JP2011251443A - Continuous fiber composite material structure, method for manufacturing the same, and composite molded object using the continuous fiber composite material structure - Google Patents

Abstract

PROBLEM TO BE SOLVED: To precisely provide a composite material structure enhanced in strength and rigidity with high productivity.SOLUTION: The continuous fiber composite material structure is composed of continuous fiber bundles arranged in a state substantially parallel to each other and thermoplastic resin and has a twist. The structure includes a part having a twist ratio of 1/(20×d) (where d is the width of the structure in a direction crossing the orientation direction of continuous fibers at a right angle before the twist is imparted) or higher (A), and (B) and (A) and satisfying that the sum total of the twist angles of the part having the twist ratio of 1/(20×d) or higher is 60° or higher (B) with respect to a skeletal line connecting centers in the width direction of the structure in a direction crossing the orientation direction of the continuous fiber bundles at a right angle without buckling the continuous fiber bundles.

Description

  The present invention relates to a continuous fiber composite material structure having a twist, a method for producing the structure, and a composite molded body using the structure.

  In recent years, many resin panels have been proposed from the viewpoint of weight reduction in many scenes including vehicle panels. Increasing the thickness of the resin or using a large amount of reinforcing material as a means for increasing the rigidity of the resin panel impairs the original purpose of weight reduction. As a method for overcoming this, a local reinforcing structure has been proposed in which continuous fibers excellent in strength and rigidity are formed into a tape shape or a plate shape and are locally disposed in a portion where input to a part is large. Actual panel parts generally have a three-dimensional shape due to their design and fastening feasibility, and the local reinforcement structure for the panel part has a shape along the surface of the part, so that the reinforcement effect is more effective. To express. For that purpose, it is necessary that the tape-like / plate-like structure is molded with local twist or specific curvature of the reinforced body, but it does not undergo plastic deformation like glass fiber or carbon fiber, and stretches. In the case of using a non-reinforcing fiber as a reinforcing fiber, it is generally difficult to produce a twisted structure without wrinkles or buckling in a tape-like / plate-like structure. As a manufacturing method of a reinforcing structure having a twisted structure or a bent structure, a dry preform is continuously arranged in a circumferential direction of a curved mold as described in Patent Document 1, and a resin, transfer, There is a method of molding by impregnating resin by molding (RTM) method, etc., but dry preforming is done manually and it takes a long time to complete reaction of thermosetting resin. Was unsuitable.

Japanese Patent No. 4309748

  An object of the present invention is a continuous fiber composite material structure composed of continuous fibers and a thermoplastic resin, and provides a continuous fiber composite material structure having high strength and rigidity with twist in the fiber orientation direction with high productivity. There is to do. Another object of the present invention is to provide a composite molded body excellent in weight reduction and rigidity by combining a continuous fiber composite material structure as a reinforcing structure with a resin molded body.

The present invention realizes a continuous fiber composite material structure having a twist and a curvature.
That is, the present invention is a structure having a twist composed of a continuous fiber bundle and a thermoplastic resin arranged substantially parallel to each other, and the continuous fiber bundle goes straight in the orientation direction of the continuous fiber bundle without buckling. (A) and (B) below for the skeleton line connecting the center of the width direction of the structure in the direction
(A) including a portion having a torsion (rad / mm) of 1 / (20 × d) or more,
(B) The total twist angle of the portion having a twist rate (rad / mm) of 1 / (20 × d) or more is 60 degrees or more (d is perpendicular to the orientation direction of the continuous fiber before imparting twist. Width of structure in direction
Satisfying the requirements, a continuous fiber composite material structure, a method for producing the continuous fiber composite material structure, and a composite molded body obtained by combining the continuous fiber composite material structure as a reinforcing structure.
Further, there are a continuous fiber composite material structure having twist and curvature, a manufacturing method thereof, and a composite molded body formed by combining the continuous fiber composite material structure as a reinforcing structure.

  According to the present invention, it is possible to provide a continuous fiber composite material structure made of a continuous fiber and a thermoplastic resin, which is twisted in the fiber direction and has a curvature and high strength and rigidity, with high accuracy and economically. In addition, by using the continuous fiber composite material structure, it is possible to provide a composite molded body excellent in weight reduction and rigidity, and to reduce the weight and rigidity of a back door, a side door, a fender, a front hood, a roof, or a floor pan. An excellent vehicle panel can be provided. Further, since these structures are made of a thermoplastic resin, they can be manufactured with high productivity.

Schematic of example structure with twist Schematic of example structure with twist and specific curvature Schematic which shows an example of the mechanism which provides twist in the manufacturing method of this invention. Schematic which shows an example of the mechanism which provides a twist and a curvature in the manufacturing method of this invention. Diagram showing division of skeletal lines and angles Simplified model diagram showing each step of twisting process Schematic showing an example of a composite molded body Schematic showing an example of a composite molded body

Hereinafter, the present invention will be described in detail.
The present invention relates to a continuous fiber composite material structure comprising continuous fibers and a thermoplastic resin, having a twist, and further having a curvature, a manufacturing method thereof, and a continuous fiber composite molded body excellent in weight reduction and rigidity using the same. is there.

[Continuous fiber composite material structure]
The present invention is a structure having a twist made of continuous fibers and a thermoplastic resin arranged substantially parallel to each other. The width of the structure in the direction perpendicular to the orientation direction of the continuous fiber before the twist is given is represented by d (unit: mm). When the width of the structure changes, the average of the width over the longitudinal direction of the structure is defined as d.

The continuous fiber bundle is characterized in that the skeleton line connecting the central portions in the width direction of the structure includes a portion having a specific twist without buckling. Specific twists are the following (A) and (B)
(A) including a portion having a torsion (rad / mm) of 1 / (20 × d) or more,
(B) The total twist angle of the portion having a torsion (rad / mm) of 1 / (20 × d) or more is satisfied to be 60 degrees or more.

