JP2009137062A - Method for producing fiber-reinforced resin member - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a high-quality fiber-reinforced resin member in which, on the periphery of a mandrel having at least a curved part, axial direction threads can be arranged without being slid, and the axial direction threads and inclination threads are arranged uniformly. <P>SOLUTION: The method includes the first process in which the axial direction threads Q... extending in the axial direction of a mandrel 1a and the inclination threads P... inclined at a prescribed angle in the axial direction are supplied to the lengthy mandrel 1a having at least a curved part, and a fiber fabric wherein the axial direction threads and the inclination threads are woven together is produced and the second process in which the fiber-reinforced resin member is manufactured by making the fiber fabric be impregnated with the resin and curing the resin. In the first process, a slipping preventing member such as a steel pin 2 or a resin film 3 is attached to the curved part of the mandrel 1a, and the inclination threads are wound on the axial direction threads Q... which are positioned by the slipping preventing member. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a fiber reinforced resin member used particularly as a roof side rail of a vehicle.

  The vehicle's A-pillar (also called the roof side rail, located diagonally forward when viewed from the driver and supporting the left and right ends of the front window) has static strength characteristics (for example, bending rigidity) and crash resistance in the event of a vehicle collision For hybrid vehicles, electric vehicles, and the like that have recently pursued high safety and light weight, fiber reinforced resin members that satisfy both rigidity and light weight are suitable. .

  An example of the fiber reinforced resin member is a carbon fiber reinforced plastic member (CFRP). In this fiber reinforced resin member, a fiber yarn having a predetermined tensile strength or the like is knitted using an axial yarn extending in the axial direction of the member and an oblique yarn having a predetermined inclination angle with respect to the axial direction. And forming a multi-layered wound layer structure and impregnating and curing the resin. In this fiber reinforced resin member, the axial direction yarn contributes to the bending rigidity, and the wound layer structure having different orientation directions contributes to the crash resistance.

  The roof side rail described above has a shape along the roof from the front side of the vehicle, that is, a shape in which a straight portion and a bent portion are continuous, and an axial yarn and a diagonal yarn are wound along this shape. ing.

  By the way, the method for manufacturing the fiber fabric which forms the above-mentioned fiber reinforced resin member is disclosed by patent document 1. FIG. Specifically, using a manufacturing device with two braiders, each equipped with an axial yarn feeder and a brader yarn feeder, one of the braiders is driven while reciprocating a linear mandrel in the braider. During this time, both the axial yarn and the brader yarn are wound around the outer periphery of the mandrel by executing a control method for stopping the other drive.

Japanese Patent No. 3215308

  In the apparatus disclosed in Patent Document 1, it is possible to wind both the axial yarn and the brader yarn on the outer periphery of the linear mandrel. However, when the axial yarn is supplied to the outer periphery of the mandrel having the bent portion as in the roof side rail, the axial yarn slides on the mandrel at the bent portion, and the axial yarn is smoothly and uniformly distributed on the mandrel outer periphery. Can not be placed. If the axial thread slips at the bent part, the axial thread concentrates in one part and the axial thread does not exist in another part. It is inevitable that the part becomes a weak part.

  The present invention has been made in view of the above-mentioned problems, and can be arranged without slipping the axial yarn on the outer periphery of the mandrel having at least a bent portion, so that the axial yarn and the oblique yarn are both uniform. It aims at providing the manufacturing method for manufacturing the arrange | positioned high quality fiber reinforced resin member.

  In order to achieve the above object, a method for producing a fiber reinforced resin member according to the present invention is an elongated mandrel having at least a bent portion and an axial thread extending in the axial direction of the mandrel and a predetermined angle with respect to the axial direction. A first step of producing a fiber fabric in which a plurality of axial yarns and a plurality of oblique yarns are knitted together by supplying the oblique yarn; and impregnating the fiber fabric with a resin and curing the fiber fabric In the manufacturing method of the fiber reinforced resin member comprising the second step of manufacturing the fiber reinforced resin member by this, an anti-slip member is attached to at least the bent portion of the mandrel, and in the first step, In the bent portion of the mandrel, the oblique yarn is wound thereon in a posture in which the axial yarn is positioned by the anti-slip member.

