JP2014136383A - Composite material and method for manufacturing the same - Google Patents

Composite material and method for manufacturing the same Download PDF

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Publication number
JP2014136383A
JP2014136383A JP2013006480A JP2013006480A JP2014136383A JP 2014136383 A JP2014136383 A JP 2014136383A JP 2013006480 A JP2013006480 A JP 2013006480A JP 2013006480 A JP2013006480 A JP 2013006480A JP 2014136383 A JP2014136383 A JP 2014136383A
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Japan
Prior art keywords
side frame
adhesive layer
composite material
plate
reinforced resin
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JP2013006480A
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Japanese (ja)
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JP6057330B2 (en
Inventor
Kenzo Yasuda
賢三 安田
Yoshisuke Hayashi
良輔 林
Shigeto Yamamoto
重人 山本
Masaya Ubukata
雅也 生方
Fumisato O
文学 汪
Akitake Matsubara
監壮 松原
Yoshihiro Takao
善裕 高雄
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YAJIMA KOGYO KK
NHK Spring Co Ltd
Kyushu University NUC
Kimigafuchi Gakuen
Original Assignee
YAJIMA KOGYO KK
NHK Spring Co Ltd
Kyushu University NUC
Kimigafuchi Gakuen
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Application filed by YAJIMA KOGYO KK, NHK Spring Co Ltd, Kyushu University NUC, Kimigafuchi Gakuen filed Critical YAJIMA KOGYO KK
Priority to JP2013006480A priority Critical patent/JP6057330B2/en
Priority to PCT/JP2014/050705 priority patent/WO2014112562A1/en
Publication of JP2014136383A publication Critical patent/JP2014136383A/en
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Publication of JP6057330B2 publication Critical patent/JP6057330B2/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/483—Reactive adhesives, e.g. chemically curing adhesives
    • B29C65/4835—Heat curing adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5007—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like characterised by the structure of said adhesive tape, threads or the like
    • B29C65/5028—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like characterised by the structure of said adhesive tape, threads or the like being textile in woven or non-woven form
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5057—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like positioned between the surfaces to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/82—Testing the joint
    • B29C65/8207—Testing the joint by mechanical methods
    • B29C65/8215—Tensile tests
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/001—Joining in special atmospheres
    • B29C66/0012—Joining in special atmospheres characterised by the type of environment
    • B29C66/0014—Gaseous environments
    • B29C66/00145—Vacuum, e.g. partial vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/342—Preventing air-inclusions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B29C66/545—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles one hollow-preform being placed inside the other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/74—Joining plastics material to non-plastics material
    • B29C66/742—Joining plastics material to non-plastics material to metals or their alloys
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
    • B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
    • B60N2/68—Seat frames
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
    • B29C66/7316—Surface properties
    • B29C66/73161—Roughness or rugosity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3002—Superstructures characterized by combining metal and plastics, i.e. hybrid parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3055—Cars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/771—Seats
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54—Yield strength; Tensile strength
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • B32B2605/12—Ships
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/18—Aircraft

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Transportation (AREA)
  • Laminated Bodies (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

PROBLEM TO BE SOLVED: To secure, within a composite material, a sufficient thickness of an adhesive layer for pasting a metal plate and a fiber-reinforced resin plate.SOLUTION: The SB side frame 10 provided as an example of composite material obtained by pasting, via an adhesive layer 40, a side frame substrate 20 provided as a metal plate and a side frame reinforcement plate 30 provided as a fiber-reinforced resin plate possesses, as an example of layer thickness regulating member sandwiched in-between the side frame substrate 20 and side frame reinforcement plate 30 for regulating the thickness of the adhesive layer 40, a non-woven fabric 42.

Description

本発明は、複合材及び複合材の製造方法に関する。   The present invention relates to a composite material and a method for manufacturing the composite material.

従来から、自動車を構成する部材として、金属板に繊維強化プラスチック（ＦＲＰ）を貼り合せた複合材が用いられている。このような金属板にＦＲＰを貼り合せる構造としては、特許文献１のように、金属にＦＲＰを接着剤で接着する構造が知られている。   Conventionally, as a member constituting an automobile, a composite material in which a fiber reinforced plastic (FRP) is bonded to a metal plate is used. As a structure in which FRP is bonded to such a metal plate, a structure in which FRP is bonded to a metal with an adhesive as in Patent Document 1 is known.

特開２０１２−１７６５１４号公報JP 2012-176514 A

ところで、金属板にＦＲＰを接着剤で接着する場合、金属板とＦＲＰとの間に接着剤を介在させた状態で金属板とＦＲＰをプレス成形するため、加圧力によっては接着剤が流れ出たり、片寄ったりなどして、金属板とＦＲＰとの間の接着層の厚みを十分に確保できないことがある。   By the way, when bonding FRP to the metal plate with an adhesive, the metal plate and FRP are press-molded with the adhesive interposed between the metal plate and FRP, so that the adhesive flows out depending on the applied pressure, In some cases, the thickness of the adhesive layer between the metal plate and the FRP cannot be sufficiently ensured due to deviation.

本発明は、上記事実を考慮して、複合材において金属板と繊維強化樹脂板を貼り合わせる接着層の厚みを十分に確保することを目的とする。   In view of the above facts, an object of the present invention is to ensure a sufficient thickness of an adhesive layer for bonding a metal plate and a fiber reinforced resin plate in a composite material.

請求項１に記載の複合材は、金属板と繊維強化樹脂板を接着層で貼り合せた複合材であって、前記金属板と前記繊維強化樹脂板に挟まれ、前記接着層の層厚を規定する層厚規定部材を有している。   The composite material according to claim 1 is a composite material in which a metal plate and a fiber reinforced resin plate are bonded together with an adhesive layer, and is sandwiched between the metal plate and the fiber reinforced resin plate. A layer thickness defining member is defined.

請求項１に記載の複合材では、金属板と繊維強化樹脂板の間に層厚規制部材を挟んでいることから、金属板と繊維強化樹脂板のプレス成形時に接着層がプレスされても、接着層の厚み（層厚）を十分に確保することができる。   In the composite material according to claim 1, since the layer thickness regulating member is sandwiched between the metal plate and the fiber reinforced resin plate, even if the adhesive layer is pressed during press molding of the metal plate and the fiber reinforced resin plate, the adhesive layer The thickness (layer thickness) can be sufficiently secured.

