JP2009137066A - Fiber-reinforced resin member and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a fiber-reinforced resin member having at least a curved part which is processed to make the fiber densities of the outside and inside of the curve in the curved part approximately equal, and to provide a method for manufacturing the fiber-reinforced resin member. <P>SOLUTION: In a lengthy fiber fabric, a plurality of inclination threads which are inclined at a prescribed angle in the axial direction of the fabric are woven. The fabric is impregnated with the resin, and the resin is cured to produce the fiber-reinforced resin member. The curved part is formed in at least a part of the fiber-reinforced resin member. A relatively larger number of the fibers are arranged on the outside of the curve in the curved part as compared with the number of the fibers on the inside of the curve. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

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

  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). This fiber reinforced resin member forms a multi-layer wound layer structure by knitting fiber yarns having a predetermined tensile strength and the like into oblique yarns having a predetermined inclination angle with respect to the axial direction of the member. It is formed by impregnating and curing a resin.

  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 oblique yarns are wound along this shape.

  Patent Document 1 discloses a method for producing a fiber fabric that forms the above-described fiber-reinforced resin member. 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

  By the way, in the fiber reinforced resin member having the bent portion as described above, the fiber density is different between the curved outer side and the inner side of the bent portion, and the fiber density decreases on the curved outer side and the fiber-impregnated resin amount on the curved outer side is large. May occur (so-called resin-rich generation). Due to the difference in fiber density at the bent portion, the strength characteristics on the curved outer side of the bent portion are lowered, and the thickness of the resin-impregnated fiber layer is relatively reduced. The problem in the bent portion of the fiber reinforced resin member cannot be a problem in the linear fiber reinforced resin member targeted by the manufacturing method of Patent Document 1 described above, and therefore there is no disclosure of a solution to this problem. it is obvious.

  The present invention has been made in view of the above-described problem, and in a fiber reinforced resin member having at least a bent portion, a fiber reinforced resin member in which the fiber density on the bent outer side and the inner side in the bent portion is processed to the same level. An object of the present invention is to provide a production method for producing the fiber-reinforced resin member.

  In order to achieve the above-mentioned object, the fiber reinforced resin member according to the present invention is formed by knitting a long fiber woven fabric with a plurality of oblique yarns inclined at a predetermined angle with respect to the axial direction of the fiber woven fabric, In the fiber reinforced resin member obtained by impregnating and curing the resin to the fiber fabric, the fiber reinforced resin member has a bent portion at least at a part, and the curved outer side of the bent portion is relatively compared to the inner side. A large number of fibers are arranged on the surface.

  In this fiber reinforced resin member, for example, a winding layer made of oblique yarns (brader yarns) inclined at a predetermined angle with respect to the axial direction of the mandrel is formed on the outer periphery of the mandrel that is the core material, and between the winding layers. A thermosetting resin is impregnated and cured.

  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 an elliptical 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 preferably formed from a lightweight and high-strength ABS resin (acrylonitrile, butadiene, styrene copolymer synthetic resin) or the like.

  The fiber-reinforced resin member of the present invention has a straight portion and a bent portion, and is intended to eliminate the difference in fiber density that occurs on the outside and inside of the bent portion. More fibers are arranged on the outside.

  There is also a form in which an axial yarn is arranged in addition to the oblique yarn outside the curved portion of the bent portion of the mandrel. In this case, a triaxial structure of fibers is formed outside the curved portion of the bent portion. According to this arrangement, it is possible to expect an improvement in bending strength characteristics due to the axial yarn added particularly at the outer periphery of the bent portion.

  The fiber density on the curved outer side and inner side of the bent portion of the mandrel can be made the same level, and it can be avoided that only the curved outer side is in a resin-rich state. Can be comparable.

  Furthermore, the method for producing a fiber-reinforced resin member according to the present invention supplies a plurality of oblique yarns by supplying oblique yarns inclined at a predetermined angle with respect to the axial direction of the mandrel to a mandrel having at least a bent portion. A fiber reinforced resin comprising: a first step of manufacturing a long fiber woven fabric formed by weaving and a second step of manufacturing a fiber reinforced resin member by impregnating the resin into the fiber woven fabric and curing it. In the member manufacturing method, in the first step, a relatively large number of fibers are arranged outside the curved portion of the bent portion as compared with the inside.

  The manufacturing method of the present invention is a manufacturing method of a fiber reinforced resin member having a bent portion as described above, and by making the fiber density of the bent outer side and the bent inner side of the bent portion the same level, in all parts of the bent portion. The thickness and strength can be made uniform. Therefore, in the first step of the present manufacturing method, a relatively large number of fibers are arranged on the curved outer side of the bent portion as compared with the inner side, and the added fibers are axial yarns. Is as described above.