  This fiber reinforced resin member is composed of, for example, a wound layer made of an axial yarn extending in the axial direction of the mandrel on the outer periphery of the mandrel serving as the core material, and an oblique yarn (blader yarn) inclined at a predetermined angle with respect to the axial direction. And a plurality of combinations of these two types of winding layers are formed, and a thermosetting resin is impregnated and cured between these winding layers.

  An arbitrary material such as steel or resin is used as the mandrel to be used. However, depending on the shape of the member, the mandrel remains as a member component without being finally pulled out. In addition, when this fiber reinforced resin member is applied as the A pillar described above, the shape of the A pillar is not a simple long cylindrical member, for example, one end thereof is a circular cross section, and the center has a dent. The mandrel which is a core material remains as a member element because it has a pentagonal cross section and has a complicated shape such that the other end gradually approaches the bolt fastening plate. In this case, in order to reduce the weight of the entire member as much as possible, the mandrel is molded from a lightweight and high-strength ABS resin (acrylonitrile, butadiene, styrene copolymer synthetic resin), a urethane-based foamed resin, or the like. It is preferable.

  The fiber-reinforced resin member targeted by the manufacturing method of the present invention has, for example, a straight portion and a bent portion, and is intended to uniformly and efficiently arrange axial yarns at the bent portion. Thus, according to the present manufacturing method, the axial yarns can be arranged uniformly even at the bent portion, and thus a fiber-reinforced resin member having a high bending strength can be manufactured.

  According to the empirical rules and experiments of the present inventors, when the axial yarn is arranged in the member axial direction at the bent portion of the member, the axial yarn slips on the mandrel outer periphery, resulting in a uniform axial yarn arrangement. It has been found that it is very difficult to produce a member having (a uniform density axial yarn).

  Therefore, in the manufacturing method of the present invention, an anti-slip member is attached to at least the outer periphery of the bent portion of the mandrel prior to the winding of the axial yarn, and the axial yarn is arranged on this.

  Here, there are a plurality of embodiments of the anti-slip member described above. One of them is to use a pin that is detachable from the mandrel as an anti-slip member, and when the mandrel is made of, for example, urethane-based foamed resin, the steel pin can be easily inserted into the mandrel, It can be easily extracted from the mandrel after forming the wound layer made of the axial yarn.

  As another embodiment of the anti-slip member, there is a method of sticking a viscous film on the outer periphery of the mandrel.

  Here, as a sticking form of a film, there exists arbitrary sticking forms, such as spiral winding and a hoop winding, with respect to a bending part.

  The film material is preferably the same material as the thermosetting resin that is finally impregnated in the wound layer, or a material that is familiar to the impregnated resin, such as an epoxy resin material or a polyester resin material. Film can be applied.

  According to the manufacturing method of the present invention described above, it is possible to arrange the axial yarns at a uniform density on the outer periphery of the mandrel having the bent portion simply by providing an appropriate non-slip member on the bent portion of the mandrel. . Since it is not necessary to prepare a device that is more expensive than the conventional method in this method, it is possible to manufacture a fiber reinforced resin member having high bending strength characteristics without any increase in manufacturing cost. Become.

  As can be understood from the above description, according to the method for manufacturing a fiber-reinforced resin member of the present invention, a fiber-reinforced resin member having high bending strength characteristics can be efficiently manufactured without increasing the manufacturing cost. .

  Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a view for explaining an on-vehicle position of an A pillar to which a fiber reinforced resin member of the present invention is applied, FIG. 2 is a perspective view of one embodiment of a fiber reinforced resin member to be manufactured, and FIG. It is the III-III arrow line view of FIG. FIG. 4 is a side view of a manufacturing apparatus used in the manufacturing method of the present invention, and FIGS. 5 to 9 are perspective views of an embodiment of an anti-slip member provided at a bent portion of a mandrel. The shape of the mandrel, the number of winding layers forming the fiber reinforced resin member, and the like are not limited to the illustrated embodiment.

