2.基质树脂的浸渗
接着，如图4B所示，将层叠后的第一纤维层5、第二纤维层7和连接用纤维4装入成形用的成形模具10内。予以说明，在成形模具10内，可以层叠多层的第一纤维层5，同时层叠多层的第二纤维层7。
然后，如图4C所示，从未图示的树脂注入口将基质树脂6、8注入到成形模具10内，使基质树脂(第一树脂)6浸渗到第一纤维层5中，并且使基质树脂(第二树脂)8浸渗到第二纤维层7中。另外，在使基质树脂6、8浸渗到第一纤维层5和第二纤维层7中的状态下，使基质树脂6、8硬化(固化)。
3.基质树脂的浸渗抑制方法
例如，如图5A所示，通过在连接用纤维4的中间部4c配设密封件(packings)等密封构件11，从而不使基质树脂6、8浸渗到连接用纤维4的中间部4c。即，通过在成形模具10内配设密封构件11，从而不使基质树脂6、8流入到成形模具10中的配置有连接用纤维4的中间部4c的部分。
另外，如图5B所示，通过利用丙烯酸类树脂等脆性树脂12覆盖连接用纤维4的中间部4c，从而可以不使基质树脂6、8浸渗到连接用纤维4的中间部4c中。即，通过预先利用脆性树脂12覆盖连接用纤维4的中间部4c，从而不使基质树脂6、8流入到成形模具10的配置有连接用纤维4的中间部4c的部分。予以说明，此时，在基质树脂6、8的硬化后(固化后)，脆性树脂12从连接用纤维4的中间部4c去除。
另外，如图5C所示，通过利用聚氨酯、聚乙烯等软性树脂13覆盖连接用纤维4的中间部4c，从而可以不使基质树脂6、8浸渗到连接用纤维4的中间部4c中。即，通过预先利用软性树脂13覆盖连接用纤维4的中间部4c，从而不使基质树脂6、8流入到成形模具10中的配置有连接用纤维4的中间部4c的部分。予以说明，此时，软性树脂13由于在硬化后具有挠性，因此可以在基质树脂6、8硬化后(固化后)，不从连接用纤维4的中间部4c去除而残留。
4.基质树脂的硬化后(固化后)
如图6A所示，在基质树脂6、8的硬化后(固化后)，将第一部件2、第二部件3和连接用纤维4从成形模具10取出。在图6A所示的基质树脂6、8的硬化后(固化后)的状态下，连接用纤维4的中间部4c是可自由变形的状态。
此外，如图6B及图6C所示，通过使用粘接剂粘接第一部件2和第二部件3，从而在第一部件2与第二部件3之间形成粘接层9。使用粘接剂粘接第一部件2与第二部件3时，例如，将连接用纤维4的中间部4c嵌入到粘接层9。另外，为了使连接用纤维4不妨碍第一部件2与第二部件3的粘接，可以使连接用纤维4的中间部4c在粘接层9中迂回地配置。
以下对本实施方式所带来的作用效果进行说明。
(1)本实施方式的纤维增强树脂制部件1的连接结构具备：第一部件2，其具有多层的第一纤维层5和浸渗于第一纤维层5中的基质树脂6；以及第二部件3，其借助粘接层9粘接于第一部件2上。该连接结构还具备连接第一部件2与第二部件3的连接用纤维4。第二部件3具有多层的第二纤维层7和浸渗于第二纤维层7中的基质树脂8。连接用纤维4的一端部4a被夹持于第一纤维层5间，连接用纤维4的另一端部4b被夹持于第二纤维层7间。
本实施方式的纤维增强树脂制部件1的连接结构中，第一部件2与第二部件3利用连接用纤维4连接，在该连接用纤维4的中间部4c未浸渗有基质树脂6、8。因此，即使在因向第一部件2或第二部件3输入比较大的载荷而解除了第一部件2与第二部件3的连接(利用粘接剂的粘接)的情况下，也能利用连接用纤维4来维持第一部件2与第二部件3的连接(利用连接用纤维4的连接)。因此，根据本实施方式的纤维增强树脂制部件1的连接结构，能够抑制第一部件2与第二部件3发生分离。
连接用纤维4的一端部4a被夹持于第一纤维层5间，连接用纤维4的另一端部4b被夹持于第二纤维层7间，因此对于第一部件2和第二部件3来说，能够比较牢固地保持连接用纤维4。
(2)连接用纤维4的一端部4a被配置于第一纤维层5的中间层，且连接用纤维4的另一端部4b被配置于第二纤维层7的中间层。
通过连接用纤维4的一端部4a被配置于第一纤维层5的中间层，且连接用纤维4的另一端部4b被配置于第二纤维层7的中间层，从而对于第一部件2和第二部件3而言，能够更牢固地保持连接用纤维4。
(3)例如，连接用纤维4被嵌入到粘接层9中。
通过连接用纤维4被嵌入到粘接层9中，在借助粘接层9粘接第一部件2与第二部件3的状态下，能够使连接用纤维4(中间部4c)不露出。
(4)连接用纤维4可以在粘接层9中迂回地配置。
通过连接用纤维4在粘接层9中迂回地配置，从而连接用纤维4(中间部4c)能够不妨碍第一部件2与第二部件3的粘接。
(5)例如，第一部件2是车辆的外板面板，第二部件3是用于将外板面板安装于车辆的车体的支架。
即使在因向车辆的外板面板或支架输入比较大的载荷而解除了外板面板与支架的连接(利用粘接剂的粘接)的情况下，也能够抑制外板面板与支架发生分离。