  In the present invention, continuous fibers are substantially parallel to each other means that 90% or more of the continuous fibers constituting the structure are arranged at an angle of 45 degrees or less with respect to the skeleton line of the structure. The buckling in the present invention is a state in which the structure is locally discontinuously bent or wrinkled.

  A schematic view of a continuous fiber composite material structure having twist in the present invention is shown in FIG. The twist rate is 1 / (20 × d) or more, and the total twist angle in the entire structure is 60 degrees or more. Although there is no particular limitation on the torsion range, specifically, it is 1 / (20 × d) or more and 1 / (0.1 × d) or less. The twist is more preferably 1 / (20 × d) or more and 1 / d or less.

  Although there is no particular limitation on the total range of twist angles, specifically, it is 60 degrees or more and 720 degrees or less. More preferably, it is 60 degrees or more and 360 degrees or less. One twist angle is preferably 60 to 120 degrees, more preferably 60 to 90 degrees. The number of portions having twist in the continuous fiber composite material structure is preferably 1 to 6, more preferably 1 to 4.

The continuous fiber composite material structure of the present invention preferably further has a specific curvature. In the present invention, the specific curvature means that the skeleton line connecting the center of the structure is further represented by the following (C) and (D)
(C) including a portion having a curvature (rad / mm) of 1 / (20 × d) or more,
(D) Satisfies that the sum of the central angles of the portions having a curvature (rad / mm) of 1 / (20 × d) or more is 30 degrees or more. FIG. 2 shows a schematic diagram of a continuous fiber composite material structure having twist and specific curvature in the present invention. If the curvature range is out of this range, the continuous fibers in the continuous fiber composite material structure may break. A preferable curvature is specifically 1 / (20 × d) or more and 1 / (0.01 × d) or less. The curvature is more preferably 1 / (20 × d) or more and 1 / (0.1 × d) or less.

Although there is no particular limitation on the total central angle of the portion having the curvature, specifically, it is 30 degrees or more and 720 degrees or less. More preferably, it is 30 degrees or more and 360 degrees or less. The central angle of the portion having one curvature is preferably 30 to 120 degrees, more preferably 30 to 90 degrees. The site | part which has a specific curvature in a continuous fiber composite material structure becomes like this. Preferably it is 1-6, More preferably, it is 1-4.
The width and length of the composite material structure of the present invention are appropriately selected according to various uses as described later.

[About continuous fibers]
Natural fibers or chemical fibers can be used as continuous fibers in the present invention. Specifically, cotton, hemp, jute, wool, silk, polylactic acid fiber, polyamide fiber, polyester fiber, polyolefin fiber, acrylic fiber, para-aramid fiber, meta-aramid fiber, boron fiber, azole fiber, alumina fiber, Examples thereof include glass fiber and carbon fiber.

The continuous fiber bundle is preferably made of fibers having a specific elastic modulus of 2.5 × 10 ⁸ cm or more. Further, it is preferably made of fibers having a specific elastic modulus of 5.0 × 10 ⁸ cm or more. Here, the specific elastic modulus is calculated by the following equation.
Specific modulus (cm) = Young's modulus of fiber (GPa) / Fiber density (g / cm ³ ) /9.8×10 ⁸

The fiber diameter of the continuous fiber bundle is not particularly limited, but is preferably 1 μm to 20 μm.
In the continuous fiber composite material structure, the continuous fibers are combined without being cut except at the ends.
The continuous fiber composite material structure can take a shape having no curvature in the width direction.

[Matrix resin]
As a matrix which comprises a continuous fiber composite material structure, they are a thermoplastic resin and those compositions. Specifically, polycarbonate resin, polyester resin, polyolefin resin, acrylic resin, polylactic acid, polyamide resin, ASA resin, ABS resin, polyether ketone resin, polyether imide resin, polyphenylene ether resin, polyphenylene oxide resin, polysulfone resin , Polyethersulfone resin, polyetherimide resin, polyetheretherketone resin, polyphenylene sulfide resin, polyamideimide resin and the like. Of these, polycarbonate resin, polyester resin, polyolefin resin, and polyamide resin are preferable.
The continuous fiber content in the continuous fiber composite material structure is preferably 10 to 300 parts by volume with respect to 100 parts by volume of the resin. Furthermore, 40-150 volume parts is preferable.

[Production method of continuous fiber composite material structure]
A preferred method for producing the continuous fiber composite material structure of the present invention will be described. The present invention also includes the production method. According to the method of the present invention, it is possible to manufacture with high accuracy, efficiency and stability.

  The method of the present invention includes (1) a step of drawing a plurality of fibers impregnated with a thermoplastic resin or a mixture of thermoplastic resin and continuous fibers from individual fiber unwinding devices to obtain a bundle of fibers that are aligned in parallel; (2) a step of gripping the aligned fiber bundle by a fiber bundle gripping mechanism that grips the aligned fiber bundle in a direction perpendicular thereto; and (3) a translation of the fiber bundle gripping mechanism in a state where the fiber bundle is gripped, and A twisting step of adjusting the path length of each part of the fiber in the fiber bundle by rotating the set twist; and (4) a step of fixing the fiber bundle in the width direction at a portion where the fiber bundle gripping mechanism grips the fiber bundle; (5) A method for producing a continuous fiber composite material structure including a step of pressurizing a fixed fiber bundle to form a structure having a predetermined width.

Each step will be described below. Step (1) is a step of drawing out a plurality of continuous fiber bundles impregnated with thermoplastic resin from individual fiber unwinding devices or a plurality of fiber bundles in which thermoplastic resin and continuous fibers are mixed and aligning them in parallel. When the continuous fiber bundle impregnated with the thermoplastic resin is used here, the continuous fiber bundle impregnated so as to satisfy the preferable content of the continuous fibers in the composite material structure is used as described above.
Similarly, when using a fiber bundle in which a thermoplastic resin and continuous fibers are mixed, a fiber bundle mixed so as to satisfy a preferable content of continuous fibers in the composite material structure is used.

