JP2008254594A - Frp structural member and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an FRP structural member capable of suppressing any breakage of a circumference of a through hole by an external load, and its manufacturing method. <P>SOLUTION: In a dash panel 10, a cylindrical part 18A of an FRP bulk 18 is fitted in a through hole 12A of a core 12 as a foamed body, and flange parts 18B, 18C provided on both ends in the axial direction of the cylindrical part 18A are joined with FRP surface skin layers 14, 16. A circumference of the through hole is reinforced by the bulk 18, any breakage of the circumference of the through hole 12A by a shock load when a vehicle collides, is suppressed. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to an FRP structural member having a core material and a skin layer made of fiber reinforced resin formed on the surface thereof, and having a through hole at a predetermined portion, and a method for manufacturing the same.

Conventionally, a fish tank in which a fiber reinforced resin layer is laminated on the surface of a core formed of a foam is known (for example, see Patent Document 1). In this fish tank, the drain port provided on the side wall communicates with the bottom of the water tank through the drain hole.
Japanese Utility Model Publication No. 6-84847

  However, in the fish tank (structure member made of FRP) having the above configuration, the inner periphery of the drainage hole is not reinforced, and therefore there is a possibility that the periphery of the drainage hole (through hole) is easily destroyed by an external load.

  An object of the present invention is to obtain an FRP structural member and a method of manufacturing the same that can prevent the periphery of the through hole from being broken by an external load in consideration of the above fact.

  The structural member made of FRP according to the invention of claim 1 includes a core material in which a through hole is formed, and a skin layer made of a fiber reinforced resin that is formed on the outer surface of the core material and through which the through hole is penetrated. And a reinforcing member having a cylindrical portion fitted in the through-hole and a bonding portion provided at an axial end portion of the cylindrical portion and bonded to the skin layer.

  In the FRP structural member according to claim 1, the cylindrical portion of the reinforcing material is fitted into the through hole formed in the core material, and the joint portion provided at the end in the axial direction of the cylindrical portion is a fiber reinforced resin. It is joined to the made skin layer. Therefore, since the periphery of the through hole is reinforced by this reinforcing material, it is possible to suppress the periphery of the through hole from being destroyed by an external load.

  The FRP structural member according to claim 2 is the FRP structural member according to claim 1 or 2, wherein a fastener for fastening another member is attached to the reinforcing member. It is characterized by being.

  In the FRP structural member according to claim 2, a fastener for fastening another member is attached to a reinforcing member which is a strength member. For this reason, the fastening strength of another member can be improved.

  According to a third aspect of the present invention, there is provided a method of manufacturing an FRP structural member, comprising: a cylindrical portion having a bottom wall; a main body portion having a flange portion provided on an opening side of the cylindrical portion; and the flange portion. And manufacturing a reinforcing member having a lid portion that closes the opening of the cylindrical portion, and manufacturing a core member in which the reinforcing member is assembled by forming a through hole into which the cylindrical portion is fitted. A fiber reinforced resin skin layer provided on the outer surface of the core material on both sides in the axial direction and bonded to the bottom wall or the lid portion is formed by lamination molding, and the inside of the tube portion is externally formed by drilling. It is characterized by communicating with.

  In the manufacturing method of the FRP structural member according to claim 3, the reinforcing material is assembled to the core material in a state where the cylindrical portion of the reinforcing material is fitted in the through hole of the core material. A fiber reinforced resin skin layer provided on the outer surface of the core member on both sides in the axial direction of the tube portion and joined to the bottom wall or lid portion of the tube portion is formed by lamination molding, and the tube layer is formed by drilling. The inside of the part communicates with the outside. Here, in the FRP structural member manufactured by this manufacturing method, the cylindrical portion of the reinforcing material is fitted into the through hole of the core material, and the lid portion joined to the flange portion of the reinforcing material and the bottom of the cylindrical portion The wall is joined to a skin layer made of fiber reinforced resin. Therefore, since the periphery of the through hole is reinforced by the reinforcing material, it is possible to suppress the periphery of the through hole from being broken by an external load.

