JP2015174247A - 複合構造体及びその製造方法 - Google Patents

複合構造体及びその製造方法 Download PDF

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Publication number
JP2015174247A
JP2015174247A JP2014050751A JP2014050751A JP2015174247A JP 2015174247 A JP2015174247 A JP 2015174247A JP 2014050751 A JP2014050751 A JP 2014050751A JP 2014050751 A JP2014050751 A JP 2014050751A JP 2015174247 A JP2015174247 A JP 2015174247A
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Japan
Prior art keywords
base member
composite structure
reinforcing member
reinforcing
slit
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
JP2014050751A
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English (en)
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JP5959558B2 (ja
Inventor
山下　祐司
Yuji Yamashita
祐司 山下
近藤　清人
Kiyoto Kondo
清人 近藤
澤田　義政
Yoshimasa Sawada
義政 澤田
浩和 河邊
Hirokazu Kawabe
浩和 河邊
好輝 稲本
Yoshiteru Inamoto
好輝 稲本
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Aisin Takaoka Co Ltd
Toyota Motor Corp
Original Assignee
Aisin Takaoka Co Ltd
Toyota Motor Corp
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Publication date
Application filed by Aisin Takaoka Co Ltd, Toyota Motor Corp filed Critical Aisin Takaoka Co Ltd
Priority to JP2014050751A priority Critical patent/JP5959558B2/ja
Priority to CN201580013464.9A priority patent/CN106103060B/zh
Priority to US15/125,538 priority patent/US10328660B2/en
Priority to DE112015001228.1T priority patent/DE112015001228T5/de
Priority to PCT/IB2015/051751 priority patent/WO2015136451A1/en
Publication of JP2015174247A publication Critical patent/JP2015174247A/ja
Application granted granted Critical
Publication of JP5959558B2 publication Critical patent/JP5959558B2/ja
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Abstract

【課題】接合部における歪みや剥離の発生を良好に抑制すること。
【解決手段】本発明は、金属材料からなるベース部材と、強化繊維が一方向に配向した繊維強化プラスチックからなり前記ベース部材に接合された補強部材と、を有する複合構造体において、強化繊維の配向方向に沿って補強部材にスリットが形成されていることを特徴とする。
【選択図】図１

Description

本発明は、繊維強化プラスチックと金属材料との複合構造体、及びその製造方法に関する。
この種の複合構造体及びその製造方法として、例えば、特開２０１０−１４９３５０号公報、国際公開第２０１３／１４６９００号、等に開示されたものが知られている。