  Step (2) is a gripping step using a fiber bundle gripping mechanism that grips the aligned fiber bundles in a direction perpendicular thereto. The fiber gripping mechanism used here is preferably formed of a material having a large friction coefficient and flexibility such as a rubber plate. This is because it is possible to prevent fiber slippage and fiber damage at the grip portion.

  In the step (3), the fiber bundle gripping mechanism is translated by a certain amount in a state where the fiber bundle is gripped, and the twisted rotation is set to adjust the path length of each part of the fiber in the fiber bundle and to apply the twist. It is. An example of the mechanism used here is shown in FIG. The fiber bundle is gripped by the fiber gripping mechanism, and the gripping mechanism moves on an annular rail whose center is located on the midpoint of the fiber bundle, thereby performing torsional rotation.

  Step (4) is a step in which the fiber bundle gripping mechanism grips the fiber bundle, and is a step of fixing the fiber bundle in the width direction. Examples of the method for fixing the fiber bundle used in the width direction include adhesion using an adhesive such as thermal welding, ultrasonic welding, and hot melt adhesive.

  Step (5) is a step of pressing the fixed fiber bundle to form a structure having a predetermined width. Examples of the method of pressurizing and forming include a hot press, a press using a heating roller, and a press using a heating mechanism and a roller.

Hereinafter, preferable procedures (a) to (e) will be described for the steps (3) and (4).
In step (a), on the curve connecting the center line in the width direction of the continuous fiber composite material structure to be formed, points to be divided at intervals shorter than d / 10 are provided, and one end of the structure is changed to another end. Number from 0 in order. At this time, N is the number of the point at the end. Although there is no restriction | limiting in particular in the space | interval which divides | segments, Specifically, it is preferable that it is longer than d / 1000 and shorter than d / 10. More preferably, the interval is longer than d / 500 and shorter than d / 10. Moreover, it may divide equally and a straight line may be divided | segmented largely.

In step (b), a line segment connecting the (k−1) -th point and the k-th point is A _k and its length is B (k). Let D _{k be} the normal line raised on the minute A _k , and let P (k) be the angle formed by the normal lines D _{k + 1} and D _k . FIG. 5 shows the division of the skeleton line and the explanation of each angle.

  Each procedure of the twist provision process of procedure (c)-(e) is shown in FIG. In the twist imparting step, the direction perpendicular to the fiber direction of the aligned fibers is the “gripping direction”, the center of the fiber bundle width direction in the fiber bundle gripping portion is the “fiber bundle midpoint”, and the surface includes the fiber direction and the gripping direction Is the “fiber bundle surface”, the fiber bundle is gripped by the fiber bundle gripping mechanism at the fiber bundle gripping position ((I) in the figure), and the fiber gripping mechanism is first moved from the fiber bundle gripping position by the length of B (1). Next, the fiber bundle gripping mechanism is rotated by an angle P (1) / 2 around an axis that passes through the fiber bundle midpoint and goes straight in the gripping direction within the fiber bundle surface (II in the figure). After that ((III) in the figure), the fiber bundle is fixed in the width direction ((IV) in the figure).

  In step (d), the fiber bundle is released from the fiber bundle gripping mechanism, the fiber bundle gripping mechanism is returned to the fiber gripping position, a new fiber bundle is gripped at that position ((V) in the figure), and B (2) The fiber gripping mechanism is translated from the fiber bundle gripping position by the length, and then the fiber bundle gripping mechanism is angled (P (1) + P) around an axis that goes straight in the gripping direction through the fiber bundle midpoint within the fiber side surface. (2) After rotating by / 2, the fiber bundle is fixed in the width direction.

  In step (e), the same operation as in step (d) is repeated N-2 times. However, in the m-th operation after the operation of step (d), the fiber bundle is released from the fiber bundle gripping mechanism, the fiber bundle gripping mechanism is returned to the fiber gripping position, and the fiber bundle is newly gripped at that position. The fiber gripping mechanism is translated from the fiber bundle gripping position by the length of B (m + 2), and then the fiber bundle gripping mechanism is angled around an axis that passes through the fiber bundle midpoint in the fiber side surface and goes straight in the gripping direction. After rotating by P (m + 1) + P (m + 2)) / 2, the fiber bundle is fixed in the width direction.

  Next, a method for manufacturing a composite material structure having a twist and a specific curvature will be described. In the composite material structure having a twist and a specific curvature, the twisting step (3) in the manufacturing method of the composite material structure having the twist is a twisting and bending step (3) '. (1) A step of drawing a plurality of fibers impregnated with thermoplastic resin or a mixture of thermoplastic resin and continuous fibers from individual fiber unwinding apparatuses and drawing them in parallel to obtain a fiber bundle; 2) A process of gripping the aligned fiber bundle by a fiber bundle gripping mechanism that grips the bundle in the vertical direction; and (3) 'Translating and setting the fiber bundle gripping mechanism by a certain amount while holding the fiber bundle. A twisting and bending step of adjusting the path length of each part of the fiber in the fiber bundle by rotating and twisting in the plane, and (4) a portion in which the fiber bundle gripping mechanism grips the fiber bundle in the width direction And (5) pressurizing the fixed fiber bundle and molding it into a structure having a predetermined width.

For the steps (3) ′ and (4), the following steps (b) ′ to (e) ′ are preferably performed after the above step (a). An example of the mechanism used here is shown in FIG.
In step (b) ′, the line segment connecting the (k−1) -th point and the k-th point is A _k and the length is B (k), and the continuous fiber composite material structure to be formed is line _a and陪法line stood on _k and _{D k,} the angle between the normal line _{D k + 1} and _{D k} and P (k), the line segment _{a k + 1} and the angle between the line segment _{a k} T (k) And

  In step (c) ′, the fiber bundle is gripped by the fiber bundle gripping mechanism at the fiber bundle gripping position, and first, the fiber gripping mechanism is translated from the fiber bundle gripping position by the length of B (1), and the center of the fiber bundle is centered. In the fiber bundle surface, the fiber bundle gripping mechanism is rotated by an angle T (1) / 2, and then the fiber bundle gripping mechanism is rotated around an axis that passes through the fiber bundle midpoint in the fiber bundle surface and goes straight in the gripping direction. Is rotated by an angle P (1) / 2, and then the fiber bundle is fixed in the width direction.