請求項２に記載の複合材は請求項１に記載の複合材において、前記層厚規定部材は、絶縁性を有している。   A composite material according to a second aspect is the composite material according to the first aspect, wherein the layer thickness defining member has an insulating property.

請求項２に記載の複合材では、層厚規定部材が絶縁性を有していることから、金属板と繊維強化樹脂板との間の電蝕（電位差腐食）を防止することができる。   In the composite material according to claim 2, since the layer thickness defining member has an insulating property, electric corrosion (potential corrosion) between the metal plate and the fiber reinforced resin plate can be prevented.

請求項３に記載の複合材は、請求項１または請求項２に記載の複合材において、前記層厚規定部材は不織布または織物である。   The composite material according to claim 3 is the composite material according to claim 1 or 2, wherein the layer thickness defining member is a nonwoven fabric or a woven fabric.

請求項３に記載の複合材では、層厚規定部材を不織布または織物としていることから、接着層に亀裂が生じるのを抑制することができる。また、接着層に亀裂が生じても、不織布または織物のブリッジ効果（繊維同士が絡み合う効果）により、亀裂の進行を抑制することができる。   In the composite material according to the third aspect, since the layer thickness defining member is a non-woven fabric or a woven fabric, the occurrence of cracks in the adhesive layer can be suppressed. Moreover, even if a crack occurs in the adhesive layer, the progress of the crack can be suppressed by the bridging effect of the non-woven fabric or the woven fabric (effect in which the fibers are intertwined).

請求項４に記載の複合材の製造方法は、金属板と繊維強化樹脂板の貼り合せ面に、接着層と前記接着層の層厚を規定する層厚規定部材を配置する工程と、前記金属板と前記繊維強化樹脂板をプレス成形して、前記金属板と前記繊維強化樹脂板を貼り合せる工程と、を有している。   The method for producing a composite material according to claim 4 includes a step of disposing an adhesive layer and a layer thickness defining member defining a layer thickness of the adhesive layer on a bonding surface of the metal plate and the fiber reinforced resin plate, and the metal Press-molding the plate and the fiber-reinforced resin plate, and bonding the metal plate and the fiber-reinforced resin plate.

請求項４に記載の複合材の製造方法では、金属板と繊維強化樹脂板の間に層厚規定部材を挟んだ状態で金属板と繊維強化樹脂板をプレス成形することから、接着層がプレスされても接着層の厚み（層厚）を確保することができる。   In the method of manufacturing a composite material according to claim 4, since the metal plate and the fiber reinforced resin plate are press-molded with the layer thickness defining member sandwiched between the metal plate and the fiber reinforced resin plate, the adhesive layer is pressed. Also, the thickness (layer thickness) of the adhesive layer can be ensured.

請求項５に記載の複合材の製造方法は、請求項４に記載の複合材の製造方法において、プレス成形する前に前記接着層を真空引きする工程を有している。   According to a fifth aspect of the present invention, there is provided a method of manufacturing a composite material according to the fourth aspect of the present invention, including the step of evacuating the adhesive layer before press molding.

請求項５に記載の複合材の製造方法では、プレス成形する前に接着層を真空引きすることから、接着層内に空気が滞留するのを抑制することができる。   In the method for manufacturing a composite material according to claim 5, since the adhesive layer is evacuated before press molding, it is possible to suppress air from staying in the adhesive layer.

請求項６に記載の複合材の製造方法は、請求項４または請求項５に記載の複合材の製造方法において、前記金属板と前記繊維強化樹脂板を製品形状に曲げ加工した後で、前記金属板と前記繊維強化樹脂板の貼り合せ面に前記接着層と前記層厚規定部材を配置する。   The composite material manufacturing method according to claim 6 is the composite material manufacturing method according to claim 4 or 5, wherein the metal plate and the fiber reinforced resin plate are bent into a product shape, The adhesive layer and the layer thickness regulating member are disposed on the bonding surface of the metal plate and the fiber reinforced resin plate.

請求項６に記載の複合材の製造方法では、金属板と繊維強化樹脂板を製品形状に曲げ加工した後で、金属板と繊維強化樹脂板の貼り合せ面に接着層と層厚規定部材を配置し、プレス成形することから、例えば、金属板または繊維強化樹脂板を曲げ加工しながらプレス成形する場合と比較して、接着層と層厚規定部材の片寄りを防止することができる。   In the method of manufacturing a composite material according to claim 6, after bending the metal plate and the fiber reinforced resin plate into a product shape, the adhesive layer and the layer thickness regulating member are formed on the bonding surface of the metal plate and the fiber reinforced resin plate. Since it arrange | positions and press-molds, the shift | offset | difference of an adhesion layer and a layer thickness regulation member can be prevented compared with the case where it press-molds, for example, bending a metal plate or a fiber reinforced resin board.

本発明の複合材及び複合材の製造方法によれば、接着層の厚みを十分に確保することができる。   According to the composite material and the composite material manufacturing method of the present invention, it is possible to sufficiently ensure the thickness of the adhesive layer.

本発明の第１実施形態の複合材（ＳＢサイドフレーム）の断面図である。It is sectional drawing of the composite material (SB side frame) of 1st Embodiment of this invention. 図１の複合材（ＳＢサイドフレーム）にせん断力が作用した状態を示す複合材の断面図である。It is sectional drawing of the composite material which shows the state which the shear force acted on the composite material (SB side frame) of FIG. サイドフレーム基板に接着フィルムを配置する工程を説明するための図である。It is a figure for demonstrating the process of arrange | positioning an adhesive film to a side frame board | substrate. 金型にサイドフレーム補強板と接着フィルムを貼り付けたサイドフレーム基板をセットする作業を説明するための図である。It is a figure for demonstrating the operation | work which sets the side frame board | substrate which affixed the side frame reinforcement board and the adhesive film on the metal mold | die. サイドフレーム基板とサイドフレーム補強板をプレス成形する工程を説明するための図である。It is a figure for demonstrating the process of press-molding a side frame board | substrate and a side frame reinforcement board. 図５の矢印６Ｘ部拡大図である。FIG. 6 is an enlarged view of an arrow 6X portion of FIG. 金型からＳＢサイドフレームを取り出す作業を説明するための図である。It is a figure for demonstrating the operation | work which takes out SB side frame from a metal mold | die. 真空引き工程を説明するための図である。It is a figure for demonstrating a evacuation process. 第１実施形態の複合材（ＳＢサイドフレーム）を用いたシートバックフレームをシート左斜め前方から見た斜視図である。It is the perspective view which looked at the seat back frame using the composite material (SB side frame) of a 1st embodiment from the seat left slanting front. ＳＢサイドフレームの荷重と変形量の関係を示すグラフである。It is a graph which shows the relationship between the load of a SB side frame, and a deformation amount.