特開２０１０−１４９３５０号公報 国際公開第２０１３／１４６９００号
この種の複合構造体において、繊維強化プラスチック部分と金属部品との接合部における歪みや剥離の発生（特に両者の熱膨張係数の相違に基づくもの）の懸念があった。本発明は、上記に例示した事情等に鑑みてなされたものである。
上記の課題に対処するため、請求項１に記載の発明は、金属材料からなるベース部材と、強化繊維が一方向に配向した繊維強化プラスチックからなり前記ベース部材に接合された補強部材と、を有する複合構造体において、前記補強部材には前記強化繊維の配向方向に沿ってスリットが形成されていることを特徴とする。
繊維強化プラスチックにおいては、強化繊維の配向方向（以下、単に「配向方向」と称することがある。）と、かかる配向方向と交差（典型的には直交）する方向とで、加熱・冷却時における膨張・収縮量が異なる。このため、繊維強化プラスチックとして、強化繊維が一方向に配向したもの（いわゆるＵＤ材：ＵＤはＵｎｉ Ｄｉｒｅｃｔｉｏｎの略）が用いられた場合、配向方向に起因して、膨張・収縮量の異方性が生じる。すなわち、ＵＤ材においては、配向方向に対して直交する方向における膨張・収縮量の方が、配向方向における膨張・収縮量よりも大きくなる。このような異方性に伴い、接合部における歪みや剥離の発生の懸念が生じる。
この点、請求項１に記載の発明によれば、金属部品であるベース部材とＵＤ材である補強部材との接合体である複合構造体において、補強部材に、強化繊維の配向方向に沿ったスリットが形成されている。これにより、配向方向に対して直交する方向における接合部の長さが削減され、以て当該方向における補強部材の膨張・収縮量が抑制される。したがって、本発明によれば、接合部における歪みや剥離の発生を良好に抑制しつつ、ＵＤ材による配向方向についての繊維強化特性を得ることが可能となる。
請求項２に記載の発明においては、熱硬化性樹脂を含有する補強部材が、ベース部材と直接接合されている。かかる構成によれば、上述の構成を有する複合構造体が、簡易な製造工程によって得られる。
請求項３に記載の発明は、上記構成を有する複合構造体の製造方法であって、以下の工程を含むことを特徴とする：（１）上述のスリットに対応する形状を有する突起が設けられた一対の金型を用意し、（２）一対の金型の間に、ベース部材と、強化繊維が一方向に配向した繊維強化プラスチックのプリプレグからなる補強部材前駆体とを、強化繊維の配向方向が突起の長手方向に沿うようにセットし、（３）一対の金型を閉じ合わせることで、補強部材前駆体に対して所定形状への成形及びスリットの形成を行うとともに、ベース部材と補強部材前駆体との積層体を形成し、（４）一対の金型を閉じ合わせた状態で、一対の当該金型内にて積層体を加熱する。
請求項３に記載の発明によれば、上述の構成を有する複合構造体が、簡易な製造工程によって得られる。
本発明の一実施形態に係る複合構造体の概略構成を示す平面図。 図１における２−２断面図。 本発明の一実施形態に係る製造方法の説明図。 本発明の一実施形態に係る製造方法の説明図。 本発明の一実施形態に係る製造方法の説明図。 一変形例に係る複合構造体の概略構成を示す断面図。 図６に示された複合構造体の製造方法の説明図。 図６に示された複合構造体の製造方法の説明図。 図６に示された複合構造体の製造方法の説明図。 他の一変形例に係る複合構造体の概略構成を示す平面図。
以下、本発明を具体化した一実施形態を、図面を参照しつつ説明する。なお、変形例は、当該実施形態の説明中に挿入されると首尾一貫した一実施形態の説明の理解が妨げられるので、末尾にまとめて記載されている。
＜複合構造体の構成＞
図１は、本実施形態に係る複合構造体１０の平面図である。図２は、図１における２−２断面図である。以下、図１及び図２を参照しつつ、複合構造体１０の具体的構成について説明する。
複合構造体１０は、図１に示されているように所定の（図中上下方向と平行な）長手方向を有するとともに、図２に示されているように所謂「ハット形状」に形成されている。具体的には、複合構造体１０は、フランジ部１０ａと、第一Ｕ字部１０ｂと、接続部１０ｃと、第二Ｕ字部１０ｄと、フランジ部１０ｅと、を有している。
フランジ部１０ａは、上述の長手方向と平行な長手方向を有する平面視にて矩形状の平板状部分であって、複合構造体１０の幅方向（上述の長手方向と直交し且つ複合構造体１０の厚さ方向と直交する方向：図中左右方向）における一端側に設けられている。第一Ｕ字部１０ｂは、図２に示されているように、断面視にて略Ｕ字形状に形成された部分であって、その一端がフランジ部１０ａに接続されるとともに他端が接続部１０ｃに接続されている。