  In step (d) ′, the fiber bundle is released from the fiber bundle gripping mechanism, the fiber bundle gripping mechanism is returned to the fiber gripping position, a new fiber bundle is gripped at that position, and the fiber bundle is gripped by the length of B (2). The fiber gripping mechanism is translated from the position, the fiber bundle gripping mechanism is rotated by an angle (T (1) + T (2)) / 2 within the fiber bundle surface around the fiber bundle midpoint, and then within the fiber side surface Then, the fiber bundle gripping mechanism is rotated by an angle (P (1) + P (2)) / 2 around an axis passing through the middle point of the fiber bundle and perpendicular to the gripping direction, and then the fiber bundle is fixed in the width direction.

  In step (e) ', the same operation as in step (d)' is repeated N-2 times. However, in the m-th operation after the operation of (d) ′, the fiber bundle is released from the fiber bundle gripping mechanism, the fiber bundle gripping mechanism is returned to the fiber gripping position, and the fiber bundle is newly gripped at that position. The fiber gripping mechanism is translated from the fiber bundle gripping position by the length of B (m + 2), and the fiber bundle gripping mechanism is angled (T (m + 1) + T (m + 2)) within the fiber bundle plane around the fiber bundle midpoint. / 2, and then the fiber bundle gripping mechanism was rotated by an angle (P (m + 1) + P (m + 2)) / 2 around an axis passing through the fiber bundle midpoint and orthogonal to the gripping direction within the fiber side surface. After that, the fiber bundle is fixed in the width direction.

  In the present invention, when the skeleton line is a closed curve, a seam is generated between the ends. In order to prevent the seam from being generated at a place where a large load stress is applied, in the case of multilayer lamination, the structure is manufactured so as to shift the seam in order to prevent a decrease in rigidity, or from the terminal 0 again without cutting at the terminal N. It is preferable to perform lamination by repeating the above procedure.

[Composite molded body]
By combining the continuous fiber composite material structure of the present invention with a resin molded body as a reinforcing structure, a composite molded body can be obtained. The present invention also includes a composite molded body obtained by combining a continuous fiber composite material structure as a reinforcing structure with a resin molded body. A schematic diagram of the continuous fiber composite molded body in the present invention is shown in FIG.

  The resin constituting the resin molded body used in the continuous fiber composite molded body of the present invention is a thermoplastic resin or a thermosetting resin, preferably a thermoplastic resin and a composition thereof. Specifically, polycarbonate resin, polyolefin resin, acrylic resin, polylactic acid, polyamide resin, ASA resin, ABS resin, polyether ketone resin, polyether imide resin, polyphenylene ether resin, polyphenylene oxide resin, polysulfone resin, polyether Sulfone resin, polyetherimide resin, polyetheretherketone resin, polyphenylene sulfide resin, polyamideimide resin, composition of polycarbonate resin and polyester resin, composition of polycarbonate and ABS resin, composition of polyphenylene ether resin and polyamide resin, Composition of polyamide resin and ABS resin, composition of polyester resin and polyamide resin, phenol resin, epoxy resin, unsaturated polyester resin, melamine resin, Polyurethane resin, polyimide resin is not particularly limited.

The resin molding can be molded by injection molding, blow molding, compression molding including hot press / cold press, vacuum molding, pressure molding or the like.
Examples of the composite method of the composite material structure and the resin molded body include an insert method, an outsert method, an adhesive bonding method, a mechanical bonding method, a fitting method, a hook method, and a fastener method.

  In the composite molded body of the present invention, a fiber reinforced resin molded body made of a fiber reinforced resin can be used as the resin molded body. Examples of the reinforcing fiber used in the fiber reinforced resin molded article include glass fiber, polyester fiber, polyolefin fiber, carbon fiber, para-aramid fiber, meta-aramid fiber, boron fiber, azole fiber, and alumina fiber, but there is no particular limitation. .

The matrix resin constituting the fiber-reinforced resin molded body is a thermoplastic resin or a thermosetting resin, preferably a thermoplastic resin or a composition thereof. Specifically, polycarbonate resin, polyester resin, polyolefin resin, acrylic resin, polylactic acid, polyamide resin, ASA resin, ABS resin, polyether ketone resin, polyether imide resin, polyphenylene ether resin, polyphenylene oxide resin, polysulfone resin , Polyethersulfone resin, polyetherimide resin, polyetheretherketone resin, polyphenylene sulfide resin, polyamideimide resin, phenol resin, epoxy resin, unsaturated polyester resin, melamine resin, polyurethane resin, polyimide resin, etc. There is no limit.
The content of the reinforcing fiber in the fiber reinforced material constituting the fiber reinforced resin molded body is preferably 10 to 100 parts by volume with respect to 100 parts by volume of the resin. Furthermore, 10-50 volume parts is preferable with respect to 100 volume parts of resin.

The form of the reinforcing fiber in the fiber reinforced resin molded product is not limited. Short fibers, long fibers, or continuous fibers may be used. Short fibers are fibers having a fiber length of 0.1 to 10 mm, long fibers are fibers having a length of 10 to 100 mm, and continuous fibers are fibers having a fiber length of 100 mm or more. In the case of short fibers or long fibers, paper made using chopped strands or the like may be used. In the case of continuous fibers, it is also preferable that they are contained in the matrix resin in the form of a woven or knitted fabric, a sheet of a unidirectionally arranged strand and a sheet of a multiaxial woven fabric, or a nonwoven fabric. In addition, a multiaxial woven fabric is generally a polyamide yarn, a polyester yarn, or a glass fiber made by laminating a bundle of fiber reinforcements aligned in one direction into a sheet and changing the angle (multiaxial woven fabric base material). This refers to a woven fabric that is stitched by stitches such as yarns, penetrates the laminate in the thickness direction, and reciprocates between the front and back surfaces of the laminate along the surface direction. The fiber reinforced material constituting the fiber reinforced resin molding may be one in which reinforcing fibers are randomly dispersed or one having a specific fiber orientation, one in which fibers are plane-oriented or one-axis oriented, or a combination thereof, Or it is preferable that it is those laminated bodies.
The fiber-reinforced resin molding can be molded by injection molding, blow molding, compression molding including hot press / cold press, vacuum molding, pressure molding, or the like.