  According to a fourth aspect of the present invention, there is provided a manufacturing method of an FRP structural member, wherein a tubular member and a reinforcing material having flanges on both sides in the axial direction of the tubular portion are manufactured, and a through hole into which the tubular portion is fitted is provided. A fiber which is formed and manufactured with the reinforcing material assembled thereon, is provided on the outer surface of the core material on both sides in the axial direction of the cylindrical portion, and is joined to the flange portion and through which the through hole penetrates A skin layer made of reinforced resin is formed by lamination molding.

  In the manufacturing method of the FRP structural member according to claim 4, the reinforcing material is assembled to the core material in a state where the cylindrical portion of the reinforcing material is fitted in the through hole of the core material. Then, a fiber reinforced resin skin layer is formed by lamination molding that is provided on the outer surface of the core material on both sides in the axial direction of the cylindrical portion and joined to the flange portion of the reinforcing material and through the through hole of the core material. The Here, in the FRP structural member manufactured by this manufacturing method, the cylindrical portion of the reinforcing material is fitted into the through hole of the core material, and the flange portions provided on both sides in the axial direction of the cylindrical portion are fiber reinforced resin. It is joined to the made skin layer. Therefore, since the periphery of the through hole is reinforced by the reinforcing material, it is possible to suppress the periphery of the through hole from being broken by an external load.

  As described above, in the FRP structural member according to the present invention, it is possible to prevent the periphery of the through hole from being broken by an external load.

<First Embodiment>
FIG. 1 is a front view of a dash panel 10 as an FRP structural member according to the first embodiment of the present invention. 2 is a cross-sectional view taken along line 2-2 of FIG. 1, and FIG. 3 is a cross-sectional view taken along line 3-3 of FIG. In the figure, an arrow FR indicates a front direction of a vehicle (not shown) to which the dash panel 10 is attached, an arrow UP indicates an upward direction of the vehicle, and an arrow W indicates a vehicle width direction of the vehicle.

  The dash panel 10 according to the first embodiment partitions a vehicle engine room and a vehicle compartment (not shown), and includes a core member 12. In the first embodiment, the core material 12 is formed by foaming a foam material, and skin layers 14 and 16 are formed on both front and rear sides thereof. These skin layers 14 and 16 are formed of a carbon fiber reinforced resin material.

  The dash panel 10 is formed with a through hole 10A through which a steering shaft (not shown) passes and a through hole 10B through which a brake master cylinder (not shown) passes.

  The steering shaft through hole 10 </ b> A is composed of through holes 14 </ b> A and 16 </ b> A formed in the skin layers 14 and 16 and a through hole 12 </ b> A formed in the core member 12. A steering shaft hole bulk 18 (see FIG. 4) is provided inside the through hole 12A of the core member 12 as a reinforcing material for reinforcing the through hole 12A.

  The bulk 18 is formed of a carbon fiber reinforced resin material in the first embodiment, and has a cylindrical portion 18A formed in a cylindrical shape. The cylindrical portion 18A is fitted in the through hole 12A of the core member 12, and the steering shaft passes through the inside of the cylindrical portion 18A. At both ends in the axial direction of the cylindrical portion 18A, flange portions 18B and 18C (joint portions) are provided, and these flange portions 18B and 18C are bonded to the skin layers 14 and 16, respectively. Thereby, the bulk 18 is integrally coupled to the skin layers 14 and 16, and the inner periphery of the through hole 12 </ b> A of the core material 12 is reinforced by the cylindrical portion 18 </ b> A of the bulk 18.

  In addition, an insert collar 20 (fastener) formed in a block shape is fixed to one collar portion 18B joined to the skin layer 14 on the vehicle front side. The insert collar 20 is provided with a screw hole 20A in which a female screw is formed inside. A bolt for fastening a front side member (separate member) (not shown) to the dash panel 10 is screwed into the screw hole 20A.

