JP2017030165A - Carbon fiber composite material, and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a carbon fiber composite material with increased bonding strength of a bonding component, and a method of manufacturing the same.SOLUTION: A laminate 52 in which a resin-impregnated foam body 56 formed by impregnating thermosetting resin into a foam body having open cells is laminated between a plurality of carbon fiber prepregs 54 formed by impregnating thermosetting resin into carbon fiber cloth, is compressed by a molding tool 60 holding a bonding component 30 from a lamination direction of the laminate 52, the carbon fiber prepreg 54 on the outermost layer compressed by the bonding component 30 is deformed to follow an outer face shape of the bonding component 30, and the resin-impregnated foam body 56 is compressively deformed to follow the carbon fiber prepreg 54 of the outermost layer. Then, the laminate 52 is thermally set in a compressed state, a carbon fiber cloth hardened layer 14 formed by hardening the carbon fiber prepreg 54 and a foam body hardened layer 16 in which the resin-impregnated foam body 56 is hardened by deforming to follow the carbon fiber prepreg 54 are unified, and the bonding component 30 is embedded in an exposed state on an outer surface.SELECTED DRAWING: Figure 4

Description

  The present invention relates to a carbon fiber composite material in which a plurality of carbon fiber cloth cured layers obtained by curing a thermosetting resin impregnated in a carbon fiber woven fabric are laminated, and a method for producing the same.

  Plastics reinforced with carbon fiber are used for materials that require both light weight and high rigidity, such as casings and machine parts for OA equipment such as notebook computers and printers, fishing rods, and vehicle parts such as automobiles and bicycles. Has been. As this carbon fiber reinforced plastic, a carbon fiber cloth such as a carbon fiber woven carbon fiber sheet is impregnated with a thermosetting resin and a plurality of semi-dried carbon fiber prepregs are stacked and compressed with a mold. Carbon fiber composites integrated by heating have been put into practical use (see, for example, Patent Document 1).

JP 2004-209717 A JP 58-92522 A

  In many cases, the carbon fiber composite material formed into a required shape is formed as a product or a part of a product by being connected to other components. Here, in a metal or resin member, a tapping process is performed as a post-process after molding to form a screw hole, or a fastening part is provided by press-fitting a bolt, a nut, a pin, or the like into the lower hole, Other components are fastened using the fastening portion. However, in the carbon fiber composite material obtained by curing the carbon fiber prepreg, continuous fibers are mixed in the resin layer or short fibers are dispersed in the resin layer. However, the fiber is divided, and the thread groove is not reversed well in the resin layer, so that the processing itself is difficult.

  For this reason, with respect to the carbon fiber composite material, a method of sandwiching and fixing the joining component from the front and back of the carbon fiber composite material via the bracket is employed. However, the method using the bracket has disadvantages such as an increase in the number of parts, an increase in the number of work steps, and a restriction on the appearance.

  Here, Patent Document 2 discloses a technique for inserting a joining member into a carbon fiber composite material reinforced with carbon fiber pieces by injecting a resin into an injection mold in which the carbon fiber pieces and joining parts are arranged. Yes. However, since the carbon fiber composite material of Patent Document 2 needs to spread the resin injected into the mold in which the carbon fiber pieces are dispersed, if the blending amount (density) of the carbon fiber pieces is increased, It is feared that a resin deficiency or the like may occur to cause poor bonding, and the bonding strength of the bonded parts cannot be increased. Moreover, since it is difficult to control the uneven distribution of the carbon fiber pieces in the carbon fiber composite material, the bonding strength of the joining parts varies from product to product, and the location where the joining parts are arranged may be cracked or chipped. .

  That is, the present invention has been proposed in view of the above-mentioned problems inherent in the prior art, and provides a carbon fiber composite material with improved joint strength of a joined part and a method for producing the same. For the purpose.

In order to overcome the above-mentioned problems and achieve the intended purpose, the invention according to claim 1 of the present application provides:
A plurality of carbon fiber cloth cured layers in which the carbon fiber cloth is cured;
The foam cured layer is laminated between the carbon fiber cloth cured layers and integrated with the carbon fiber cloth cured layer, and the foam is cured in a compressed state.
A joining component joined in an embedded state in which a part is exposed from the carbon fiber cloth cured layer forming the outermost layer,
The joining component joined in an embedded state to the concave portion formed by the outermost carbon fiber cloth cured layer is surrounded by a carbon fiber cloth cured layer integrated with the foam cured layer in the concave portion forming portion. It is a summary.
According to this, the joining component is embedded in the concave concave portion formed by integrating the carbon fiber cloth cured layer formed by curing the carbon fiber cloth and the foam cured layer formed by compressing and curing the foam. Since it is joined, the carbon fiber cloth cured layer can be provided uniformly around the joined part. In other words, a carbon fiber cloth cured layer obtained by curing a carbon fiber cloth having excellent mechanical properties (high specific strength, high specific elasticity) surrounds the joined part, and the carbon fiber cloth cured layer is supported by the foam cured layer. By doing so, it is possible to prevent the joining component from falling off from the carbon fiber cloth cured layer, and to increase the joining strength of the joining component.