次に、本発明の第１実施形態の複合材、及びこの複合材の製造方法について説明する。
第１実施形態の複合材は、後述するＳＢサイドフレーム１０として用いられている。 Next, the composite material of the first embodiment of the present invention and the method for producing the composite material will be described.
The composite material of 1st Embodiment is used as SB side frame 10 mentioned later.

図９には、車両用シート１００の骨格の全体がシート左斜め前方から見た斜視図にて示されている。なお、図面に適宜示される矢印ＦＲはシート前方を示し、矢印ＵＰはシート上方を示し、矢印ＲＨはシート右方（シート幅方向一側）を示している。   FIG. 9 is a perspective view of the entire skeleton of the vehicle seat 100 as viewed from the front left of the seat. Note that an arrow FR appropriately shown in the drawings indicates the front of the seat, an arrow UP indicates the upper side of the seat, and an arrow RH indicates the right side of the seat (one side in the seat width direction).

車両用シート１００は、乗員が着座するシートクッション（図示省略）の骨格を構成するシートクッションフレーム１１０と、着座乗員の背部を支えるシートバック（図示省略）の骨格を構成するシートバックフレーム１２０と、を含んで構成されている。   The vehicle seat 100 includes a seat cushion frame 110 that constitutes a skeleton of a seat cushion (not shown) on which an occupant is seated, a seat back frame 120 that constitutes a skeleton of a seat back (not shown) that supports the back of the seated occupant, It is comprised including.

シートクッションフレーム１１０は、一対のシートクッションサイドフレーム（以下、「ＳＣサイドフレーム」という）１１２と、シートクッションパネル（以下、「ＳＣパネル」という）１１４と、を含んで構成されている。   The seat cushion frame 110 includes a pair of seat cushion side frames (hereinafter referred to as “SC side frames”) 112 and a seat cushion panel (hereinafter referred to as “SC panel”) 114.

ＳＣサイドフレーム１１２は、シートクッションフレーム１１０のシート幅方向両側部にそれぞれ設けられている。このＳＣサイドフレーム１１２は、板状とされ、板厚方向をシート幅方向にして、シート前後方向に延在している。また、ＳＣサイドフレーム１１２の短手方向の両端部（図９では、シート上下方向の両端部）は、シート幅方向内側に折り曲げられている。そして、ＳＣサイドフレーム１１２の下部には、従来周知のスライド機構１１６がそれぞれ設けられており、スライド機構１１６によってＳＣサイドフレーム１１２は車両の車体フロア（図示省略）に連結されている。   The SC side frames 112 are provided on both sides of the seat cushion frame 110 in the seat width direction. The SC side frame 112 has a plate shape, and extends in the front-rear direction of the sheet with the plate thickness direction as the seat width direction. Further, both ends of the SC side frame 112 in the short side direction (both ends in the sheet vertical direction in FIG. 9) are bent inward in the sheet width direction. A conventionally known slide mechanism 116 is provided below the SC side frame 112, and the SC side frame 112 is connected to the vehicle body floor (not shown) of the vehicle by the slide mechanism 116.

一対のＳＣサイドフレーム１１２の間には、シート後方側の端部において、略パイプ状の連結パイプ１１８が設けられており、連結パイプ１１８によって、一対のＳＣサイドフレーム１１２が連結されている。
ＳＣパネル１１４は、シート幅方向に延びて両端部が一対のＳＣサイドフレーム１１２のシート上方側の折り曲げ部分にそれぞれ固定されている。 Between the pair of SC side frames 112, a substantially pipe-shaped connection pipe 118 is provided at the end portion on the rear side of the seat, and the pair of SC side frames 112 are connected by the connection pipe 118.
The SC panel 114 extends in the sheet width direction, and both end portions thereof are fixed to bent portions on the upper side of the pair of SC side frames 112, respectively.

一方、シートバックフレーム１２０は、一対のシートバックサイドフレーム（以下、「ＳＢサイドフレーム」という）１０と、アッパーパイプ１２２と、アッパーパネル１２４と、を含んで構成されている。   On the other hand, the seat back frame 120 includes a pair of seat back side frames (hereinafter referred to as “SB side frames”) 10, an upper pipe 122, and an upper panel 124.

ＳＢサイドフレーム１０は、シートバックフレーム１２０のシート幅方向両側部に設けられている。このＳＢサイドフレーム１０は、板状とされ、板厚方向をシート幅方向にして、シート上下方向に延在している。また、ＳＢサイドフレーム１０の短手方向の両端部（図９では、シート前後方向の両端部）は、シート幅方向内側に折り曲げられている。そして、ＳＢサイドフレーム１０のシート下側の端部が、従来周知のリクライニング機構（図示省略）によって、ＳＣサイドフレーム１１２のシート後方側の端部に連結されている。   The SB side frame 10 is provided on both sides of the seat back frame 120 in the seat width direction. The SB side frame 10 has a plate shape, and extends in the vertical direction of the sheet with the plate thickness direction as the sheet width direction. Further, both end portions in the short direction of the SB side frame 10 (both end portions in the seat front-rear direction in FIG. 9) are bent inward in the seat width direction. The lower end portion of the SB side frame 10 is connected to the rear end portion of the SC side frame 112 by a conventionally known reclining mechanism (not shown).

アッパーパイプ１２２は、略コ字状に折り曲げられ、両端部が一対のＳＢサイドフレーム１０の上端部（シート上方側の端部）にそれぞれ固定されて、一対のＳＢサイドフレーム１０の上端部どうしを連結している。
アッパーパネル１２４は、シート幅方向に延びて両端部が一対のＳＢサイドフレーム１０のシート後方側の折り曲げ部分にそれぞれ固定されている。 The upper pipe 122 is bent in a substantially U shape, and both end portions are respectively fixed to upper end portions (end portions on the upper side of the seat) of the pair of SB side frames 10 so that upper end portions of the pair of SB side frames 10 are connected to each other. It is connected.
The upper panel 124 extends in the seat width direction, and both end portions thereof are respectively fixed to bent portions on the seat rear side of the pair of SB side frames 10.