接続部１０ｃは、上述の長手方向と平行な長手方向を有する平面視にて矩形状の平板状部分であって、第一Ｕ字部１０ｂと第二Ｕ字部１０ｄとの間に設けられている。第二Ｕ字部１０ｄは、断面視にて第一Ｕ字部１０ｂと同様（具体的には略同一）の略Ｕ字形状に形成された部分であって、その一端が接続部１０ｃに接続されるとともに他端がフランジ部１０ｅに接続されている。フランジ部１０ｅは、上述の長手方向と平行な長手方向を有する平面視にて矩形状の平板状部分であって、フランジ部１０ａと同様（具体的には略同一）の形状に形成されている。
複合構造体１０は、薄板状の金属材料を上述のような形状に曲げ加工することで形成されたベース部材１１と、ＣＦＲＰ（炭素繊維強化プラスチック）からなりベース部材１１に接合された補強部材１２と、を備えている。すなわち、この複合構造体１０は、ＣＦＲＰと金属材料との積層（接合）構造を有している。特に、本実施形態においては、補強部材１２は、ベース部材１１との接合部にて、熱硬化性樹脂を含有するように設けられている。具体的には、本実施形態においては、熱硬化性樹脂を含有する補強部材１２が、付加的な接着層を介さずに、ベース部材１１と直接接合されている。
ここで、本実施形態においては、この複合構造体１０は、長手方向についての強化が要求されているものとする。このため、本実施形態においては、補強部材１２は、複合構造体１０における所定の強度が必要な部分（具体的には第一Ｕ字部１０ｂ、接続部１０ｃ、及び第二Ｕ字部１０ｄ）にのみ設けられていて、その他の部分（具体的にはフランジ部１０ａ及び１０ｅ）については補強部材１２の設置が省略されている。また、補強部材１２は、一方向に揃えられた連続炭素繊維（長繊維）を含む、いわゆるＵＤ材であって、複合構造体１０の長手方向についての強化のため、配向方向が上述の長手方向に沿った方向（例えば平行）となるように設けられている。
補強部材１２には、スリット１３が、配向方向に沿って（具体的には配向方向と略平行に）形成されている。スリット１３は、ベース部材１１の内面（補強部材１２が接合されている側の表面）を露出させるように、補強部材１２の長手方向における全体にわたって設けられている。また、本実施形態においては、スリット１３は、第一Ｕ字部１０ｂの幅方向における略中央位置、及び第二Ｕ字部１０ｄの幅方向における略中央位置に配設されている。
＜製造方法＞
次に、上述の構成を有する複合構造体１０の製造方法について、図３〜図５を用いて説明する。
一対の金型のうちの固定型（雌型ともいう）である下型２０には、ハット形状に予め形成されたベース部材１１の外面（上述の内面とは反対側の面）と当接するように形成された凹部であるキャビティ２１が設けられている。また、下型２０の内部には、キャビティ２１の内面に沿って、加熱用のヒータ２２が設けられている。
一対の金型のうちの移動型（雄型ともいう）である上型３０には、上述のベース部材１１の内面に沿った形状（すなわち第一Ｕ字部１０ｂ及び第二Ｕ字部１０ｄに対応する形状）の凸部３１が設けられている。すなわち、凸部３１は、図３における紙面と垂直な方向の長手方向を有するように形成されている。
凸部３１の幅方向（長手方向と直交し且つ凸部３１の突出方向と直交する方向：図中左右方向）における略中央部には、上述のスリット１３（図１及び図２参照）に対応する形状を有するスリット形成突起３１ａが形成されている。すなわち、スリット形成突起３１ａは、上述のスリット１３と略同一の長さを有するレール状の突起であって、凸部３１の長手方向と平行な長手方向を有するように設けられている。また、上型３０の内部には、凸部３１の外面に沿って、加熱用のヒータ３２が設けられている。
図３に示されているように、最初に、下型２０に、金属部品であるベース部材１１がセット（配置）される。また、上型３０と、ベース部材１１がセットされた下型２０と、の間に、シート状のプリプレグ４１がセット（配置）される。ここで、本発明の「補強部材前駆体」としてのプリプレグ４１は、硬化前の熱硬化性樹脂を含有する、ＵＤ材のプリプレグである。このプリプレグ４１は、強化繊維の配向方向がスリット形成突起３１ａの長手方向に沿うように（具体的には当該長手方向と略平行となるように）セットされる。
次に、図４に示されているように、下型２０と上型３０とを閉じ合わせる。これにより、プリプレグ４１が、ベース部材１１の内面形状に倣ったハット形状に成形されつつ、ベース部材１１と積層される。このとき、スリット形成突起３１ａがプリプレグ４１内に侵入することで、プリプレグ４１に、スリット１３の形状に相当するスリット４２が形成される。
続いて、図４に示されている状態で、プリプレグ４１とベース部材１１との積層体は、ヒータ２２及び３２により所定温度・所定時間加熱される。これにより、プリプレグ４１にて熱硬化性樹脂の硬化反応が進行して、スリット１３を有する補強部材１２が生成するとともに、ベース部材１１と補強部材１２とが積層されつつ互いに強固に接合される。その後、図５に示されているように、下型２０と上型３０とが開型され、成形された複合構造体１０が抜き取り可能となる。