  On the other hand, the above-described through hole 10B for the brake master cylinder is constituted by through holes 14B and 16B formed in the skin layers 14 and 16, and a through hole 12B formed in the core material 12. Inside the through hole 12B of the core member 12, a brake master cylinder hole bulk 22 (see FIG. 5) is provided as a reinforcing material for reinforcing the through hole 12B.

  The bulk 22 is formed of a carbon fiber reinforced resin material in the first embodiment, and has a cylindrical portion 22A formed in a cylindrical shape. The cylinder portion 22A is fitted in the through hole 12B of the core member 12, and the brake master cylinder penetrates the inside of the cylinder portion 22A. At both ends in the axial direction of the cylindrical portion 22A, flange portions 22B and 22C (joint portions) are provided, and these flange portions 22B and 22C are bonded to the skin layers 14 and 16, respectively. Accordingly, the bulk 22 is integrally coupled to the skin layers 14 and 16, and the inner periphery of the through hole 12 </ b> B of the core material 12 is reinforced by the cylindrical portion 22 </ b> A of the bulk 22.

  A plurality of insert collars 24 (fasteners) formed in a block shape are fixed to one collar portion 22C joined to the skin layer 16 on the vehicle rear side. Each of the insert collars 24 is provided with a screw hole 24A having a female screw formed inside. A bolt for fastening a brake pedal bracket (separate member) (not shown) to the dash panel 10 is screwed into the screw hole 24A.

  Next, a manufacturing method of the dash panel 10 having the above configuration will be described with reference to FIGS. In addition, since the bulk 18 and the bulk 22 described above have basically the same configuration, only one bulk 18 is mentioned here. 6 and 7, the configuration of the bulk 18 is simplified for convenience of explanation.

  In the manufacturing method according to the first embodiment, first, a bulk 18 as a reinforcing material is manufactured (see FIG. 6). As the material of the bulk 18, a fiber reinforced resin material, a seal molding compound, aluminum, or other materials can be used. Then, as shown in FIG. 7A, an insert collar 20 (fastener) is bonded in advance to the flange portion 18B of the bulk 18.

  Next, as shown in FIG. 7B, the bulk 18 is assembled to the core material 12. As the core material 12, a foam molded body, an aluminum structure (so-called aluminum honeycomb), or the like can be used. In addition, when using a foaming molding as the core material 12, the bulk 18 can be assembled | attached to the core material 12 by insert molding, for example. Further, when an aluminum honeycomb is used as the core material 12, the bulk material 18 can be assembled to the core material 12 by dividing the core material 12 with the through hole 12 </ b> A into which the cylindrical portion 18 </ b> A is fitted as a boundary.

  Then, as shown in FIG. 7C, the skin layer 14 is formed by laminating the FRP sheet on the upper surface of the mold 26 provided with the protrusions 26A on the upper part. The protrusion 26A of the mold 26 can be fitted inside the cylindrical portion 18A, and the through hole 14A is formed in advance in the above-described FRP sheet at a position corresponding to the protrusion 26A.

  Next, as shown in FIG. 7D, the core material 12 assembled with the bulk 18 is set on the mold 26 from above the skin layer 14. At this time, the protrusions 26 </ b> A are fitted inside the cylindrical portion 18 </ b> A of the bulk 18, whereby the bulk 18 is positioned on the mold 26 and the insert collar 20 bonded to the bulk 18 is positioned on the mold 26. . A thermosetting adhesive (not shown) formed in a film shape is interposed between the flange portion 18B of the bulk 18 and the skin layer 14.

  Next, as shown in FIG. 7E, the skin layer 16 is formed by laminating FRP sheets on the top surfaces of the core material 12 and the bulk 18. A through hole 16A is formed in advance in the FRP sheet at a position facing the cylindrical portion 18A. Further, a thermosetting adhesive (not shown) formed in a film shape is interposed between the flange portion 18 </ b> C of the bulk 18 and the skin layer 16.

  Next, a bag (not shown) is set above the skin layer 16 and heated in a vacuum state. Accordingly, the skin layers 14 and 16 are cured, and the film adhesive interposed between the collar portion 18B and the skin layer 14 and between the collar portion 18C and the skin layer 16 is cured, whereby the collar portion 18B and 18C are joined to the skin layers 14 and 16. Thereby, the dash panel 10 according to the first embodiment is completed.