  The manufactured fiber reinforced resin member is particularly suitable for an A-pillar of a vehicle where bending strength and impact resistance are required. The A pillars are front window support members positioned on the left and right sides of the front of the occupant of the vehicle C shown in FIG. By applying the fiber reinforced resin member 1 to this A-pillar, it can be said that it is particularly suitable for recent hybrid vehicles and the like because of its light weight in addition to sufficiently ensuring the above-mentioned strength characteristics.

  FIG. 2 shows an embodiment of the fiber reinforced resin member 1 applied to the A pillar. This fiber reinforced resin member 1 is not a simple straight cylindrical member, and since it is applied to the A-pillar, its shape has not only straight portions 1 ′ and 1a ′ but also a bent portion 1 ″. Also has a fastening plate portion 1 ′ ″ with other members constituting the vehicle. Also, the cross-sectional shape of each portion is not uniform, and the straight portion 1 ′ has a circular cross section, The portion 1a ′ has an elliptical cross section, the bent portion 1 ″ has an elliptical cross section having a recessed portion 1 ″ a partially recessed inward, and the fastening plate portion 1 ′ ″ is flat. It has a cross section and also has bolt holes.

  FIG. 3 illustrates the structure of the fiber reinforced resin member 1 in a cross-sectional view. The fiber reinforced resin member 1 includes a mandrel 1a made of ABS resin or urethane foam resin as a core material, a wound layer 1b made of an axial yarn wound around the outer periphery thereof, and a slant wound around the outer periphery thereof. The wound layer 1c is composed of a wound layer 1c made of a spun yarn, a wound layer 1d made of an axial yarn on the outer periphery thereof, and a wound layer 1e made of a diagonally oriented yarn on the outer periphery thereof, and a thermosetting resin is impregnated and cured in each wound layer. A fiber reinforced resin member 1 is formed. The number of wound layers made of axial yarns and wound layers made of oblique yarns is not limited to the illustrated example, and may be three or more.

Next, with reference to FIG. 4, the manufacturing method of the fiber reinforced resin member of this invention is outlined.
FIG. 4 shows a braider 100 for forming a winding layer composed of a plurality of axial yarns and a winding layer composed of oblique yarns on the outer periphery of a mandrel 1a having a straight portion and a bent portion.

  The blader machine 100 is generally composed of a rotatable brader 10 having oblique thread bobbins 11,... In the circumferential direction, and a plurality of axial thread bobbins 21,.

  The mandrel 1a can reciprocate through the central opening of the brader 10. In FIG. 4, the ends of the axial yarns Q,... Move to the left (X1 direction). At this time, the axial yarn is arranged along the axial direction of the outer periphery of the mandrel, and the braider 10 rotates at a predetermined rotational speed in synchronization with the movement of the mandrel 1a, so that the oblique yarn is placed on the axial yarn. The wound layer is formed at a predetermined angle (for example, 45 degrees) with respect to the axial direction.

  Here, when the axial yarn is wound around the outer periphery of the mandrel, in the manufacturing method of the present invention, an anti-slip member for the axial yarn as shown in FIGS. 5 to 9 is provided on the outer periphery of the mandrel.

  The anti-slip member shown in FIG. 5 is a large number of steel pins 2... In this embodiment, when the mandrel 1 a is made of a urethane-based foamed resin, it is easily inserted into the bent portion of the mandrel. I can leave. The steel pins 2,... Prevent the axial yarn from slipping at the bent portion of the mandrel, and the axial yarn can be uniformly arranged on the outer periphery thereof. In addition, this steel pin is extracted after winding layer formation.

  The anti-slip member shown in FIGS. 6 to 9 shows a resin film made of the same material as the thermosetting resin impregnated and cured in the wound layer, and the sticking forms thereof are different from each other. 6 shows a form in which the resin film 3 is spirally wound around the bent portion of the mandrel, FIG. 7 shows a form in which the resin film 3A is hoop-wrapped around the bent portion, and FIG. 8 shows a bent portion of the semicircular resin film 3B. 9 is a form in which a horizontally long piece of the resin film 3C is attached along the longitudinal direction of the bent portion.