＜作用・効果＞
本実施形態の複合構造体１０においては、金属部品であるベース部材１１とＵＤ材である補強部材１２との接合体である複合構造体１０において、補強部材１２に、強化繊維の配向方向に沿ったスリット１３が形成されている。これにより、配向方向に対して直交する幅方向における接合部の長さが削減され、以て当該幅方向における補強部材１２の膨張・収縮量が抑制される。したがって、かかる構成によれば、接合部における歪みや剥離の発生を良好に抑制しつつ、ＵＤ材による配向方向についての繊維強化特性を得ることが可能となる。
特に、本実施形態の構成のように、熱硬化性樹脂を含むＣＦＲＰと金属部品との接合の場合、完成品の使用環境下における膨張・収縮のみならず、製造工程における硬化反応に起因する収縮と硬化後の冷却に起因する収縮とが問題となる。この点、本実施形態の構成によれば、熱硬化性樹脂を含むＣＦＲＰである補強部材１２と、金属部品であるベース部材１１と、の接合に際しても、接合部における歪みや剥離の発生が良好に抑制され得る。
また、本実施形態の複合構造体１０においては、補強部材１２が、ベース部材１１との接合部にて熱硬化性樹脂を含有している。具体的には、ベース部材１１と、熱硬化性樹脂を含有する補強部材１２とが、直接接合されている。したがって、かかる構成によれば、ベース部材１１の内面に補強部材１２との接着性を向上するための前処理（表面処理：鍍金処理、プラズマ処理、ブラスト処理、等。）を行ったり、ベース部材１１と補強部材１２との間に特別な接着層（接合層）を設けたりしなくても、ベース部材１１と補強部材１２との接合が良好に行われる。また、上述の構成を有する複合構造体１０が、簡易な製造工程によって得られる。
さらに、本実施形態の複合構造体１０及びその製造方法によれば、補強部材１２の成形と、成形した補強部材１２とベース部材１１との接合とを、同時に行うことで、工程数の削減及びこれによる製品の低コスト化が可能となる。
＜変形例＞
以下、代表的な変形例について、幾つか例示する。以下の変形例の説明において、上述の実施形態にて説明されているものと同様の構成及び機能を有する部分に対しては、上述の実施形態と同様の符号が用いられ得るものとする。そして、かかる部分の説明については、技術的に矛盾しない範囲内において、上述の実施形態における説明が適宜援用され得るものとする。もっとも、言うまでもなく、変形例とて、以下に列挙されたものに限定されるものではない。また、上述の実施形態の一部、及び、複数の変形例の全部又は一部が、技術的に矛盾しない範囲内において、適宜、複合的に適用され得る。
本発明は、上述したような具体的な構成及び製造方法の例示に限定されない。例えば、複合構造体１０の形状は、上述のようなハット形状に限定されない。具体的には、複合構造体１０は、略平板状であってもよい。また、補強部材１２は、ＣＦＲＰに限定されない。また、補強部材１２における配向方向は、複合構造体１０の実際の使用条件における外力あるいは内部応力の方向等に応じて、上述の長手方向に対して所定角度傾斜した方向に設定され得る。
図６に示されているように、スリット１３を形成するための突起である隆起部１１１が、ベース部材１１に設けられていてもよい。この場合、隆起部１１１における、ベース部材１１の外面側には、スリット１３と平行な凹部である金型突起収容部１１２が設けられている。この金型突起収容部１１２は、スリット１３と略同一の長さに形成されている。かかる変形例の複合構造体１０の製造方法について、図７〜図９を用いて説明する。
本変形例における下型２０のキャビティ２１には、スリット対応突起２１１が、上型３０に向かって突出するように設けられている。スリット対応突起２１１は、図８に示されているように、スリット１３に対応する位置及び形状に形成されている。すなわち、このスリット対応突起２１１は、ベース部材１１に設けられた金型突起収容部１１２に嵌合するように設けられている。その一方で、上型３０における凸部３１には、上述のレール状の突起（図３におけるスリット形成突起３１ａ参照）が省略されている。
図７に示されているように、最初に、下型２０に設けられたスリット対応突起２１１がベース部材１１に設けられた金型突起収容部１１２に嵌合する（収容される）ように、ベース部材１１が下型２０にセット（配置）される。また、上型３０と、ベース部材１１がセットされた下型２０と、の間に、シート状のプリプレグ４１が、強化繊維の配向方向がスリット対応突起２１１の長手方向に沿うように（具体的には当該長手方向と略平行となるように）セットされる。