  In the manufacturing method of the present invention, it is based on a very simple method in which a large number of fibers are arranged on the outside of the curved portion of the bent portion of the mandrel as compared with the inside, so that the bent portion with excellent quality is obtained without reducing the manufacturing efficiency. It becomes possible to manufacture the fiber reinforced resin member which has this.

  As can be understood from the above description, according to the fiber reinforced resin member and the manufacturing method thereof of the present invention, even if the fiber reinforced resin member has a bent portion, the fibers on the outer side and the inner side of the bent portion are curved. A high-quality fiber-reinforced resin member having uniform density, thickness of the resin-impregnated fiber layer, and strength can be obtained.

  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 figure which showed the arrangement | positioning aspect of the diagonal thread | yarn and the axial direction thread | yarn in the bending part of a mandrel. 4A and 4B are views showing a triaxial structure of the oblique yarn and the axial yarn outside the curved portion of the bent portion of the mandrel, in which FIG. 4a is a plan view and FIG. 4b is a cross-sectional view thereof. FIG. 5 is a side view of an embodiment of a blader machine used in the manufacturing method of the present invention, and FIG. 6A is a view showing a side view of another embodiment of the blader machine together with its operation mode. FIG. 6b is an enlarged view of a portion b in FIG. 6a. 7 and 8 are diagrams for explaining the operation mode of the brader machine shown in FIG. 6 in order, FIG. 9 is an enlarged view of the IX part of FIG. 8, and FIGS. It is a figure explaining the operation | movement aspect of. FIGS. 13 to 15 are diagrams sequentially showing a side view of still another embodiment of the brader machine together with its operation mode, and FIGS. 16a and 16b are both a slanted yarn and a shaft formed at the bent portion of the mandrel. It is the figure which showed the arrangement | positioning form of a direction thread | yarn.

  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.

  The arrangement | positioning aspect of the diagonal thread | yarn and the axial direction thread | yarn in the bending part of this fiber reinforced resin member 1 is shown in FIG. In the bent portion, a wound layer is formed on the inner side thereof by oblique yarns P,... Knitted in a 45 degree direction, and on the outer side of the curve, the oblique yarns P,. A wound layer is formed by braiding. The fiber reinforced resin member 1 includes a mandrel 1a made of ABS resin as a core material, a wound layer made of oblique yarns wound around the outer periphery thereof, and a thermosetting resin impregnated and cured in the wound layer to strengthen the fiber. A resin member 1 is formed. In particular, by arranging a predetermined number of axial yarns as shown in the bent part, the fiber density on the curved outer side and inner side of the bent part is made substantially uniform, and the thickness of the resin-impregnated fiber layer impregnated with the resin is made uniform. Can be.

  FIG. 4 shows a triaxial structure of fibers composed of oblique yarns and axial yarns on the curved outer side of the bent portion of the mandrel. FIG. 4a shows a plan view and FIG. 4b shows a sectional view. . On the curved outer side of the bent portion, a knitted structure having a triaxial structure as shown in the figure increases the thickness of the knitted structure as compared with a biaxial structure consisting only of oblique yarns inside the bent portion. However, since the oblique yarns are relatively densely arranged on the inner side, the thickness of the knitted structure is adjusted to the same degree at the inner and outer periphery of the bent portion by making the curved outer side a triaxial structure as shown in the figure. It becomes possible to do.

  FIG. 5 illustrates a blader machine 100 that forms a wound layer made of skewed yarn on the outer periphery of the mandrel and further supplies axial yarn at the bent portion.

  The blader machine 100 includes an axial thread bobbin including a rotatable blader 10 provided with an oblique thread bobbin 11,... In the circumferential direction and a plurality of axial thread bobbins 21,. The fixture 20 is generally constituted.

  The mandrel 1a can freely reciprocate through the central opening of the brader 10. In FIG. 5, the end of the oblique yarns P,... Is taped to the mandrel end, and the mandrel 1a moves from the right side to the left side. A slanted yarn is arranged on the outer periphery to form a wound layer made of the slanted yarn. Here, when forming the winding layer of the bent portion of the mandrel 1a, the axial yarns Q,... Are pulled out from the axial yarn bobbins 21 corresponding to the curved outer side of the bent portion, and taped to the curved outer side of the bent portion. By operating the rotation of the brader 10, a knitted structure having a triaxial structure shown in FIG. 4 is formed on the outer side of the bent portion, and a biaxial structure having only a diagonal yarn is formed on the inner side.

  FIG. 6 shows another embodiment of the blader machine, and FIGS. 7 to 12 sequentially explain the operation mode in detail.