When the composite material structure of the present invention is used as a reinforcing structure and a composite molded body, the following (i) and (ii) are preferably satisfied.
When the projected area of the entire structure is projected at the projection angle that maximizes the projected area of the structure is S1, the projected area of only the reinforcing structure when projected at the same projected angle is S2, and 0.60. > S2 / S1> 0.04 (i)
When projecting at the projection angle that maximizes the projected area of the structure, J2 is the polar second moment related to the centroid of the projection of all structures, and all of the projections of the reinforcing structure only when projected at the same projection angle. 0.92> J2 / J1> 0.15 where J2 is the polar second moment related to the centroid of the structure (ii)
The pole second moment is also called a second pole moment, and is obtained by integrating the square of the distance (r ² ) from the centroid as shown in the following equation (iii) over the entire area of the object.
Ip = ∫ (r ² × dA) (iii)
(Ip is the polar second moment, r is the distance between the minute area (dA) and the centroid)
In actual calculation, (iii) may be obtained by subtraction.

  When the reinforcing structure is a set of a plurality of separated reinforcing structures, the sum of the projected areas of all the reinforcing structures is S2, and the polar second moment with respect to the centroids of all the reinforcing structures J2 is the sum of.

  In the formula (i), when S2 / S1 is 0.60 or more, the use amount of the reinforcing fiber becomes large, and the economical efficiency and the lightness may be impaired. When S2 / S1 is 0.04 or less, the rigidity of the composite molded body may be insufficient. A preferable range of S2 / S1 is 0.2 or more and 0.6 or less. Furthermore, 0.3 or more and 0.5 or less are preferable.

  In the formula (ii), when J2 / J1 is 0.95 or more, even if S2 / S1 in the formula (i) is less than 0.6, the reinforcing fiber is excessively used, which is not preferable in terms of economy. When / J1 is 0.15 or less, even if S2 / S1 is greater than 0.05, the rigidity of the composite molded body may be insufficient. A preferable range of J2 / J1 is 0.20 or more and 0.95 or less. In particular, when the reinforcing fiber is carbon fiber, it is preferably 0.25 or more and 0.95 or less.

  In the composite molded body of the present invention, when the resin molded body is a fiber reinforced resin molded body made of a fiber reinforced resin, S2 / S1 is preferably 0.04 or more and 0.55 or less, and J2 / J1 is 0.15 or more and 0.00. 90 or less is preferable.

A vehicle panel selected from the group consisting of a back door, a side door, a fender, a front hood, a roof, and a floor pan can be provided from the composite molded body of the present invention.
The vehicle panel component may have a glass portion such as a window portion, and the proportion and shape of the window portion in the panel are not limited. Moreover, the vehicle panel component may have a fixed metal component or the like. In this case, the entire structure also includes a window and a fixed metal part.

  EXAMPLES Hereinafter, although an Example demonstrates this invention further more concretely, this invention does not receive any limitation by this.

[Example 1]
The continuous fiber composite material structure having a twist to be formed has a width of 50 mm, a thickness of 0.5 mm, a twist rate of 0.0028 rad / mm, a total twist angle of 80 degrees, and a length of 500 mm. 1 / (20 × d) is 0.001 rad / mm. On the curve connecting the center lines in the width direction, points to be divided at intervals of 5 mm were provided, and numbers from 0 to 99 were assigned from one end of the structure toward another end. At this time, the length B (k) of the line segment was 5 mm, and the angle P (k) formed by the normal line was 0.8 degrees.
Carbon fiber as the continuous fiber, Tenax STS40 (registered trademark) specific modulus 14 × 10 ⁸ cm manufactured by Toho Tenax Co., Ltd., Nylon 6 resin (manufactured by Mitsubishi Engineering Plastics, Novamid (registered trademark) 1010C2) as the thermoplastic resin ) Was used. Thirty fiber bundles impregnated with the thermoplastic resin were drawn out from the individual fiber unwinding apparatus so that the continuous fiber content was 50 parts by volume with respect to 100 parts by volume of the resin, and were aligned in parallel. The aligned composite fiber bundle was gripped by the fiber bundle gripping mechanism using the manufacturing apparatus shown in FIG.

  The fiber gripping mechanism is translated from the fiber bundle gripping position by 5 mm, and then the fiber bundle gripping mechanism is rotated by an angle of 0.4 degrees around an axis that passes through the midpoint of the fiber bundle and goes straight in the gripping direction within the fiber bundle surface. After that, the fiber bundle was fixed in the width direction using an ultrasonic welder. (Α) Release the fiber bundle from the fiber bundle gripping mechanism, return the fiber bundle gripping mechanism to the fiber gripping position, grip a new fiber bundle at that position, and move the fiber gripping mechanism from the fiber bundle gripping position by a length of 5 mm. After translation, and then rotating the fiber bundle gripping mechanism by an angle of 0.8 degrees around the axis that passes through the fiber bundle midpoint and goes straight in the gripping direction within the fiber side surface, the fiber is then used with an ultrasonic welder. The bundle was fixed in the width direction. The same operation as (α) was repeated 97 times to produce a continuous fiber composite material structure having a predetermined structure. It was confirmed that the continuous fiber composite material structure having a twisted shape can be manufactured with high accuracy without buckling, and that there is no problem in rigidity.