次に、図８に示されているように、下型２０と上型３０とを閉じ合わせる。これにより、プリプレグ４１が、ベース部材１１の内面形状に倣ったハット形状に成形されつつ、ベース部材１１と積層される。このとき、スリット対応突起２１１に支持された隆起部１１１がプリプレグ４１内に侵入することで、プリプレグ４１に、スリット１３の形状に相当するスリット４２が形成される。
続いて、図８に示されている状態で、プリプレグ４１とベース部材１１との積層体は、ヒータ２２及び３２により所定温度・所定時間加熱される。これにより、プリプレグ４１にて熱硬化性樹脂の硬化反応が進行して、スリット１３を有する補強部材１２が生成するとともに、ベース部材１１と補強部材１２とが積層されつつ互いに強固に接合される。その後、図９に示されているように、下型２０と上型３０とが開型され、成形された複合構造体１０が抜き取り可能となる。
プリプレグ４１は、予め補強部材１２に対応する形状に成形されていてもよい。この場合、かかる成形体は、下型２０と上型３０とを閉じ合わせる前に、ベース部材１１とともに下型２０にセットされ得る。あるいは、図３において、下型２０にベース部材１１をセットすることに代えて、ベース部材１１の基となる金属板が、プリプレグ４１と下型２０との間に挿入され得る。この場合、閉型及びこれに続く加熱（図４参照）によって、ベース部材１１及び補強部材１２の成形と接合とが同時に行われ得る。
ベース部材１１の内面には、上述の前処理が行われてもよい（特に補強部材１２が熱可塑性ＦＲＰである場合）。なお、補強部材１２が熱可塑性ＦＲＰである場合、閉型前にて、硬化前の熱硬化性樹脂のシート（熱硬化性樹脂前駆体シート）が、ベース部材１１と補強部材１２との間に挿入され得る。すると、熱硬化性樹脂からなる接着層を介して、ベース部材１１と補強部材１２との接合が形成される。かかる構成及び製造方法によれば、ベース部材１１の内面に上述の前処理が行われなくても、ベース部材１１と、熱可塑性ＦＲＰからなる補強部材１２と、の接合が、良好に行われる。
スリット１３の数や位置についても、特段の限定はない。すなわち、例えば、図１０に示されているように、スリット１３は、接続部１０ｃにも設けられていてもよい。
この場合、接続部１０ｃにおけるスリット１３は、補強部材１２の幅方向における略中央部に設けられ得る。また、第一Ｕ字部１０ｂにおけるスリット１３は、第一Ｕ字部１０ｂの幅方向における略中央部よりも接続部１０ｃ寄りの位置に設けられ得る。同様に、第二Ｕ字部１０ｄにおけるスリット１３は、第二Ｕ字部１０ｄの幅方向における略中央部よりも接続部１０ｃ寄りの位置に設けられ得る。
図１０に記載された構成によれば、３分割された補強部材１２のそれぞれにおける、ベース部材１１との接合部長さを、略同一に設定することが可能となる。これにより、接合部における歪みや剥離の発生が、よりいっそう良好に抑制され得る。
その他、特段に言及されていない変形例についても、本発明の本質的部分を変更しない範囲内において、本発明の技術的範囲に含まれることは当然である。また、本発明の課題を解決するための手段を構成する各要素における、作用・機能的に表現されている要素は、上述の実施形態や変形例にて開示されている具体的構成及びその均等物の他、当該作用・機能を実現可能ないかなる構成をも含む。
１０…複合構造体、１１…ベース部材、１１１…隆起部、１２…補強部材、１３…スリット、２０…下型、２１…キャビティ、２１１…スリット対応突起、２２…ヒータ、３０…上型、３１…凸部、３１ａ…スリット形成突起、３２…ヒータ、４１…プリプレグ。

Claims (3)

  1. 金属材料からなるベース部材と、
    強化繊維が一方向に配向した繊維強化プラスチックからなり、前記ベース部材に接合された、補強部材と、
    を有し、
    前記補強部材には、前記強化繊維の配向方向に沿ってスリットが形成されたことを特徴とする、複合構造体。
  2. 前記補強部材は、熱硬化性樹脂を含有するものであって、前記ベース部材と直接接合されたことを特徴とする、請求項１に記載の複合構造体。
  3. 請求項１又は２に記載の複合構造体の製造方法であって、
    前記スリットに対応する形状を有する突起が設けられた一対の金型を用意し、
    一対の前記金型の間に、前記ベース部材と、強化繊維が一方向に配向した繊維強化プラスチックのプリプレグからなる補強部材前駆体とを、前記強化繊維の配向方向が前記突起の長手方向に沿うようにセットし、
    一対の前記金型を閉じ合わせることで、前記補強部材前駆体に対して所定形状への成形及び前記スリットの形成を行うとともに、前記ベース部材と前記補強部材前駆体との積層体を形成し、
    一対の前記金型を閉じ合わせた状態で、一対の当該金型内にて前記積層体を加熱する、
    ことを特徴とする、複合構造体の製造方法。
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