  In addition to the configuration of the blader machine 100, the brader machine 200 includes a gear mechanism 30 for automatically pulling out the axial thread Q from the bobbin 21 for the axial thread, and the bent axial thread Q of the mandrel 1a. The robot hand 40 which sticks on the curved outer side of a part is comprised.

  In this gear mechanism 30, a slider 31 that meshes with a gear 32 reciprocates back and forth by the rotation of the gear 32 (Y1 direction), and an axial thread Q passes through the slider 31 and is pulled out to the tip. Thus, the posture in which the axial thread Q is pulled out by the rotatable roller 34 (X1 direction) corresponding to the fixed roller 33 can be maintained.

  As shown in FIG. 6a, a robot hand 40 having five degrees of freedom indicated by five rotation arrows is placed in the vicinity of the mandrel 1a, and the tip of the axial thread Q is pulled out by the robot hand 40. It can be fixed to the mandrel 1a.

  Next, based on FIGS. 7-12, the formation method of the fiber winding layer in the mandrel bending part at the time of using the brader machine 200 is outlined.

  When a plurality of oblique yarns P,... Are knitted into the straight portion of the mandrel to form a wound layer and the transition to the bent portion is made, the robot hand 40 corresponds to the outside of the bent portion as shown in FIG. Pull out the axial thread Q (Y2 direction).

  With this robot hand 40, a predetermined number of axial yarns Q,... Are stuck on the curved outer side of the mandrel bent portion. This specific method will be described with reference to FIG. 9 in which the robot hand 40 is enlarged.

  The robot hand 40 has two rollers 41 and 42 for fixing the axial thread Q to the fingertip, and the roller 41 positioned above is rotationally driven and controlled according to the rotation of the roller 41. Will follow. A resin film S is wound above the robot hand, and the tip of the resin film S is sandwiched between the roller 41 described above and a roller 43 that is above and winds the resin film S. It is supplied to the axial direction thread Q in a different posture.

  A heater 44 is interposed between the roller 43 and the winding portion of the resin film S. The resin film heated and melted by the heater 44 is supplied to the axial yarn Q, and the axial yarn Q is a bent portion of the mandrel. When the resin film S is transferred to a predetermined position on the outer side of the curve and the resin film S is cured, the bent portion of the axial direction thread Q is automatically attached to the outer side of the curve.

  Next, moving to FIG. 10, after returning the slider 31 to the original position (Y3 direction), as shown in FIG. 11, the blader 10 is rotated while moving the mandrel 1a in the left direction of the figure, and the oblique direction is set. A triaxial structure of the yarns P,... And the axial yarn Q is formed on the outer periphery of the bent portion. In addition, since the axial direction thread | yarn Q is not stuck inside the bending part, the biaxial structure which consists only of the diagonal thread P, ... is formed inside the bending part.

  After the winding is performed to a predetermined position of the bent portion, the slider 31 is again moved forward (Y4 direction) as shown in FIG. This cutting is also preferably performed by a separate robot hand.

  Next, based on FIGS. 13 to 16, an outline of a method for forming a fiber wound layer in a mandrel bent portion when a separate braider 300 is used will be described.

  In this blader machine 300, as shown in FIG. 13, an axial thread bobbin 21 is detachably fixed to the tip of a slider 31 constituting a gear mechanism 30, and further receives an axial thread bobbin 21 in front of it. A bobbin receiver 50 is provided.

  The slider 31 reciprocates according to the rotation of the gear 32 (Y5 direction). As shown in the drawing, the slanted yarns P,... And the axial yarns Q,. A knitted structure having a triaxial structure is formed.

  When the winding layer is formed up to a predetermined portion of the bent portion, the slider 31 moves to the bobbin receiver 50 side (Y6 direction) as shown in FIG. 14, and the bobbin receiver 50 moves to the bobbin receiver 50 as shown in FIG. The slider 31 returns to its original position after depositing the axial thread supply bobbin 21 (Y7 direction).

  Next, a biaxial knitted structure consisting only of the oblique yarns P,... Is formed in the straight part of the mandrel. In FIG. 15, the t1 section indicates a bent portion, and the t2 section indicates a straight portion.

  FIG. 16 shows the form of a knitted structure having a triaxial structure formed on the curved outer side of the bent portion as described above. FIG. 16a shows a knitting configuration in which triaxial knitting structures appear at intervals in the longitudinal direction of the mandrel, and FIG. 16b shows alternating triaxial knitting structures in the longitudinal direction of the mandrel and in the hoop direction. The knitting form that appears in a deviated posture is shown.