次に本発明の複合材の一例としてのＳＢサイドフレーム１０について詳細に説明する。
図１には、ＳＢサイドフレーム１０の断面（板厚方向と直交する方向の断面）が示されている。ＳＢサイドフレーム１０は、金属製のサイドフレーム基板２０と、繊維強化樹脂（ＦＲＰ）製のサイドフレーム補強板３０と、サイドフレーム基板２０とサイドフレーム補強板３０とを貼り合せる接着層４０と、を有している。なお、本実施形態のサイドフレーム基板２０は金属板の一例であり、本実施形態のサイドフレーム補強板３０は繊維強化樹脂板の一例であり、本実施形態の接着層４０は接着層の一例である。 Next, the SB side frame 10 as an example of the composite material of the present invention will be described in detail.
FIG. 1 shows a cross section of the SB side frame 10 (cross section in a direction orthogonal to the plate thickness direction). The SB side frame 10 includes a metal side frame substrate 20, a fiber reinforced resin (FRP) side frame reinforcing plate 30, and an adhesive layer 40 for bonding the side frame substrate 20 and the side frame reinforcing plate 30 together. Have. The side frame substrate 20 of the present embodiment is an example of a metal plate, the side frame reinforcing plate 30 of the present embodiment is an example of a fiber reinforced resin plate, and the adhesive layer 40 of the present embodiment is an example of an adhesive layer. is there.

また、ＳＢサイドフレーム１０は、サイドフレーム基板２０のシート幅方向外側に接着層４０とサイドフレーム補強板３０が順次配置されて形成されている。   The SB side frame 10 is formed by sequentially arranging an adhesive layer 40 and a side frame reinforcing plate 30 on the outer side of the side frame substrate 20 in the sheet width direction.

サイドフレーム基板２０は、ＳＢサイドフレーム１０のシート幅方向内側部分を形成している。このサイドフレーム基板２０としては、高張力鋼板やアルミニウム板（例えば、ジュラルミンなど）などを用いてもよい。なお、本実施形態では、サイドフレーム基板２０として、板厚０.５ｍｍ、引張強度５９０ＭＰａ級の高張力鋼板を用いている。   The side frame substrate 20 forms an inner portion of the SB side frame 10 in the seat width direction. As the side frame substrate 20, a high-tensile steel plate, an aluminum plate (for example, duralumin) or the like may be used. In the present embodiment, a high-tensile steel plate having a plate thickness of 0.5 mm and a tensile strength of 590 MPa is used as the side frame substrate 20.

サイドフレーム補強板３０は、接着層４０を介してサイドフレーム基板２０の外周面（シート幅方向外側の面）２０Ａ全体を覆っている。このサイドフレーム補強板３０としては、炭素繊維強化樹脂（ＣＦＲＰ）、ガラス繊維強化樹脂（ＧＦＲＰ）、天然繊維（例えば、竹、ケナフなど）強化樹脂などを用いてもよい。なお、本実施形態では、サイドフレーム補強板３０として、厚さ０．２２ｍｍのプリプレグ素材（マトリックス樹脂に炭素繊維を混在させたもの）を８枚重ねて形成した炭素繊維強化樹脂板を用いている。   The side frame reinforcing plate 30 covers the entire outer peripheral surface (surface on the outer side in the sheet width direction) 20 </ b> A of the side frame substrate 20 via the adhesive layer 40. As the side frame reinforcing plate 30, carbon fiber reinforced resin (CFRP), glass fiber reinforced resin (GFRP), natural fiber (for example, bamboo, kenaf, etc.) reinforced resin, or the like may be used. In the present embodiment, as the side frame reinforcing plate 30, a carbon fiber reinforced resin plate formed by stacking eight prepreg materials (matrix resin mixed with carbon fibers) having a thickness of 0.22 mm is used. .

接着層４０は、接着剤と、この接着剤が含浸された不織布４２と、を含んで構成されている。なお、本実施形態の不織布４２は層厚規定部材の一例である。   The adhesive layer 40 includes an adhesive and a nonwoven fabric 42 impregnated with the adhesive. In addition, the nonwoven fabric 42 of this embodiment is an example of a layer thickness regulating member.

不織布４２は、接着層４０の全体、言い換えれば、サイドフレーム基板２０とサイドフレーム補強板３０との間に全体に亘って配置されている。この不織布４２としては、天然繊維や化学繊維を用いてもよい。また、不織布４２は、絶縁性を有する繊維を用いることが好ましい。なお、本実施形態の不織布４２は、ポリエステル繊維で形成した不織布である。   The nonwoven fabric 42 is disposed over the entire adhesive layer 40, in other words, between the side frame substrate 20 and the side frame reinforcing plate 30. As this nonwoven fabric 42, natural fibers or chemical fibers may be used. Moreover, it is preferable that the nonwoven fabric 42 uses the fiber which has insulation. In addition, the nonwoven fabric 42 of this embodiment is a nonwoven fabric formed with the polyester fiber.

接着剤としては、エポキシ系樹脂やウレタン系樹脂などの熱硬化性樹脂を用いることが好ましい。なお、本実施形態では、接着剤としてエポキシ系樹脂を用いている。   As the adhesive, it is preferable to use a thermosetting resin such as an epoxy resin or a urethane resin. In this embodiment, an epoxy resin is used as the adhesive.

また、接着層４０は、不織布４２がサイドフレーム基板２０とサイドフレーム補強板３０に挟まれているため、厚み（層厚）ｔがほぼ一定とされている。すなわち、接着層４０の厚みｔは、不織布４２の厚みで規定することができる。なお、接着層４０の層厚ｔは、７０μｍ以上が好ましく、１００μｍ程度がさらに好ましい。   Further, since the non-woven fabric 42 is sandwiched between the side frame substrate 20 and the side frame reinforcing plate 30, the adhesive layer 40 has a substantially constant thickness (layer thickness) t. That is, the thickness t of the adhesive layer 40 can be defined by the thickness of the nonwoven fabric 42. The layer thickness t of the adhesive layer 40 is preferably 70 μm or more, more preferably about 100 μm.