The invention according to claim 2
The gist is that the bonded part is engaged with the carbon fiber cloth cured layer forming the recessed part in the direction in which the bonded part is pulled out from the recessed part.
According to this, when a force acts in the direction in which the joined part is pulled out from the concave portion, the joined part is engaged with the carbon fiber cloth cured layer, thereby preventing the joined part from being pulled out.

Furthermore, regarding the invention including the configuration of claim 1, the invention having the following configuration can also be provided. That is, a carbon fiber cloth forming a surface layer impregnated with a thermosetting resin, a resin-impregnated foam laminated on the carbon fiber cloth and impregnated with a thermosetting resin, and the carbon fiber cloth are formed. A carbon fiber configured such that a bonded part integrally embedded in a concave part is in a state where the resin-impregnated foam embeds the bonded part and the carbon fiber cloth and the embedded part of the bonded member are in close contact with each other. The gist is that it is a composite material.
Furthermore, a plurality of the carbon fiber cloth and the resin-impregnated foam can be laminated. By laminating a plurality of layers, the strength and rigidity of the carbon fiber composite material are increased.

In order to overcome the above-mentioned problems and achieve the intended purpose, the invention according to claim 3 of the present application provides:
A layered product obtained by laminating a resin-impregnated foam obtained by impregnating a thermosetting resin into a foam having open cells and laminating between a plurality of carbon fiber prepregs obtained by impregnating a carbon fiber cloth with a thermosetting resin, The outermost carbon fiber prepreg compressed by the joining part is compressed by a molding die holding the joining part on the outer surface and deformed following the outer surface shape of the joining part, and the outermost carbon fiber is compressed. Following the prepreg, the resin-impregnated foam is compressed and deformed,
A carbon fiber cloth cured layer formed by curing the carbon fiber prepreg that is heated in a compressed state and is deformed following the outer surface shape of the joining component as the thermosetting resin is cured, and the carbon The gist is to embed the joint component in a state of being exposed to the outer surface by integrating a foam cured layer obtained by curing the resin-impregnated foam that has been deformed following the fiber prepreg.
According to this, by compressing and heating the laminate with the mold holding the joined parts, the carbon fiber cloth cured layer and the foam cured layer are integrated and exposed from the outermost carbon fiber cloth cured layer. The joining parts are buried in the state. When this laminate is compressed, the carbon fiber cloth prepreg is bent in accordance with the shape of the joining member, and at the same time, the resin-impregnated foam can be closely attached to the shape of the joining member due to its elastic characteristics, so that the joining component is Firmly fixed to the carbon fiber composite. Moreover, since the joining component is embedded while integrating the carbon fiber cloth cured layer and the foam cured layer, it is not necessary to provide a step of attaching the joining component separately from the step of compressing and heating with the molding die. Further, since the obtained carbon fiber composite material is surrounded by the carbon fiber cloth cured layer integrated with the foam cured layer in a form following the outer shape of the joined part, the carbon fiber is uniformly distributed around the joined part. A cloth cured layer can be provided. That is, a carbon fiber cloth cured layer obtained by curing a carbon fiber cloth having excellent mechanical properties (high specific strength, high specific elasticity) surrounds the joining component and supports the carbon fiber cloth cured layer with the foam cured layer. Accordingly, it is possible to obtain a carbon fiber composite material in which the joining component is prevented from falling off the carbon fiber cloth cured layer and the joining strength of the joining component is increased.

The invention according to claim 4
A state in which the outermost layer carbon fiber prepreg is deformed following the concavo-convex shape portion of the joint component by heating the laminate with the molding die holding the joint component provided with the concavo-convex shape portion. Then, the gist is to integrate the carbon fiber cloth cured layer and the foam cured layer.
According to this, since the carbon fiber cloth hardened layer is fitted to the concavo-convex shape portion formed in the joined part, the joining strength of the joined part can be further increased.

Furthermore, regarding the invention including the configuration of claim 3, the invention having the following configuration can also be provided. That is, a step of obtaining a carbon fiber prepreg by impregnating a carbon fiber cloth with a thermosetting resin, a step of obtaining a resin-impregnated foam by impregnating a foam with a thermosetting resin, and holding a joining component in a mold A step of laminating the carbon fiber prepreg on a mold holding the joining component, a step of laminating the resin-impregnated foam on the carbon fiber prepreg, and a step of compressing and heating the mold. A carbon fiber composite material comprising at least one step of forming a surface layer by laminating the carbon fiber prepreg on the mold and laminating the resin-impregnated foam on the carbon fiber prepreg. It is a manufacturing method.
Furthermore, the step of laminating the resin-impregnated foam on the carbon fiber prepreg may be performed a plurality of times.

