JP2002059485A - Joint type composite member made of stocks having different thermal expansion coefficients and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a joint type composite member made of stocks solving a problem of a warp, a distortion or the like by absorbing and alleviating a thermal stress of the composite member made of two types of stocks having different thermal expansion coefficients by a rubber material. SOLUTION: The composite member is made by integrally molding the two types of the stocks having the different thermal expansion coefficients in a joint structure. The composite member is further made by laminating an unvulcanized rubber material at an intermediate of the stocks having the different thermal expansion coefficients, forming the member in a joint structure in which a contact distance of the two types of the stocks having the different thermal expansion coefficients with the rubber material is set to 1.5 or more when a thickness of its contact part is 1, and vulcanizing the rubber material by heating and pressurizing.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention belongs to the technical field of a joint type composite member formed by molding two kinds of materials having different coefficients of thermal expansion into an integral structure by a joint and a method of manufacturing the same. The present invention relates to a joint type composite member made of two types of materials having different coefficients of thermal expansion, which is suitably used for a vehicle such as a car, an aircraft, a ship, or a medical device, and a method of manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, a composite member made of two materials having different coefficients of thermal expansion used for a vehicle such as a racing car, an aircraft, a ship, or a medical device, for example, an aluminum material 10 shown in FIG. The composite member 9 composed of the fiber-reinforced plastic material 11 (hereinafter, sometimes abbreviated as CFRP) is formed by directly integrating the two materials 10 and 11 in series.

Further, two materials having different coefficients of thermal expansion, for example, a molding material comprising an uncured epoxy resin composition and an unvulcanized acrylonitrile-butadiene copolymer rubber composition are laminated, and heated and pressed under pressure. For producing a composite material in which both are cured and adhered to each other to improve the adhesiveness between them (Japanese Patent Laid-Open No. 5-3017).
No. 92) and a laminated composite material produced by the same method are also known.

[0004]

However, when the temperature of the composite member 9 shown in FIG. 6 changes from room temperature (20 ° C.) to the curing temperature (about 140 ° C.) at the time of molding, or at room temperature during use, When the two materials 10 and 11 are heated to a high temperature from above, the two materials 10 and 11 thermally expand at a specific coefficient of thermal expansion. As a result, a large thermal stress is generated and concentrated at the joint between the two materials 10 and 11 whose thermal expansion is restrained, and the joint is peeled off, or the shape of the composite member 9 is indicated by a dotted line. There is a problem that warpage and distortion occur. As an example, FIG.
Is about L = 300 mm, a warp of about λ = 2 to 3 mm occurs. Therefore, it lacks reliability such as durability in a high-temperature environment, and is not suitable for being installed in a place under a high-temperature condition or used as a component of a precision device or equipment that generates a high temperature.

An object of the present invention is to obtain a composite material in which two types of materials having different coefficients of thermal expansion are firmly integrated by heating and pressing with a rubber material. Material), instead of the joint structure,
An object of the present invention is to provide a "joint-type composite member" obtained by heating and pressurizing and a method for producing the same.

[0006] The next object of the present invention is to provide a different thermal expansion coefficient.
By providing a joint type composite member made of a material having a different coefficient of thermal expansion, which solves the above-described problems such as warpage and distortion by absorbing and relaxing the thermal stress of a composite member made of a different material by a rubber material, and a method of manufacturing the same. is there.

A further object of the present invention is to provide a joint type composite member made of a material having a different coefficient of thermal expansion, which significantly improves the reliability such as durability in use at a high temperature, and can thereby expand the usable range, and a joint member thereof. It is to provide a manufacturing method.

[0008]

As a means for solving the above-mentioned problems, a joint type composite member made of a material having a different coefficient of thermal expansion according to the first aspect of the present invention has two kinds of coefficients of thermal expansion. A composite member formed by integrally molding different materials by a joint structure, wherein an unvulcanized rubber material is laminated between two materials having different coefficients of thermal expansion, and the two materials having different coefficients of thermal expansion. When the contact distance with the rubber material is 1 and the thickness of the contact portion is 1, it is formed into a joint structure of 1.5 or more, molded into an integral structure, and vulcanized by heating and pressing the rubber material. It is characterized by processing.

According to a second aspect of the present invention, there is provided a method of manufacturing a joint type composite member made of materials having different coefficients of thermal expansion. A method of manufacturing, comprising: laminating an unvulcanized rubber material between two materials having different coefficients of thermal expansion, and determining the contact distance between the two materials having different coefficients of thermal expansion and the rubber material by a thickness of a contact portion. When the length is set to 1, it comprises a step of forming a joint structure of 1.5 or more to form an integrated structure, and a step of performing a vulcanization treatment by heating and pressing the rubber material. And

According to a third aspect of the present invention, in the method for manufacturing a joint type composite member made of a material having a different coefficient of thermal expansion according to the second aspect, one of the materials having a different coefficient of thermal expansion is a thermosetting resin, When laminating an unvulcanized rubber material in the middle of another material and integrally molding it into a joint structure, in the step of vulcanizing the rubber material by heating and pressing, the thermosetting It is also characterized in that the resin is cured.