次に、本実施形態のＳＢサイドフレーム１０の製造方法について説明する。
まず、図３に示すように、金属板（本実施形態では、高張力鋼板）を製品形状に曲げ加工してサイドフレーム基板２０を形成する。次に、未硬化の接着剤を含浸させた不織布４２（厚みがほぼ均一の不織布）によって構成されたフィルム状の接着層４０をサイドフレーム基板２０の外周面２０Ａ全体に配置する。
なお、接着層４０を配置する前に、サイドフレーム基板２０を脱脂処理してもよい。また、接着層４０の外周面２０Ａ全体を粗面化処理（例えば、プラズマ処理など）してもよい。上記処理などを行うことで、サイドフレーム基板２０と接着層４０との接着力を高めることができる。 Next, a method for manufacturing the SB side frame 10 of this embodiment will be described.
First, as shown in FIG. 3, a side frame substrate 20 is formed by bending a metal plate (in this embodiment, a high-tensile steel plate) into a product shape. Next, a film-like adhesive layer 40 composed of a nonwoven fabric 42 (nonwoven fabric having a substantially uniform thickness) impregnated with an uncured adhesive is disposed on the entire outer peripheral surface 20 </ b> A of the side frame substrate 20.
Note that the side frame substrate 20 may be degreased before the adhesive layer 40 is disposed. Further, the entire outer peripheral surface 20A of the adhesive layer 40 may be roughened (for example, plasma treatment). By performing the above processing and the like, the adhesive force between the side frame substrate 20 and the adhesive layer 40 can be increased.

次に、図４に示すように、あらかじめ製品形状に曲げ加工したサイドフレーム補強板３０の内周面３０Ａを、サイドフレーム基板２０の外周面２０Ａ全体を覆うように接着層４０を介して配置する。これにより、サイドフレーム基板２０とサイドフレーム補強板３０の貼り合せ面（外周面２０Ａ及び内周面３０Ａ）に不織布４２を有する接着層４０が配置される。
なお、サイドフレーム補強板３０は、製品形状に曲げ加工済みのフィルム状のプリプレグ素材（マトリックス樹脂に炭素繊維を混在させたもの）を複数枚重ねて形成される。 Next, as shown in FIG. 4, the inner peripheral surface 30 </ b> A of the side frame reinforcing plate 30 that has been bent into a product shape in advance is disposed via the adhesive layer 40 so as to cover the entire outer peripheral surface 20 </ b> A of the side frame substrate 20. . Accordingly, the adhesive layer 40 having the nonwoven fabric 42 is disposed on the bonding surface (the outer peripheral surface 20A and the inner peripheral surface 30A) of the side frame substrate 20 and the side frame reinforcing plate 30.
The side frame reinforcing plate 30 is formed by stacking a plurality of film-shaped prepreg materials (matrix resin mixed with carbon fibers) bent into a product shape.

次に、あらかじめ加熱（予熱）した下型５０にサイドフレーム補強板３０を下にしてサイドフレーム基板２０をセットし、下型５０と上型６０を閉じる。これにより、サイドフレーム基板２０とサイドフレーム補強板３０がプレス成形される。このプレス成形は、接着層４０の接着剤の種類によって異なるが、１４０℃で１０分程度行われる。そして、接着剤が硬化することによって、接着層４０を介してサイドフレーム基板２０とサイドフレーム補強板３０が貼り合わされる（なお、図１、図２、図７の接着層４０は硬化済みであり、図３〜６の接着層は未硬化である。）。
ここで、サイドフレーム基板２０とサイドフレーム補強板３０の間に不織布４２を挟んだ状態でプレス成形が行われることから、接着層４０がプレスされてもサイドフレーム基板２０とサイドフレーム補強板３０を貼り合わせる接着層４０の厚み（層厚）を十分に確保することができる。特に、不織布４２は、サイドフレーム基板２０の外周面２０Ａ全体に配置されるため、接着層４０の厚みをほぼ均一に確保することができる。
また、プレス成形を行う前にサイドフレーム基板２０とサイドフレーム補強板３０を製品形状に曲げ加工していることから、例えば、サイドフレーム基板２０またはサイドフレーム補強板３０を曲げ加工しながらプレス成形する製造方法ものと比較して、接着層４０（不織布４２）の厚みが片寄るのを防止することができる。
なお、プレス成形時には、下型５０の代わりに上型６０をあらかじめ加熱（予熱）しておいてもよく、下型５０及び上型６０の両方をあらかじめ加熱しておいてもよい。 Next, the side frame substrate 20 is set with the side frame reinforcing plate 30 facing down on the preheated (preheated) lower mold 50, and the lower mold 50 and the upper mold 60 are closed. Thereby, the side frame board | substrate 20 and the side frame reinforcement board 30 are press-molded. This press molding is performed at 140 ° C. for about 10 minutes, depending on the type of adhesive of the adhesive layer 40. Then, as the adhesive is cured, the side frame substrate 20 and the side frame reinforcing plate 30 are bonded to each other via the adhesive layer 40 (Note that the adhesive layer 40 in FIGS. 1, 2, and 7 has been cured). 3 and 6 are uncured.)
Here, since the press molding is performed in a state where the nonwoven fabric 42 is sandwiched between the side frame substrate 20 and the side frame reinforcing plate 30, the side frame substrate 20 and the side frame reinforcing plate 30 can be connected even if the adhesive layer 40 is pressed. A sufficient thickness (layer thickness) of the adhesive layer 40 to be bonded can be ensured. In particular, since the nonwoven fabric 42 is disposed on the entire outer peripheral surface 20A of the side frame substrate 20, the thickness of the adhesive layer 40 can be ensured substantially uniformly.
Further, since the side frame substrate 20 and the side frame reinforcing plate 30 are bent into a product shape before press forming, for example, the side frame substrate 20 or the side frame reinforcing plate 30 is press formed while being bent. Compared with the manufacturing method, the thickness of the adhesive layer 40 (nonwoven fabric 42) can be prevented from being offset.
During press molding, the upper die 60 may be preheated (preheated) instead of the lower die 50, or both the lower die 50 and the upper die 60 may be preheated.

次に、下型５０と上型６０を開いてサイドフレーム補強板３０が接着層４０を介して貼り合せられたサイドフレーム基板２０、すなわちＳＢサイドフレーム１０を取り出す。これにより、ＳＢサイドフレーム１０が完成する。   Next, the lower mold 50 and the upper mold 60 are opened, and the side frame substrate 20 to which the side frame reinforcing plate 30 is bonded through the adhesive layer 40, that is, the SB side frame 10, is taken out. Thereby, the SB side frame 10 is completed.