[Example 2]
The continuous fiber composite material structure having a twist to be formed has a width of 50 mm, a thickness of 0.5 mm, a twist rate of 0.0047 rad / mm, a total twist angle of 40 degrees, and a length of 150 mm. On the curve connecting the center lines in the width direction, points to be divided at intervals of 5 mm were provided, and numbers from 0 to 29 were assigned from one end of the structure to another. At this time, the length B (k) of the line segment was 5 mm, and the angle P (k) formed by the normal line was 0.4 degrees.
A structure was obtained using the same materials and manufacturing method as in Example 1. It was confirmed that the continuous fiber composite material structure having a molded twist can be manufactured with high accuracy without buckling, and there is no problem in rigidity.

[Example 3]
The continuous fiber composite material structure having the twist and curvature to be formed has a width of 20 mm, a thickness of 1.0 mm, a twist of 0.0028 rad / mm, a total twist angle of 160 degrees, and a curvature of 0.004 rad / mm, the sum of the central angles of the portions having curvature is 230 degrees, and the length is 1000 mm. On the curve connecting the center lines in the width direction, points to be divided at intervals of 2 mm were provided, and numbers from 0 to 499 were assigned from one terminal of the structure toward another terminal. At this time, the length B (k) of the line segment was 2 mm, the angle P (k) formed by the normal line was 0.32 degrees, and the angle T (k) formed by the line segment was 0.458 degrees.
Twenty fiber bundles impregnated with the thermoplastic resin were drawn out from individual fiber unwinding devices so that the continuous fiber content was 50 parts by volume with respect to 100 parts by volume of the resin, and were aligned in parallel. Tenax STS40 (registered trademark) manufactured by Toho Tenax Co., Ltd. was used as the continuous fiber, and nylon 6 resin was used as the thermoplastic resin. The aligned composite fiber bundle was gripped by the fiber bundle gripping mechanism using the manufacturing apparatus shown in FIG.

  The fiber gripping mechanism is translated from the fiber bundle gripping position by 2 mm, and then the fiber bundle gripping mechanism is rotated by an angle of 0.16 degrees around an axis that passes through the fiber bundle midpoint and goes straight in the gripping direction within the fiber bundle surface. Then, after rotating the fiber bundle gripping mechanism by an angle of 0.229 degrees within the fiber bundle plane around the middle point of the fiber bundle, the fiber bundle was fixed in the width direction using an ultrasonic welder. (Β) The fiber bundle is released from the fiber bundle gripping mechanism, the fiber bundle gripping mechanism is returned to the fiber gripping position, a new fiber bundle is gripped at that position, and the fiber gripping mechanism is moved from the fiber bundle gripping position by a length of 2 mm. Then, the fiber bundle gripping mechanism is rotated by an angle of 0.32 degrees around an axis that passes through the fiber bundle midpoint within the fiber side surface and goes straight in the gripping direction, and within the fiber bundle plane around the fiber bundle midpoint. Then, after rotating the fiber bundle gripping mechanism by an angle of 0.458 degrees, the fiber bundle was fixed in the width direction using an ultrasonic welding machine. By repeating the same operation as (β) 497 times, a continuous fiber composite material structure having a predetermined structure was produced. It was confirmed that the continuous fiber composite material structure having the twist and curvature formed can be manufactured with high accuracy without buckling and there is no problem in rigidity.

[Example 4]
The continuous fiber composite material structure having a twist and a curvature to be formed has a width of 20 mm, a thickness of 0.5 mm, a twist of 0.0049 rad / mm, a total twist angle of 140 degrees, a curvature of 0.008 rad / mm, and a curvature. The sum of the central angles of the portions having the length is 230 degrees and the length is 500 mm. On the curve connecting the center lines in the width direction, points to be divided at intervals of 2 mm were provided, and numbers from 0 to 249 were assigned from one terminal of the structure toward another terminal. At this time, the length B (k) of the line segment was 2 mm, the angle P (k) formed by the normal line was 0.56 degrees, and the angle T (k) formed by the line segment was 0.92.
A structure was obtained using the same materials and production method as in Example 3. It was confirmed that the continuous fiber composite material structure having a twisted and curved shape can be manufactured with high accuracy without buckling and there is no problem in rigidity.

[Example 5]
The continuous fiber composite material structure produced in Example 1 was twisted in the same manner as the composite material structure, and a polycarbonate resin molded body having a thickness of 2 mm, a width of 50 mm, and a length of 550 mm was bonded to the entire surface with an adhesive (Sikaflex). (Registered trademark) -255Extra) was bonded at a thickness of 2 mm to obtain a composite molded body. The rigidity was 2.2 times that in the case where there was no reinforcement of the continuous fiber composite material structure.

[Example 6]
It is obtained in Example 1 in the same manner as in Example 5 except that the material of the molded body is a fiber reinforced resin composition composed of epoxy resin and glass fiber instead of polycarbonate resin (45% by volume of glass fiber in the composition). A composite molded body using the continuous fiber composite material structure was obtained. The rigidity was 1.9 times that in the case where there was no reinforcement of the continuous fiber composite material structure.

[Example 7]
An automobile back door having the window shown in FIG. 8 was produced. Polypropylene (Prime Polypro J105G manufactured by Prime Polymer Co., Ltd.) was used as the resin molding (15).
The reinforcing structure (17) is a carbon fiber (manufactured by Toho Tenax Co., Ltd., Tenax STS40, specific modulus of elasticity 14 × 10 ⁸ cm) as a continuous fiber using the production apparatus shown in FIG. The nylon 6 (Mitsubishi Engineering Plastics Co., Ltd., Novamid (registered trademark) 1010C2) 100 parts by volume with respect to 100 parts by volume of the fibers was arranged as shown in FIG. The width is 20 mm, the thickness is 1.0 mm, the torsion of the part with twist is 0.004 rad / mm, the part with torsion and curvature is 4 places, the torsion angle, the sum of the torsion angles is 360 degrees, the part with the curvature A continuous fiber composite material having a twist and a specific curvature with a curvature of 0.004 rad / mm, a central angle of the curved portion of 90 degrees, a total of the central angles of the curved portions of 360 degrees, and a length of 3568 mm A structure was used.