  When the dash panel 10 is manufactured by the above manufacturing method, since the through holes 14A and 16A are formed in advance in the sheet-like fibers constituting the skin layers 14 and 16, drilling after vacuum heat forming is unnecessary, Manufacturing costs can be kept low.

  Next, the operation of the first embodiment will be described.

  In the dash panel 10 configured as described above, the cylindrical portion 18A of the bulk 18 is fitted into the through hole 12A of the core member 12 constituting the through hole 10A for the steering shaft, and is provided at both axial ends of the cylindrical portion 18A. The flanges 18B and 18C thus formed are joined to the skin layers 14 and 16 made of fiber reinforced resin. Therefore, since the periphery of the through hole 12A is reinforced by the bulk 18, it is possible to suppress the periphery of the through hole 12A from being broken by an impact load at the time of a vehicle collision.

  Further, in this dash panel 10, the cylindrical portion 22A of the bulk 22 is fitted into the through hole 12B of the core member 12 constituting the through hole 10B for the brake master cylinder, and the axial direction both ends of the cylindrical portion 22A are fitted. The provided collars 22B and 22C are joined to the skin layers 14 and 16 made of fiber reinforced resin. Therefore, since the periphery of the through hole 12B is reinforced by the bulk 22, it is possible to suppress the periphery of the through hole 12B from being broken by an impact load or the like at the time of a vehicle collision.

  Moreover, in the dash panel 10, the insert collar 20 for fastening the front side member and the insert collar 24 for fastening the brake pedal bracket are fixed to the bulks 18 and 22 which are reinforcing members (strength members). ing. Accordingly, the fastening strength of the front side member and the bracket to the dash panel 10 can be improved.

  Incidentally, as shown in FIG. 8, even when the cylindrical portion 14 </ b> C integrated with the display layer 14 is configured to be fitted into the through hole 12 </ b> A of the core member 12, the periphery of the through hole 12 </ b> A can be reinforced. However, in this case, when the skin layer 14 is formed, the FRP sheet must be laminated along the protrusions 26A of the mold 26, so that there is a problem that it is very difficult to laminate. In this regard, in the first embodiment, since the bulks 18 and 22 are manufactured separately from the skin layers 14 and 16, the stacking operation of the FRP sheets for forming the skin layers 14 and 16 becomes easy. As a result, the manufacturing cost can be reduced.

  In the case of the configuration shown in FIG. 8, there is a problem that the degree of freedom in design is low because the strength of the cylinder portion 14 </ b> C can only be increased by extending the FRP sheet. On the other hand, in the first embodiment, since the material of the bulks 18 and 22 can be arbitrarily selected, the through-holes 10A and 10B can be reinforced with an optimal material, and the design with a high degree of freedom ( Reinforcement).

  Further, in the case of the configuration shown in FIG. 8, since it is necessary to pull out the cylindrical portion 14C from the protrusion 26A of the mold 26 after the lamination molding, a draft angle must be set in the cylindrical portion 14C. In addition, when the draft angle is a negative angle, the mold mechanism 26 must be provided with a slider mechanism. In this respect, in the first embodiment, since it is not necessary to consider the draft angle, the degree of freedom in design is improved, and it is not necessary to provide a slider mechanism in the mold 26. Therefore, the manufacturing cost of the mold 26 is reduced. Can be reduced.

In the configuration shown in FIG. 8, when an insert collar (fastener) is bonded to the inner surface of the skin layer 14 or the skin layer 16, it is difficult to accurately position the insert collar. In this regard, in the first embodiment, since the insert collars 20 and 24 are bonded to the bulks 18 and 22, the insert collars 20 and 24 are positioned on the mold 26, so that the insert collars 20 and 24 are positioned on the mold 26. Can be accurately positioned. Therefore, the positioning of the insert collars 20 and 24 is facilitated, and the manufacturing efficiency can be improved.
<Second Embodiment>
Next, a second embodiment of the present invention will be described. In addition, about the structure and effect | action fundamentally similar to the said 1st Embodiment, the same sign as the said 1st Embodiment is provided, and the description is abbreviate | omitted.