次に、本実施形態のＳＢサイドフレーム１０の作用効果について説明する。
ＳＢサイドフレーム１０では、サイドフレーム基板２０とサイドフレーム補強板３０の間に不織布４２を挟んでいることから、サイドフレーム基板２０とサイドフレーム補強板３０のプレス成形時に接着層４０がプレスされても、接着層４０の厚み（層厚）を十分に確保することができる。すなわち、サイドフレーム基板２０とサイドフレーム補強板３０の間に挟まれる不織布４２の厚みに応じて接着層４０の厚みを規定することができる。
ここで、接着層４０の厚みを増すと、ＳＢサイドフレーム１０に例えば、シート後方側のモーメントが作用してサイドフレーム基板２０とサイドフレーム補強板３０とが板厚方向と直交する方向にずれて接着層４０にせん断力Ｆ（図２参照）が作用した場合に、接着層４０が許容できる最大許容せん断歪（図２では、せん断歪をＬで示している。）を増やすことができる。
すなわち、本実施形態では、接着層４０の厚みを規定することで、最大許容せん断歪を調整することができるため、最大せん断強度を適切なものに設定することができる。このように最大せん断強度を適切なものに設定することで、サイドフレーム基板２０とサイドフレーム補強板３０の分離を防ぐことができ、後方モーメントが作用した際の破壊靭性を高めることができる。 Next, the effect of the SB side frame 10 of this embodiment is demonstrated.
In the SB side frame 10, since the nonwoven fabric 42 is sandwiched between the side frame substrate 20 and the side frame reinforcing plate 30, even if the adhesive layer 40 is pressed during press molding of the side frame substrate 20 and the side frame reinforcing plate 30. The thickness (layer thickness) of the adhesive layer 40 can be sufficiently ensured. That is, the thickness of the adhesive layer 40 can be defined according to the thickness of the nonwoven fabric 42 sandwiched between the side frame substrate 20 and the side frame reinforcing plate 30.
Here, when the thickness of the adhesive layer 40 is increased, for example, a moment on the rear side of the seat acts on the SB side frame 10 so that the side frame substrate 20 and the side frame reinforcing plate 30 are displaced in a direction perpendicular to the plate thickness direction. When the shearing force F (see FIG. 2) acts on the adhesive layer 40, the maximum allowable shear strain that can be allowed by the adhesive layer 40 (in FIG. 2, the shear strain is indicated by L) can be increased.
That is, in this embodiment, the maximum allowable shear strain can be adjusted by defining the thickness of the adhesive layer 40, so that the maximum shear strength can be set to an appropriate value. Thus, by setting the maximum shear strength to an appropriate value, separation of the side frame substrate 20 and the side frame reinforcing plate 30 can be prevented, and the fracture toughness when the rear moment acts can be increased.

また、サイドフレーム１０では、絶縁性を有する繊維（ポリエステル繊維）で形成した不織布４２を用いることから、サイドフレーム基板２０とサイドフレーム補強板３０との間の電蝕（電位差腐食）を防止することができる。   Moreover, in the side frame 10, since the nonwoven fabric 42 formed with the fiber (polyester fiber) which has insulation is used, the electric corrosion (potential difference corrosion) between the side frame board | substrate 20 and the side frame reinforcement board 30 is prevented. Can do.

またさらに、サイドフレーム１０では、不織布４２を用いることから、接着層４０に亀裂が生じるのを抑制することができる。また、接着層４０に亀裂が生じても、不織布４２のブリッジ効果（繊維同士が絡み合う効果）により、亀裂の進行を抑制することができる。   Furthermore, in the side frame 10, since the nonwoven fabric 42 is used, it is possible to suppress the occurrence of cracks in the adhesive layer 40. Moreover, even if a crack occurs in the adhesive layer 40, the progress of the crack can be suppressed by the bridging effect of the nonwoven fabric 42 (effect in which fibers are entangled with each other).

第１実施形態では、層厚規定部材の一例として不織布４２を用いているが、本発明はこの構成に限定されず、層厚規定部材の一例として織物を用いてもよい。なお、織物は前述の不織布４２に適用できる繊維と同様のものを用いることができる。また、不織布４２の代わりに織物を用いた場合でも第１実施形態と同様の効果を得ることができる。またさらに、層厚規制部材の一例としては絶縁性を有する繊維などを一方向に並べた繊維体などを用いてもよい。さらに、層厚規定部材の一例としてガラスビーズなどの固形物を用いてもよい。このように固形物を接着剤に混入して接着層４０を形成しても、接着層４０の層厚を確保（規定）する効果は得られる。   In 1st Embodiment, although the nonwoven fabric 42 is used as an example of a layer thickness prescription | regulation member, this invention is not limited to this structure, You may use a textile fabric as an example of a layer thickness prescription | regulation member. In addition, the thing similar to the fiber applicable to the above-mentioned nonwoven fabric 42 can be used for a textile fabric. Further, even when a woven fabric is used instead of the nonwoven fabric 42, the same effect as that of the first embodiment can be obtained. Furthermore, as an example of the layer thickness regulating member, a fiber body in which insulating fibers are arranged in one direction may be used. Furthermore, you may use solid substances, such as a glass bead, as an example of a layer thickness prescription | regulation member. Thus, even if solid matter is mixed into the adhesive to form the adhesive layer 40, the effect of securing (specifying) the layer thickness of the adhesive layer 40 can be obtained.

また、前述の実施形態のサイドフレーム１０の製造方法では、サイドフレーム補強板３０をサイドフレーム基板２０に接着層４０を介して貼り合せた後でプレス成形をしているが、本発明はこの製造方法に限定されず、図８に示すように、サイドフレーム補強板３０を貼り合せたサイドフレーム基板２０を、減圧装置７０の袋状の減圧バック７２内に収容し、減圧バック７２内を減圧器７４（所謂真空ポンプ）で減圧して接着層４０内の空気抜き（真空引き）を行ってからプレス成形を行ってもよい。このように、減圧（真空引き）を行うことで、接着層４０内の空気入りを抑制することができ、サイドフレーム基板２０とサイドフレーム補強板３０と接着力を高めることができる。
なお、プレス成形機に減圧機能を持たせてプレス成形と同時に減圧を行ってもよい、 Moreover, in the manufacturing method of the side frame 10 of the above-described embodiment, the side frame reinforcing plate 30 is press-molded after being bonded to the side frame substrate 20 via the adhesive layer 40. Without being limited to the method, as shown in FIG. 8, the side frame substrate 20 to which the side frame reinforcing plate 30 is bonded is housed in a bag-like decompression bag 72 of the decompression device 70, and the decompression bag 72 is filled with a decompressor. Press molding may be performed after the pressure is reduced by 74 (so-called vacuum pump) to release air from the adhesive layer 40 (evacuation). Thus, by performing pressure reduction (evacuation), it is possible to suppress air in the adhesive layer 40 and to increase the adhesive force between the side frame substrate 20 and the side frame reinforcing plate 30.
Note that the press molding machine may have a pressure reducing function to perform pressure reduction simultaneously with press molding.