The procedure for producing the continuous fiber composite material structure was as follows. Points that are divided at intervals of 2 mm were provided in a curved line connecting the center lines in the width direction of the structure, and numbers from 0 to 1783 were assigned from one end of the structure to another.
The lengths of the line segments from 0 to 250, 446 to 696, 892 to 1142, and 1338 to 1588 were 2 mm, and the angle formed by the normal line and the angle formed by the line segment were 0 degrees. Also, the lengths of the line segments from 250 to 446, from 696 to 892, from 1142 to 1338, and from 1588 to 1783 are 2 mm, and the angle between the normal line and the angle between the line segments is 0.46 degrees. It was.
A urethane-based elastic adhesive (Sikaflex (registered trademark) -255 Extra, elastic modulus 0.003 GPa) as an elastic layer was disposed on the entire surface at the boundary between the resin molded body (15) and the reinforcing structure (17).
The value of S2 / S1 was 0.3 when the projected area of all structures was S1, and the projected area of only the reinforcing structure when projected at the same projection angle was S2. J2 is the polar second moment related to the centroid of the projection of the entire structure, and J2 is the polar second moment related to the centroid of the entire structure of the projection of only the reinforcing structure when projected at the same projection angle. The value of / J1 was 0.4. The manufactured back door achieved a 50% weight reduction by comparing the weight of the steel back door (Comparative Example 1 below) with the same shape excluding the window. The torsional rigidity and bending rigidity of the manufactured back door were measured. The results are shown in Table 1.

[Comparative Example 1]
The torsional rigidity and bending rigidity of the steel back door having the same shape as in Example 7 were measured. The results are shown in Table 1.

[Comparative Example 2]
The torsional rigidity and bending rigidity of the same back door panel as in Example 7 were measured except that the reinforcing structure (17) was not arranged. The results are shown in Table 1.

  As is apparent from Table 1, the vehicle panel component of the composite molded body of the present invention has sufficient torsional rigidity and bending rigidity, although it is slightly inferior to the steel panel of the same shape.

1 orientation direction of continuous fibers 2 continuous fiber composite material structure 3 width d of structure
4 Skeletal line 11a Fiber bundle gripping mechanism 11b Fiber bundle gripping mechanism 12 Torsion imparting fiber gripping mechanism moving rail 13 Curvature imparting fiber gripping mechanism moving cylinder 14 Fiber bundle fixing mechanism 15 Resin molded body 16 Window 17 Continuous fiber composite material structure body

Claims (13)