[0011]

1 and 3 show a first embodiment of the present invention.
3 is a conceptually exaggerated embodiment of a joint-type composite member made of materials having different coefficients of thermal expansion according to the inventions described in 3 to 3 and a method of manufacturing the same. Each embodiment uses, as an example of a material having a different coefficient of thermal expansion, a metal outer peripheral frame material 1 such as aluminum having a large coefficient of thermal expansion, a thermosetting resin 2 having a small coefficient of thermal expansion, and a rubber material 3 for a joint. And integrally molded.

FIG. 1 shows a metal outer frame material 1 such as aluminum.
A thermosetting resin 2 containing carbon fiber or the like is disposed inside the inside, and a rubber material 3 is interposed between them (joining portion) so that the metal outer peripheral frame material 1 and the thermosetting resin 2 are interposed therebetween. Is conceptually showing an enlarged cross-section of a "joint-type composite member" in which the relationship with the rubber material 3 is joined and formed integrally by a joint structure having irregularities.

The joint having the concave-convex structure shown in FIG. 1 has a thickness T of a vertical cross section of a joining portion between the metal outer frame material 1 and the rubber material 3 or a thermosetting material as means for obtaining sufficient bonding or joining strength. The ratio of the contact distance S or S 'of each concavo-convex to the thickness T' of the vertical cross section of the joint between the resin 2 and the rubber material 3 is 1: 1.5.
The joint structure described above, that is,

[0014]

(Equation 1) Needs to be satisfied. Incidentally, the contact distance S or S ′ of the uneven joint structure is a length obtained by adding the length W or W ′ of the upper and lower horizontal surfaces of each convex portion of the uneven joint structure to the thickness T or T ′ of each joint, That is,

[0015]

(Equation 2) It is.

The shape of the joint structure between the metal outer frame member 1 and the thermosetting resin 2 and the rubber material 3 may be any of the inclined joint structures illustrated in FIG. The present invention can be implemented with the illustrated saw-toothed joint structure, and the same operation and effect can be obtained. Of course, as long as the above [Equation 1] is satisfied, the present invention is not limited to the form of the joint structure having the irregularities, slopes, and saw blades shown in FIGS.

The molding process of the "joint-type composite member" is as shown in FIGS. 1 to 3 in the middle of the metal outer peripheral frame member 1 and the thermosetting resin 2 arranged on the molding die 4. The rubber material 3 is interposed in the joint structure. The thermosetting resin 2
And the rubber material 3 has a thickness of 0.1 to 0.5 mm, respectively.
The sheet materials 2 ′ and 3 ′ are formed and arranged as a laminated body in which the sheet materials 2 ′ and 3 ′ are stacked.

At the time of lamination, the thermosetting resin 2 is cut out of the uncured resin sheet material 2 ′ which is uncured, thin, flexible and easy to be processed into a desired size and shape, and the joint with the rubber material 3 is joined to the joint. Laminated to the structure and molded.

As the uncured resin sheet material 2 ', an epoxy resin composition, for example, bismaleide manufactured by Mitsubishi Gas Chemical Co., Ltd. or Epoxy # 2500 manufactured by Toray Industries, Inc. is preferably used. Not. It is also possible to use a fiber-reinforced resin or the like containing other fibers such as glass fiber and carbon fiber as a reinforcing material.

Similarly to the thermosetting resin 2, the rubber material 3 is formed by forming the unvulcanized, thin, flexible, and easy-to-process unvulcanized rubber sheet 3 'with the metal outer frame member 1. And, those cut out into dimensions and shapes corresponding to the shape of the joint portion of the thermosetting resin 2 are laminated and molded into a joint structure.

Incidentally, as the unvulcanized rubber sheet 3 ',
An acrylonitrile-butadiene rubber (NBR) composition excellent in heat resistance and oil resistance, for example, unvulcanized NBR for tank interior manufactured by Fujikura Rubber Industries, Ltd. is preferably used,
This is not the case.

The metal outer peripheral member 1 and the thermosetting resin 2 formed by laminating and forming the concavo-convex joint structure in the molding die 4 are subjected to heat of 120 ° C. under a pressure of 5 kg / cm ^{2 while} maintaining an integral structure. The step of vulcanizing the rubber material 3 which is a laminate of the vulcanized rubber sheets 3 'and the step of curing the thermosetting resin 2 which is a laminate of the uncured resin sheet 2' are simultaneously executed and completed.

The vulcanization treatment by pressurization and heating is as follows:
The processing conditions are not limited to the above. It is also possible to carry out the treatment under heating conditions of about 100 to 200 ° C. under a pressure of 1 to 10 kg / cm ² .