  FIG. 9 is a sectional view showing a partial configuration of a dash panel 30 as an FRP structural member according to the second embodiment of the present invention. The dash panel 30 has basically the same configuration as the dash panel 10 according to the first embodiment, and is formed in the through holes 14A and 16A formed in the skin layers 14 and 16 and the core material 12. The through-hole 30A is constituted by the formed through-hole 12A. However, in this dash panel 30, the structure of the bulk 32 (reinforcing material) that reinforces the through hole 12A of the core material 12 is different from the bulks 18 and 22 according to the first embodiment.

  The bulk 32 according to the second embodiment is disposed between the skin layers 14 and 16 in the same manner as the bulks 18 and 22 according to the first embodiment. The bulk 32 has a bottomed cylindrical tube portion 36A in which a through hole 34 is formed in the center portion of the bottom wall 37, and a main body portion 34 having a flange portion 36B formed at the opening side end portion of the tube portion 36A. And a disc-shaped lid portion 38 joined to the flange portion 36B by an adhesive 42. A through hole 40 is formed at the center of the lid portion 38.

  The cylindrical portion 36 </ b> A of the main body portion 36 is fitted in the through hole 12 </ b> A formed in the core member 12, and the bottom wall 37 of the cylindrical portion 36 </ b> A is joined to the skin layer 16. A through hole 16A is formed in the skin layer 16 at a position facing the through hole 34 of the bottom wall 37 of the cylindrical portion 36A. The bulk 32 has a lid portion 38 joined to the skin layer 14, and the skin layer 14 has a through hole 14 </ b> A at a position facing the through hole 40 of the lid portion 38. These through holes 34, 16A, 40, and 14A are arranged coaxially with the cylindrical portion 36A.

  Next, a method for manufacturing the dash panel 30 having the above configuration will be described with reference to FIGS.

  In the manufacturing method according to the second embodiment, first, the body portion 36 and the lid portion 38 of the bulk 32 are manufactured using a fiber reinforced resin material, a seal molding compound, aluminum, or other materials, and a foam material or The core material 12 having the through holes 12A is manufactured using a material such as an aluminum honeycomb. However, at this time, the through holes 34 and 40 are not formed in the main body portion 36 and the lid portion 38 (Note that the main body portion 36 in which the through hole 34 is omitted is shown in FIGS. 10 and 11A). Have been).

  Next, as shown in FIG. 11B, the lid portion 38 is bonded to the flange portion 36B of the main body portion 36 using an adhesive 42, and the cylindrical portion 36A of the main body portion 36 is fitted into the through hole 12A. The bulk 32 is assembled to the core material 12.

  Next, the skin layer 14 is formed on the upper surface of the mold 44, the core material 12 assembled with the bulk 32 is set on the mold 44 from the top of the skin layer 14, and the skin layer is formed above the core material 12 and the bulk 32. 16 is formed (the state shown in FIG. 11C). A thermosetting adhesive (not shown) formed in a film shape is interposed between the lid portion 38 and the skin layer 14 and between the bottom wall 37 of the cylinder portion 36A and the skin layer 16. deep.

  Next, a bag (not shown) is set above the skin layer 16 and heated in a vacuum state. Thus, the skin layers 14 and 16 are cured, and the film adhesive interposed between the lid portion 38 and the skin layer 14 and between the bottom wall 37 of the cylindrical portion 36A and the skin layer 16 is cured. Thus, the lid 38 and the bottom wall 37 of the cylindrical portion 36 </ b> A are joined to the skin layers 14 and 16.

  Next, the through hole 16A of the skin layer 16, the through hole 34 of the bottom wall 37 of the cylinder portion 36A, the through hole 40 of the lid portion 38, and the through hole 14A of the skin layer 14 are formed by drilling with a machine tool. The inside of the part 36B is communicated with the outside (see FIG. 9). Thereby, the dash panel 30 according to the second embodiment is completed. Since the through holes 16A, 34, 40, and 14A are arranged on the same axis, these through holes can be formed by a single drilling process.