  By repeating the above-described operation of the brader machine and the reciprocating movement of the mandrel 1a on the outer periphery of the mandrel, a predetermined number of wound layers made of axial yarns and wound layers made of oblique yarns are formed, and an intermediate is manufactured.

  The intermediate described above is transferred to a mold having a cavity space of a predetermined shape, and impregnation and curing with a thermosetting resin is executed in the mold. Here, as a resin impregnation curing method, an intermediate body in which a winding layer is formed on the outer periphery of a mandrel is placed in a mold, and a resin is filled and pressure-molded while the cavity is in a vacuum atmosphere. The RTM method can be applied.

  According to the above-described method for producing a fiber-reinforced resin member of the present invention, even if the mandrel that is the core material of the member has a bent portion, the axial yarn is formed by an appropriate non-slip member provided on the outer periphery of the mandrel. Can be disposed evenly and easily, and then the oblique yarn is wound thereon, so that a fiber-reinforced resin member having particularly high bending rigidity can be produced without reducing the production efficiency. It becomes possible.

  The embodiment of the present invention has been described in detail with reference to the drawings. However, the specific configuration is not limited to this embodiment, and there are design changes and the like without departing from the gist of the present invention. They are also included in the present invention.

It is a figure explaining the vehicle-mounted position of A pillar to which the fiber reinforced resin member of this invention is applied. It is a perspective view of one embodiment of the fiber reinforced resin member manufactured. It is the III-III arrow line view of FIG. It is a side view of the manufacturing apparatus used for the manufacturing method of this invention. It is a perspective view of one embodiment of a non-slip member provided in a bent part of a mandrel. It is a perspective view of other embodiment of the anti-slip | skid member provided in the bending part of the mandrel. It is a perspective view of further another embodiment of the anti-slip | skid member provided in the bending part of the mandrel. It is a perspective view of further another embodiment of the anti-slip | skid member provided in the bending part of the mandrel. It is a perspective view of further another embodiment of the anti-slip | skid member provided in the bending part of the mandrel.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 ... Fiber reinforced resin member, 1a ... Mandrel, 1b, 1d ... Winding layer of axial direction thread, 1c, 1e ... Winding layer of diagonal thread, 1 ', 1a' ... Straight line part, 1 "... Bending part, 1 ' '' ... Fastening plate part, 2 ... Steel pin (non-slip member), 3, 3A, 3B, 3C ... Resin film (non-slip member), 10 ... Brader, 11 Bobbin for diagonal yarn, 21 ... Axial yarn Bobbins, 100 ... brade machines, P ... diagonal yarns, Q ... axial yarns

Claims (4)

By supplying an axial yarn extending in the axial direction of the mandrel and an oblique yarn inclined at a predetermined angle with respect to the axial direction to a long mandrel having at least a bent portion, a plurality of axial yarns and a plurality of axial yarns are provided. A first step of producing a fiber fabric formed by weaving the oblique yarn of
In the manufacturing method of the fiber reinforced resin member comprising the second step of manufacturing the fiber reinforced resin member by impregnating the resin into the fiber fabric and curing it,
An anti-slip member is attached to at least the bent portion of the mandrel. In the first step, the axial yarn is positioned by the anti-slip member in the bent portion of the mandrel, and the oblique yarn is placed thereon. The manufacturing method of the fiber reinforced resin member by which is wound.   The manufacturing method of the fiber reinforced resin member of Claim 1 which the said anti-slip | skid member consists of a pin which can be attached or detached to a mandrel.   The manufacturing method of the fiber reinforced resin member of Claim 1 which consists of a film which has the viscosity in which the said non-slip | skid member was formed in the mandrel outer periphery. In the manufacturing method of the fiber reinforced resin member according to claim 3,
The manufacturing method of the fiber reinforced resin member in which the said film consists of resin of the same material as the said resin.

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