(6)本实施方式的纤维增强树脂制部件1的制造方法具备：将连接用纤维4的一端部4a夹入第一纤维层5间，将连接用纤维4的另一端部4b夹入第二纤维层7间，从而使连接用纤维4的中间部4c露出的工序。该制造方法还具备：使基质树脂6、8浸渗到第一纤维层5和第二纤维层7中，而不使基质树脂6、8浸渗到连接用纤维4的中间部4c中的工序；和使基质树脂6、8固化的工序。
通过如此操作，能够有效地制造纤维增强树脂制部件1。特别是由于连接用纤维4的一端部4a被夹持于第一纤维层5间，并且连接用纤维4的另一端部4b被夹持于第二纤维层7间，因此，对于第一部件2和第二部件3而言，能够比较牢固地保持连接用纤维4。
(7)例如，通过在连接用纤维4的中间部4c配设密封构件11，从而不使基质树脂6、8浸渗到连接用纤维4的中间部4c中。
通过如此操作，可以使基质树脂6、8浸渗到第一纤维层5和第二纤维层7中，另一方面，可以不使基质树脂6、8浸渗到连接用纤维4的中间部4c中。
(8)通过利用脆性树脂12覆盖连接用纤维4的中间部4c，从而可以不使基质树脂6、8浸渗到连接用纤维4的中间部4c中。
通过如此操作，还可以使基质树脂6、8浸渗到第一纤维层5和第二纤维层7中，另一方面，可以不使基质树脂6、8浸渗到连接用纤维4的中间部4c中。
(9)通过利用软性树脂13覆盖连接用纤维4的中间部4c，从而可以不使基质树脂6、8浸渗到连接用纤维4的中间部4c中。
通过如此操作，还可以使基质树脂6、8浸渗到第一纤维层5和第二纤维层7中，另一方面，可以不使基质树脂6、8浸渗到连接用纤维4的中间部4c中。
以上基于实施例对本发明的内容进行了说明，但本发明并不受这些记载限定，能够进行各种变形和改良对于本领域技术人员来说是显而易见的。
附图符号说明
1 纤维增强树脂制部件
2 第一部件
3 第二部件
4 连接用纤维
4a 一端部(第一部件连接部)
4b 另一端部(第二部件连接部)
4c 中间部
5 第一纤维层
6 基质树脂(第一树脂)
7 第二纤维层
8 基质树脂(第二树脂)
9 粘接层
11 密封构件
12 脆性树脂
13 软性树脂

Claims (9)

1.一种纤维增强树脂制部件的连接结构，其特征在于，
具备：
第一部件，其具有多层的第一纤维层和浸渗于所述第一纤维层中的基质树脂；
第二部件，其借助粘接层粘接于所述第一部件上；和
连接用纤维，其将所述第一部件与所述第二部件连接，
其中，所述第二部件具有多层的第二纤维层和浸渗于所述第二纤维层中的基质树脂，
所述连接用纤维的一端部被夹持于所述第一纤维层间，所述连接用纤维的另一端部被夹持于所述第二纤维层间。
2.根据权利要求1所述的纤维增强树脂制部件的连接结构，其特征在于，所述连接用纤维的所述一端部配置于所述第一纤维层的中间层，所述连接用纤维的所述另一端部配置于所述第二纤维层的中间层。
3.根据权利要求1或2所述的纤维增强树脂制部件的连接结构，其特征在于，所述连接用纤维被嵌入到所述粘接层中。
4.根据权利要求1或2所述的纤维增强树脂制部件的连接结构，其特征在于，所述连接用纤维在所述粘接层中迂回地配置。
5.根据权利要求1～4中任一项所述的纤维增强树脂制部件的连接结构，其特征在于，所述第一部件是车辆的外板面板，所述第二部件是用于将所述外板面板安装到所述车辆的车体上的支架。
6.一种纤维增强树脂制部件的制造方法，所述纤维增强树脂制部件具备：第一部件，其具有多层的第一纤维层和浸渗于所述第一纤维层中的基质树脂；第二部件，其具有多层的第二纤维层和浸渗于所述第二纤维层中的基质树脂；和连接用纤维，其将所述第一部件与所述第二部件连接，
其特征在于，所述制造方法具备如下工序：
通过将所述连接用纤维的一端部夹入所述第一纤维层间，将所述连接用纤维的另一端部夹入所述第二纤维层间，从而使所述连接用纤维中的所述一端部与所述另一端部之间的中间部从所述第一纤维层和所述第二纤维层露出的工序；
使所述基质树脂浸渗到所述第一纤维层和所述第二纤维层中，而不使所述基质树脂浸渗到所述连接用纤维的所述中间部中的工序；和
使所述基质树脂固化的工序。
7.根据权利要求6所述的纤维增强树脂制部件的制造方法，其特征在于，
通过在所述连接用纤维的所述中间部配设密封构件，由此不使所述基质树脂浸渗于所述连接用纤维的所述中间部中。
8.根据权利要求6所述的纤维增强树脂制部件的制造方法，其特征在于，
通过利用脆性树脂覆盖所述连接用纤维的所述中间部，从而不使所述基质树脂浸渗于所述连接用纤维的所述中间部中。
9.根据权利要求6所述的纤维增强树脂制部件的制造方法，其特征在于，
通过利用软性树脂覆盖所述连接用纤维的所述中间部，从而不使所述基质树脂浸渗于所述连接用纤维的所述中间部中。
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