  Also in the dash panel 30 configured as described above, since the periphery of the through hole 12A is reinforced by the bulk 32, it is possible to suppress the periphery of the through hole 12A from being destroyed by an impact load or the like at the time of a vehicle collision.

  In addition, in the dash panel 30, the bottom wall 37 of the cylindrical portion 36B and the skin layer 16 protrude to the inside of the through hole 30A, so that the grommet 46 (see FIG. 9) can be attached to the protruding portion.

  In the first embodiment and the second embodiment, the case where the present invention is applied to the dash panels 10 and 30 of the vehicle has been described. However, the present invention is not limited to the dash panel, and the core material. And a fiber reinforced resin skin layer formed on the surface thereof, and any FRP structural member provided with a through hole at a predetermined site can be applied.

It is a front view of the dash panel which concerns on the 1st Embodiment of this invention. FIG. 2 is a sectional view taken along line 2-2 of FIG. FIG. 3 is a sectional view taken along line 3-3 in FIG. 1. It is a perspective view which shows the structure of the bulk which is a structural member of the dash panel shown by FIG. It is a perspective view which shows the structure of the bulk which is a structural member of the dash panel shown by FIG. It is the figure which simplified the bulk shown by FIG. It is sectional drawing for demonstrating the manufacture procedure of the dash panel shown by FIG. It is sectional drawing which shows the modification of the dash panel shown by FIG. It is sectional drawing of the dash panel which concerns on the 2nd Embodiment of this invention. It is a perspective view which shows the structure of the bulk which is a structural member of the dash panel shown by FIG. It is sectional drawing for demonstrating the manufacture procedure of the dash panel shown by FIG.

Explanation of symbols

10 Dash panel (FRP structural member)
12 Core Material 12A Through Hole 14 Skin Layer 14A Through Hole 16 Skin Layer 16A Through Hole 18 Bulk (Reinforcing Material)
18A Cylinder part 18B, 18C collar part (joint part)
20 Insert collar (fastener)
22 Bulk (reinforcing material)
22A cylinder part 22B, 22C collar part (joint part)
24 Insert collar (fastener)
30 Dash panel (FRP structural member)
32 Bulk (reinforcing material)
36 body part 36A cylinder part 36B collar part 37 bottom wall (joint part)
38 Lid (joint)

Claims (4)

A core material in which a through hole is formed;
A skin layer made of fiber reinforced resin formed on the outer surface of the core material and through which the through hole has passed,
Reinforcing material comprising a cylindrical portion fitted in the through-hole, and a joint portion provided at the axial end of the cylindrical portion and joined to the skin layer;
FRP structural member having   The FRP structural member according to claim 1, wherein a fastener for fastening another member is attached to the reinforcing material.   A reinforcing member is manufactured that includes a cylindrical portion having a bottom wall, a main body having a flange provided on the opening side of the cylindrical portion, and a lid that is joined to the flange and closes the opening of the cylindrical portion. In addition, a core material in which a through hole into which the cylindrical portion is fitted is formed and the reinforcing material is assembled is manufactured, provided on the outer surface of the core material on both sides in the axial direction of the cylindrical portion, and the bottom wall or A manufacturing method of an FRP structural member, characterized in that a fiber reinforced resin skin layer joined to the lid portion is formed by lamination molding, and the inside of the cylindrical portion is communicated with the outside by drilling.   A cylindrical member and a reinforcing material having flanges on both sides in the axial direction of the cylindrical part are manufactured, and a core material in which the reinforcing material is assembled by forming a through hole into which the cylindrical part is fitted is manufactured. A fiber reinforced resin skin layer that is provided on the outer surface of the core material on both sides in the axial direction of the portion and joined to the flange portion and through which the through-hole is penetrated is formed by lamination molding. A method for manufacturing a structural member.

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