  The intermediate body in which the winding layer is formed on the outer periphery of the mandrel as described above is transferred to a mold having a cavity space of a predetermined shape, and impregnation and curing of a thermosetting resin is performed 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 method for producing a fiber-reinforced resin member of the present invention, even when the fiber-reinforced resin member has a bent portion, the fiber density on the outside and inside of the curve can be made uniform, and the thickness of the resin-impregnated fiber layer can be made uniform. Moreover, the manufacturing method according to the present invention is a simple method in which a relatively large number of axial yarns and the like are arranged on the curved outer side of the bent portion, so that the manufacturing efficiency is not lowered.

  In the embodiment described above, only the oblique yarn P is arranged in the straight portion, the oblique yarn P and the axial yarn Q are arranged on the curved outer side of the bent portion, and only the oblique yarn P is arranged on the curved inner side of the bent portion. However, the present invention is not limited to this embodiment. That is, the embodiment etc. which arrange | position both the diagonal thread P and the axial direction thread | yarn Q in a linear part may be sufficient. In this case, the number of the axial yarns Q may be increased on the curved outer side of the bent portion so that a difference in the number of fibers can be made between the curved outer side and the inner side of the bent portion. Further, both the oblique yarn P and the axial yarn Q are arranged inside the curved portion of the bent portion, and the oblique yarn P and a larger number of the axial yarn Q than the inside of the curved portion are arranged outside the curved portion of the bent portion. May be.

  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 figure which showed the arrangement | positioning aspect of the diagonal thread | yarn and the axial direction thread | yarn in the bending part of a mandrel. It is the figure which showed the triaxial structure of the diagonal thread | yarn and the axial direction thread | yarn outside the curve of the bending part of a mandrel, (a) is the top view, (b) is the sectional drawing. It is a side view of one embodiment of a blader machine used in the manufacturing method of the present invention. (A) is the figure which showed the side view of other embodiment of a brader machine with the operation mode, (b) is an enlarged view of the b section of (a). It is a figure explaining the operation | movement aspect of the brader machine shown in FIG. FIG. 8 is a diagram for explaining the operation mode of the braider machine following FIG. 7. It is an enlarged view of the IX part of FIG. FIG. 9 is a diagram for explaining the operation mode of the braider machine following FIG. 8. FIG. 11 is a diagram for explaining the operation mode of the braider machine following FIG. 10. FIG. 12 is a diagram for explaining the operation mode of the braider machine following FIG. 11. It is the figure which showed the side view of other embodiment of a braider machine with the operation mode. FIG. 14 is a diagram for explaining the operation mode of the braider machine following FIG. 13. FIG. 15 is a diagram for explaining the operation mode of the braider machine following FIG. 14. (A), (b) is the figure which showed the arrangement | positioning form of the diagonal thread formed in the bending part of a mandrel, and an axial direction thread | yarn.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 ... Fiber reinforced resin member, 1a ... Mandrel, 1 ', 1a' ... Linear part, 1 "... Bending part, 1 '" ... Fastening plate part, 10 ... Brader, 11 ... Bobbin for diagonal thread, 20 ... Shaft Bobbin fixing tool for direction thread, 21... Bobbin for axial direction thread, 21a... Fitting convex part, 50... Bobbin receiver, 30 ... gear mechanism, 31 ... slider, 32 ... gear, 40 ... robot hand, 41, 42, 43 ... Roller, 44 ... Heater, 100, 200, 300 ... Brader machine, P ... Oblique yarn, Q ... Axial yarn, S ... Resin film

Claims (4)

In a fiber reinforced resin member, a long fiber fabric is formed by weaving a plurality of oblique yarns inclined at a predetermined angle with respect to the axial direction of the fiber fabric, and the fiber fabric is impregnated and cured with resin. ,
The fiber reinforced resin member has a bent portion at least in part,
A fiber-reinforced resin member, characterized in that a relatively large number of fibers are arranged on the curved outer side of the bent portion as compared with the inner side. In the fiber reinforced resin member according to claim 1,
A fiber-reinforced resin member, wherein an axial yarn is disposed in addition to the oblique yarn on the curved outer side of the bent portion. A long fiber woven fabric in which a plurality of oblique yarns are knitted is manufactured by supplying oblique yarns inclined at a predetermined angle with respect to the axial direction of the mandrel to a mandrel having at least a bent portion. 1 process,
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,
In the first step, a relatively large number of fibers are arranged on the curved outer side of the bent portion as compared with the inner side, and the method for producing a fiber-reinforced resin member. In the manufacturing method of the fiber reinforced resin member according to claim 3,
In the first step, an axial thread is disposed in addition to the oblique thread outside the curved portion of the bent portion, and the method for producing a fiber-reinforced resin member.

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