A structure having a twist composed of a continuous fiber bundle and a thermoplastic resin arranged substantially parallel to each other, and the continuous fiber bundle is not buckled, and the structure in a direction perpendicular to the orientation direction of the continuous fiber bundle. The following (A) and (B) about the skeleton line connecting the central part in the width direction
(A) including a portion having a torsion (rad / mm) of 1 / (20 × d) or more,
(B) The total twist angle of the portion having a twist rate (rad / mm) of 1 / (20 × d) or more is 60 degrees or more (d is perpendicular to the orientation direction of the continuous fiber before imparting twist. Width of structure in direction
A continuous fiber composite material structure characterized by satisfying The continuous fiber composite material structure according to claim 1, wherein the continuous fibers are made of fibers having a specific elastic modulus of 2.5 x 10 ⁸ cm or more. Regarding the skeleton line connecting the central portions in the width direction of the structure, the following (C) and (D)
(C) including a portion having a curvature (rad / mm) of 1 / (20 × d) or more,
(D) The sum of the central angles of the portions having a curvature (rad / mm) of 1 / (20 × d) or more is satisfied to be 30 degrees or more. Continuous fiber composite material structure. (1) A step of drawing a plurality of fibers impregnated with a thermoplastic resin or a mixture of thermoplastic resins and continuous fibers from individual fiber unwinding apparatuses and drawing them in parallel to obtain a fiber bundle; (2) A step of gripping the aligned fiber bundle by a fiber bundle gripping mechanism that grips the fiber bundle in a direction perpendicular thereto, and (3) the fiber bundle gripping mechanism is translated by a certain amount in a state of gripping the fiber bundle, and set torsion A twisting step of adjusting the path length of each part of the fiber in the fiber bundle by rotating, (4) a step of fixing the fiber bundle in the width direction at a portion where the fiber bundle gripping mechanism grips the fiber bundle, and (5) The method for producing a continuous fiber composite material structure according to claim 1 or 2, further comprising a step of pressurizing the fixed fiber bundle to form a structure having a predetermined width. 5. The method for producing a continuous fiber composite material structure according to claim 4, wherein the steps (3) and (4) are performed by the following procedures (a) to (e).
(A) On the curve connecting the center lines in the width direction of the continuous fiber composite material structure to be formed, points to be divided at intervals shorter than d / 10 are provided, and the structure is directed from one end to another end. Number in order from 0, and let N be the number of the point at the end,
(B) A line segment connecting the k-1th point and the kth point is A _k and its length is B (k). _{The power} normal standing on _k is _Dk, and the angle between the normals _{Dk + 1} and _Dk is P (k).
(C) A direction perpendicular to the fiber direction of the aligned fibers is a “gripping direction”, a center portion in the width direction of the fiber bundle in the fiber bundle gripping portion is a “fiber bundle midpoint”, and a surface including the fiber direction and the gripping direction When the “fiber bundle surface” is set, the fiber bundle is grasped by the fiber bundle grasping mechanism at the fiber bundle grasping position, and the fiber grasping mechanism is first translated from the fiber bundle grasping position by the length of B (1), and then the fiber. After rotating the fiber bundle gripping mechanism by an angle P (1) / 2 around an axis that passes through the middle point of the fiber bundle in the bundle plane and goes straight in the gripping direction, the fiber bundle is fixed in the width direction.
(D) Release the fiber bundle from the fiber bundle gripping mechanism, return the fiber bundle gripping mechanism to the fiber gripping position, grip a new fiber bundle at that position, and fiber from the fiber bundle gripping position by the length of B (2) The gripping mechanism is translated, and then the fiber bundle gripping mechanism is rotated by an angle (P (1) + P (2)) / 2 around an axis that passes through the fiber bundle midpoint and goes straight in the gripping direction within the fiber side surface. After that, fix the fiber bundle in the width direction,
(E) Repeat the same operation as (d) N-2 times. However, in the m-th operation after the operation of (d), the fiber bundle is released from the fiber bundle gripping mechanism, the fiber bundle gripping mechanism is returned to the fiber gripping position, and a new fiber bundle is gripped at that position. The fiber gripping mechanism is translated from the fiber bundle gripping position by the length of (m + 2), and then the fiber bundle gripping mechanism is angled around an axis that passes through the fiber bundle midpoint and goes straight in the gripping direction within the fiber side surface (P After rotating by (m + 1) + P (m + 2)) / 2, the fiber bundle is fixed in the width direction. (1) A step of drawing a plurality of fibers impregnated with a thermoplastic resin or a mixture of thermoplastic resins and continuous fibers from individual fiber unwinding apparatuses and drawing them in parallel to obtain a fiber bundle; (2) A step of gripping the aligned fiber bundle by a fiber bundle gripping mechanism that grips the bundle in a direction perpendicular thereto, and (3) 'the fiber bundle gripping mechanism is translated by a certain amount in a state where the fiber bundle is gripped and set. A twisting and bending process for adjusting the path length of each part of the fiber in the fiber bundle by twisting and rotating in the plane; (4) The fiber bundle is fixed in the width direction at the part where the fiber bundle gripping mechanism grips the fiber bundle. The method for producing a continuous fiber composite material structure according to claim 3, comprising the step of: (5) pressurizing the fixed fiber bundle to form a structure having a predetermined width. The method for producing a continuous fiber composite material structure according to claim 6, wherein the steps (3) ′ and (4) are performed by the following procedures (a) to (e).
(A) On the curve connecting the center lines in the width direction of the continuous fiber composite material structure to be formed, points to be divided at intervals shorter than d / 10 are provided, and the structure is directed from one end to another end. Number in order from 0, and let N be the number of the point at the end,
(B) 'A line segment connecting the (k−1) -th point and the k-th point is A _k and the length is B (k). the陪法line stood on a _k and _{D k,} the angle between the normal line _{D k + 1} and _{D k} and P (k), the angle between the line segment _{a k + 1} and the line segment _{a k} and T (k) ,
(C) 'The direction perpendicular to the fiber direction of the aligned fibers is the' gripping direction ', the center in the width direction of the fiber bundle in the fiber bundle gripping portion is the' fiber bundle midpoint ', and the plane including the fiber direction and the gripping direction Is the “fiber bundle surface”, the fiber bundle is grasped by the fiber bundle grasping mechanism at the fiber bundle grasping position, and the fiber grasping mechanism is first translated from the fiber bundle grasping position by the length of B (1). Rotate the fiber bundle gripping mechanism by an angle T (1) / 2 within the fiber bundle plane around the midpoint, and then around an axis that goes straight in the gripping direction through the fiber bundle midpoint within the fiber bundle plane, After rotating the fiber bundle gripping mechanism by an angle P (1) / 2, the fiber bundle is fixed in the width direction.
(D) 'The fiber bundle is released from the fiber bundle gripping mechanism, the fiber bundle gripping mechanism is returned to the fiber gripping position, a new fiber bundle is gripped at that position, and the length of B (2) is changed from the fiber bundle gripping position. The fiber gripping mechanism is translated, the fiber bundle gripping mechanism is rotated by an angle (T (1) + T (2)) / 2 within the fiber bundle surface around the middle point of the fiber bundle, and then the fiber is moved within the fiber side surface. After rotating the fiber bundle gripping mechanism by an angle (P (1) + P (2)) / 2 around an axis passing through the midpoint of the bundle and orthogonal to the gripping direction, the fiber bundle is fixed in the width direction.
(E) 'Repeat the same operation as (d) N-2 times. However, in the m-th operation after the operation of (d), the fiber bundle is released from the fiber bundle gripping mechanism, the fiber bundle gripping mechanism is returned to the fiber gripping position, and a new fiber bundle is gripped at that position. The fiber gripping mechanism is translated from the fiber bundle gripping position by the length of (m + 2), and the fiber bundle gripping mechanism is moved at an angle (T (m + 1) + T (m + 2)) / After rotating the fiber bundle gripping mechanism by an angle (P (m + 1) + P (m + 2)) / 2 around an axis that passes through the fiber bundle midpoint and goes straight in the gripping direction within the fiber side surface. The method for producing a continuous fiber composite material structure according to claim 6, wherein the fiber bundle is fixed in the width direction.   A composite molded body obtained by combining a resin molded body and a reinforcing structure composed of the continuous fiber composite material structure according to any one of claims 1 to 3.   The composite molded body according to claim 8, wherein the resin molded body is made of a fiber reinforced resin. The composite molded body according to any one of claims 8 to 9, wherein the following (i) and (ii) are simultaneously satisfied.
When the projected area of the composite molded body when projected at the projection angle that maximizes the projected area of the resin molded body is S1, and the projected area of only the continuous fiber reinforced structure when projected at the same projection angle is S2. 0.60> S2 / S1> 0.04 (i)
When projecting at the projection angle that maximizes the projection area of the resin molding, J1 is the polar second moment related to the centroid of the projection of the composite molding, and only the continuous fiber reinforced structure is projected at the same projection angle. 0.95> J2 / J1> 0.15 where J2 is the polar second moment with respect to the centroid of all structures in the figure (ii)   The composite molded article according to claim 10, wherein the reinforcing fibers of the reinforcing structure are carbon fibers, and the J2 / J1 is 0.30 or more and 0.90 or less.   The vehicle panel using the composite molded object in any one of Claims 8-11.   The vehicle panel according to claim 12, which is a back door, a side door, a fender, a front hood, a roof, or a floor pan.