第１実施形態のＳＢサイドフレーム１０は、サイドフレーム基板２０のシート幅方向外側に接着層４０とサイドフレーム補強板３０を順次配置して形成されているが、本発明はこの構成に限定されず、ＳＢサイドフレーム１０は、サイドフレーム基板２０のシート幅方向内側に接着層４０とサイドフレーム補強板３０を順次配置して形成されてもよい。この場合でも第１実施形態と同様の作用効果を得ることができる。   The SB side frame 10 of the first embodiment is formed by sequentially arranging the adhesive layer 40 and the side frame reinforcing plate 30 on the outer side of the side frame substrate 20 in the sheet width direction, but the present invention is not limited to this configuration. The SB side frame 10 may be formed by sequentially arranging the adhesive layer 40 and the side frame reinforcing plate 30 inside the side frame substrate 20 in the sheet width direction. Even in this case, the same effects as those of the first embodiment can be obtained.

また、第１実施形態のＳＢサイドフレーム１０は、サイドフレーム基板２０の外周面２０Ａ全体が接着層４０を介してサイドフレーム補強板３０によって覆われているが、本発明はこの構成に限定されず、ＳＢサイドフレーム１０は、サイドフレーム基板２０の外周面２０Ａの一部を接着層４０を介してサイドフレーム補強板３０で覆う構成であってもよい。例えば、サイドフレーム基板２０の外周面２０Ａの短手方向（ＳＢサイドフレーム１０の短手方向と同義）の両端部（例えば、図１で折り返された部分）を接着層４０を介してサイドフレーム補強板３０で覆う構成（すなわち、サイドフレーム基板２０の外周面２０Ａの短手方向の中央部を除いた部分をサイドフレーム補強板３０で覆う構成）としてもよい。   In the SB side frame 10 of the first embodiment, the entire outer peripheral surface 20A of the side frame substrate 20 is covered with the side frame reinforcing plate 30 via the adhesive layer 40, but the present invention is not limited to this configuration. The SB side frame 10 may have a configuration in which a part of the outer peripheral surface 20A of the side frame substrate 20 is covered with the side frame reinforcing plate 30 via the adhesive layer 40. For example, both ends of the outer peripheral surface 20A of the side frame substrate 20 in the short direction (synonymous with the short direction of the SB side frame 10) (for example, the portion folded in FIG. 1) are side frame reinforced via the adhesive layer 40. It is good also as a structure covered with the board 30 (namely, the structure which covers the part except the center part of the transversal direction 20A of the outer peripheral surface 20A of the side frame board | substrate 20 with the side frame reinforcement board 30).

第１実施形態では、本発明の複合材をＳＢサイドフレーム１０に用いたが、本発明はこの構成に限定されず、シートバックフレーム１２０を構成する他の部材（例えば、アッパーパネル１２４）に用いてもよい。また、シートクッションフレーム１１０を構成する部材（例えば、ＳＣサイドフレーム１１２）などに用いてもよい。さらに、本発明の複合材を車体のＢピラー（又はセンターピラー）やボンネットなどの車体を構成する部材に用いてもよい。   In the first embodiment, the composite material of the present invention is used for the SB side frame 10. However, the present invention is not limited to this configuration, and is used for other members (for example, the upper panel 124) constituting the seat back frame 120. May be. Moreover, you may use for the member (for example, SC side frame 112) which comprises the seat cushion frame 110, etc. Furthermore, you may use the composite material of this invention for the members which comprise vehicle bodies, such as B pillar (or center pillar) of a vehicle body, and a bonnet.

前述の実施形態では、本発明の複合部材を自動車を構成する部材に用いているが、本発明はこの構成に限定されず、複合部材を自動車以外（例えば、航空機や船舶など）の機器を構成する部材にも用いてもよい。   In the above-described embodiment, the composite member of the present invention is used as a member constituting an automobile. However, the present invention is not limited to this structure, and the composite member constitutes a device other than an automobile (for example, an aircraft or a ship). You may use also for the member to do.

以上、実施形態を挙げて本発明の実施の形態を説明したが、これらの実施形態は一例であり、要旨を逸脱しない範囲内で種々変更して実施できる。また、本発明の権利範囲がこれらの実施形態に限定されないことは言うまでもない。   The embodiments of the present invention have been described above with reference to the embodiments. However, these embodiments are merely examples, and various modifications can be made without departing from the scope of the invention. It goes without saying that the scope of rights of the present invention is not limited to these embodiments.

（試験例）
次に、本発明の複合材の効果を確かめるために、本発明の複合材を用いたＳＢサイドフレームを有するシートバックフレームを２種、本発明の複合材を用いていないＳＢサイドフレームを有するシートバックフレームを４種用意し、各シートバックフレームにシート後方のモーメントを作用させたときのＳＢサイドフレームの最大荷重（破壊（剥離）荷重）及び最大変位（破断までの許容変形量（最大許容せん断歪量））を測定し、表１に示した。また、ＳＢサイドフレームの設計上の最大荷重をＳＰＥＣ、設計上の最大変位をＳＰＥＣ変位として表１に示した。なお、ＳＢサイドフレームの最大変位は、左右一対のＳＢサイドフレームのそれぞれの最大変位（ＲＨ変位、ＬＨ変位）の平均値である。また、図１０では、実施例１、比較例１、２の各ＳＢサイドフレームの荷重と変位量の関係をグラフとして示した。 (Test example)
Next, in order to confirm the effect of the composite material of the present invention, two types of seat back frames having an SB side frame using the composite material of the present invention and a sheet having an SB side frame not using the composite material of the present invention Four types of back frames are prepared, and the maximum load (breaking (peeling) load) and maximum displacement (allowable deformation (maximum allowable shear) until breaking when the moment behind the seat is applied to each seat back frame. The amount of strain)) was measured and is shown in Table 1. Table 1 shows the maximum design load of the SB side frame as SPEC and the maximum design displacement as SPEC displacement. The maximum displacement of the SB side frame is an average value of the maximum displacements (RH displacement, LH displacement) of the pair of left and right SB side frames. Further, in FIG. 10, the relationship between the load and the displacement amount of each SB side frame in Example 1 and Comparative Examples 1 and 2 is shown as a graph.