In the vulcanization step by the above-mentioned pressurization and heating, the laminated unvulcanized rubber sheets 3 ′ are chemically bonded (cross-linked) to each other on their mutual bonding surfaces, and an integrated rubber material 3 is obtained. Can be

[0025] By the thermosetting step performed at the same time,
The uncured resin sheet materials 2 ′ are chemically bonded to each other at their bonding surfaces and cured to obtain an integrated thermosetting resin 2.

As a result, the thermosetting resin 2 and the metal outer frame material 1 are bonded to the rubber material 3 interposed at each joint.
Thus, a "joint-type composite member" is integrally bonded and joined by the fine uneven structure, and is structurally integrated as a whole.

The "joint-type composite member" is heated when the temperature is increased by the pressurizing / heating treatment or when the temperature of the "joint-type composite member" is increased by heating during use.
As a matter of course, the metal outer peripheral frame material 1 and the thermosetting resin 2 expand at their own different thermal expansion coefficients to generate a difference in thermal expansion, but the intermediate peripheral portion between the metal outer peripheral frame material 1 and the thermosetting resin 2 Due to the elasticity of the interposed rubber material 3, the “difference in thermal expansion” is absorbed and alleviated without difficulty. Therefore, the thermal stress is remarkably reduced to a negligible level, and the degree of deformation such as warpage or distortion of the “joint-type composite member” is extremely small.

For example, as shown in FIG. 4, the warpage generated when the size of the CFRP 11 in the “joint type composite member 8” in which the aluminum material 10 and the CFRP 11 are integrally formed of the rubber material 3 is L = 300 mm. Is λ = 0.1 ~
It is only about 0.15mm, which is 1/2 that of the conventional product in Fig. 6.
It is as small as 0.

FIG. 5 shows an example of use in which the "joint-type composite member 5" manufactured as described above is directly attached with a bolt 7 or the like as one part of the equipment 6 that generates heat. Since the thermal stress due to the thermal expansion due to the heat conducted from the equipment 6 is reduced as described above, the “joint-type composite member 5” is not adversely affected by the thermal environment. Therefore, the “joint-type composite member 5” can be used alone or as a part without any trouble in a high-temperature environment, and is widely used in the fields of vehicles such as competition vehicles, aircraft, ships, and medical equipment. .

[0030]

According to the joint type composite member made of materials having different thermal expansion coefficients according to the first aspect of the present invention, the thermal stress of the two materials having different thermal expansion coefficients is absorbed and reduced by the rubber material. In addition, there is no possibility that the joint type composite member will cause problems such as warpage and distortion in the above-described temperature environment.

Therefore, reliability such as durability in use in a high temperature environment is remarkably improved, and the usable range can be expanded.

According to the method for manufacturing a joint type composite member made of materials having different coefficients of thermal expansion according to the present invention, the joint type composite member can be manufactured easily, reliably, and at low cost. Can be.

[Brief description of the drawings]

FIG. 1 is a sectional view schematically showing a joint type composite member according to the present invention.

FIG. 2 is a sectional view schematically showing a different joint type composite member according to the present invention.

FIG. 3 is a sectional view schematically showing a different joint type composite member according to the present invention.

FIG. 4 is a cross-sectional view schematically showing a warp generated when the joint type composite member according to the present invention is heated.

FIG. 5 is a perspective view showing an example of use of the joint type composite member according to the present invention.

FIG. 6 is a cross-sectional view schematically showing warpage generated when a composite member manufactured by a conventional manufacturing method is heated.

[Explanation of symbols]

 5, 8 Joint type composite member 3 Rubber material 2 Thermosetting resin S, S 'Contact distance T, T' Thickness of contact part

Claims (3)

[Claims] 1. A composite member obtained by integrally molding two materials having different coefficients of thermal expansion by a joint structure, wherein an unvulcanized rubber material is laminated between two materials having different coefficients of thermal expansion. When the contact distance between the two kinds of materials having different coefficients of thermal expansion and the rubber material, and the thickness of the contact portion is 1,
It is made of a material having a different coefficient of thermal expansion, characterized in that it is formed into a joint structure of 1.5 or more, molded into an integral structure, and vulcanized by heating and pressing the rubber material. Joint type composite member. 2. A method for producing a composite member comprising two materials having different coefficients of thermal expansion integrally formed by a joint structure, wherein an unvulcanized rubber material is provided between two materials having different coefficients of thermal expansion. When the contact distance between the two types of materials having different coefficients of thermal expansion and the rubber material is set to the thickness of the contact portion, the thickness of the contact portion is set to 1.5 or more, thereby forming an integral structure. A method of manufacturing a joint-type composite member made of materials having different coefficients of thermal expansion, comprising a step of molding and a step of vulcanizing the rubber material by applying heat and pressure. 3. One of the materials having a different coefficient of thermal expansion is a thermosetting resin, and when this is laminated with an unvulcanized rubber material in the middle of another material and integrally molded into a joint structure, At the stage of performing a vulcanization treatment by heating and pressing the rubber material, simultaneously performing a curing treatment of the thermosetting resin,
A method for manufacturing a joint-type composite member comprising the materials having different coefficients of thermal expansion according to claim 2.