供試ＳＢサイドフレームのサイドフレーム基板は、板厚０．５ｍｍのＳＰＦＣ５９０で形成され、サイドフレーム補強板は厚み０．２２ｍｍのＣＦＲＰのプリプレグ素材を８層積層して形成されている。なお、実施例１、２のＳＢサイドフレームは、エポキシ樹脂と不織布で構成された接着層を用いているため、層厚が７０μｍｍとなっている。一方、比較例２〜４のＳＢサイドフレームは、エポキシ樹脂のみで構成された接着層を用いているため、接着層の厚みを確保できず層厚が７０μｍｍよりも大幅に下回っている。   The side frame substrate of the test SB side frame is formed of SPFC590 having a thickness of 0.5 mm, and the side frame reinforcing plate is formed by stacking eight layers of CFRP prepreg material having a thickness of 0.22 mm. In addition, since the SB side frame of Example 1, 2 uses the contact bonding layer comprised with the epoxy resin and the nonwoven fabric, the layer thickness is 70 micrometers. On the other hand, since the SB side frames of Comparative Examples 2 to 4 use the adhesive layer composed only of the epoxy resin, the thickness of the adhesive layer cannot be ensured and the layer thickness is significantly less than 70 μm.

比較例１のＳＢサイドフレームは、サイドフレーム補強板のマトリクス樹脂を接着剤としてサイドフレーム基板にサイドフレーム補強板を貼り合せる「従来工程」で成形されている。
比較例２〜４、実施例１、２の各ＳＢサイドフレームは、サイドフレーム基板とサイドフレーム補強板を未硬化の接着層で貼り合せ、真空引きを行った後、プレス成形を行いつつ接着層を硬化させてサイドフレーム基板にサイドフレーム補強板を貼り合せる「改良工程」で成形されている。 The SB side frame of Comparative Example 1 is formed by a “conventional process” in which the side frame reinforcing plate is bonded to the side frame substrate using the matrix resin of the side frame reinforcing plate as an adhesive.
In each of the SB side frames of Comparative Examples 2 to 4 and Examples 1 and 2, the side frame substrate and the side frame reinforcing plate were bonded together with an uncured adhesive layer, and after vacuuming, the adhesive layer was subjected to press molding. Is cured in an “improving step” in which a side frame reinforcing plate is bonded to the side frame substrate.

Figure 2014136383
Figure 2014136383

表１に示すように、実施例１、２では、比較例２〜４に比べて、接着層の層厚が必要な厚み分確保されているため、許容せん断歪量の増加により、最大荷重が向上し、最大変位も向上している。
また、実施例１では、サイドフレーム基板にプラズマ処理を施していることから、実施例２よりも接着層とサイドフレーム基板の接着力が向上しているため、最大荷重及び最大変位が向上している。 As shown in Table 1, in Examples 1 and 2, compared to Comparative Examples 2 to 4, since the required thickness of the adhesive layer is secured, the maximum load is increased due to an increase in the allowable shear strain amount. The maximum displacement is also improved.
Further, in Example 1, since the side frame substrate is subjected to the plasma treatment, the adhesive force between the adhesive layer and the side frame substrate is improved as compared with Example 2, so that the maximum load and the maximum displacement are improved. Yes.

１０ ＳＢサイドフレーム（複合材）
２０ サイドフレーム基板（金属板）
２０Ａ 外周面（貼り合せ面）
３０ サイドフレーム補強板（繊維強化樹脂板）
３０Ａ 内周面（貼り合せ面）
４０ 接着層
４２ 不織布（層厚規制部材） 10 SB side frame (composite material)
20 Side frame substrate (metal plate)
20A Outer peripheral surface (bonding surface)
30 Side frame reinforcement plate (fiber reinforced resin plate)
30A Inner peripheral surface (bonding surface)
40 Adhesive layer 42 Non-woven fabric (layer thickness regulating member)

Claims (6)

金属板と繊維強化樹脂板を接着層で貼り合せた複合材であって、
前記金属板と前記繊維強化樹脂板に挟まれ、前記接着層の層厚を規定する層厚規定部材を有する複合材。 A composite material in which a metal plate and a fiber reinforced resin plate are bonded together with an adhesive layer,
A composite material having a layer thickness defining member which is sandwiched between the metal plate and the fiber reinforced resin plate and defines the thickness of the adhesive layer. 前記層厚規定部材は絶縁性を有する請求項１に記載の複合材。   The composite material according to claim 1, wherein the layer thickness defining member has an insulating property. 前記層厚規定部材は不織布または織物である請求項１または請求項２に記載の複合材。   The composite material according to claim 1, wherein the layer thickness defining member is a nonwoven fabric or a woven fabric. 金属板と繊維強化樹脂板の貼り合せ面に接着層と前記接着層の層厚を規定する層厚規定部材を配置する工程と、
前記金属板と前記繊維強化樹脂板をプレス成形して、前記金属板と前記繊維強化樹脂板を貼り合せる工程と、
を有する複合材の製造方法。 A step of disposing an adhesive layer and a layer thickness defining member defining the layer thickness of the adhesive layer on a bonding surface of the metal plate and the fiber reinforced resin plate;
Press-molding the metal plate and the fiber-reinforced resin plate, and bonding the metal plate and the fiber-reinforced resin plate;
The manufacturing method of the composite material which has this. プレス成形する前に前記接着層を真空引きする工程を有する請求項４に記載の複合材の製造方法。   The manufacturing method of the composite material of Claim 4 which has the process of evacuating the said adhesive layer before press-molding. 前記金属板と前記繊維強化樹脂板を製品形状に曲げ加工した後で、前記金属板と前記繊維強化樹脂板の貼り合せ面に前記接着層と前記層厚規定部材を配置する請求項４または請求項５に記載の複合材の製造方法。   5. The adhesive layer and the layer thickness regulating member are disposed on a bonding surface of the metal plate and the fiber reinforced resin plate after the metal plate and the fiber reinforced resin plate are bent into a product shape. Item 6. A method for producing a composite material according to Item 5.
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