  According to the carbon fiber composite material according to the present invention, the bonding strength of the bonded component can be increased. Moreover, according to the manufacturing method, a carbon fiber composite material having a high bonding strength of the bonded parts can be obtained.

It is a top view which shows roughly the principal part of the carbon fiber composite material which concerns on the Example of this invention. It is a perspective view which fractures | ruptures and shows the principal part of the carbon fiber composite material which concerns on an Example. (a) is a schematic sectional drawing in the AA line of FIG. 1, (b) is the schematic sectional drawing to which the arrangement | positioning position of the joining components in the BB line of (a) was expanded. It is the schematic which shows the manufacturing process of the carbon fiber composite material which concerns on an Example in a cross section, (a) shows the state before compressing and heating a laminated body with a shaping | molding die, (b) is a shaping | molding die for a laminated body The state compressed and heated by is shown.

  Next, the carbon fiber composite material and the method for producing the same according to the present invention will be described below with reference to the accompanying drawings, taking preferred examples.

(About carbon fiber composite material 10)
As shown in FIGS. 1 to 3, a carbon fiber composite material 10 according to the present invention includes a carbon fiber cloth cured layer 14 in which a carbon fiber cloth is cured, and a foam cured layer 16 in which the foam is cured in a compressed state. The joining component 30 is embedded in the integrated base material 12, and is configured to be detachably attachable to other components via the joining component 30. Specifically, the carbon fiber cloth cured layer 14 is a layer obtained by curing a carbon fiber prepreg 54 obtained by impregnating a carbon fiber cloth with a thermosetting resin, and the foam cured layer 16 is impregnated with a thermoplastic resin. It is a layer obtained by curing a foam having open cells in a compressed state. The carbon fiber composite material 10 is formed in a plate shape that can be used as an exterior plate of a vehicle interior part such as a door trim or a console box, and is connected to a base part of the vehicle interior part via a joining part 30. In the base 12 of the carbon fiber composite material 10, at least one foam cured layer 16 is laminated between a plurality of carbon fiber cloth cured layers 14, and the carbon fiber cloth cured layer 14, the foam cured layer 16 and the bonding are bonded. The parts 30 are integrated. The substrate 12 of the carbon fiber composite material 10 is configured by laminating a foam cured layer 16 between carbon fiber cloth cured layers 14 forming the front and back surfaces, and the outer surface (outermost layer) of the carbon fiber composite material 10 is carbon. It is formed by the fiber cloth cured layer 14. In the following description, in the carbon fiber composite material 10, one outer surface (the upper surface in FIG. 3A) in the thickness direction is referred to as a first outer surface 10A, and the other outer surface (FIG. 2) is referred to as a second outer surface 10B. There is a case.

  As shown in FIGS. 1, 2, and 3 (a), the substrate 12 of the carbon fiber composite material 10 has a recessed portion 20 that is recessed in the thickness direction (stacking direction) of the substrate 12. In addition, the joint component 30 is fixed in a state where the joint part 30 is fitted to the concave portion 20 so as to be entirely or partially embedded in the base material 12. The concave portion 20 is cured in a shape that follows so that the carbon fiber cloth (carbon fiber prepreg 54) that forms the outermost carbon fiber cloth cured layer 14 of the base material 12 is in close contact with the outer surface shape of the joining component 30. Thus, the outermost carbon fiber cloth cured layer 14 surrounds the outer surface of the joining component 30 that is formed in a concave shape in the thickness direction of the base material 12 and fitted into the concave portion 20. Yes. That is, a part of the joining component 30 is exposed to the outside of the base material 12 from the carbon fiber cloth cured layer 14 that forms the outermost layer through the opening of the concave portion 20. That is, the base material 12 is integrated with the foam cured layer 16 on the inner side with respect to the carbon fiber cloth cured layer 14 forming the concave portion 20, and the rigidity of the concave portion 20 is increased and bonded. The joint strength of the component 30 is increased. In other words, the outermost carbon fiber cloth cured layer 14 forming the concave portion 20 constitutes a bonding layer to be bonded to the bonded component 30, and the foam cured layer 16 integrated with the outermost carbon fiber cloth cured layer 14. Constitutes a support layer for supporting the carbon fiber cloth cured layer 14.

  Here, the concave portion 20 is located from the concave portion 20 to the enlarged portion 38 to be described later of the joining component 30 on the back side from the boundary edge 22 that forms a boundary with the first outer surface 10A of the carbon fiber composite material 10. A restricting portion that engages in the direction in which the joining component 30 is pulled out is formed. That is, in the direction in which the joining part 30 is pulled out from the concave part, the restricting part 26 formed by the carbon fiber cloth cured layer 14 forming the concave part 20 and the enlarged part 38 of the joining part 30 engage with each other. The extraction of the joining component 30 from the portion 20 is regulated. The restricting portion 26 is formed by expanding the inner diameter dimension of the recessed portion 20 on the back side from the forming position of the restricting portion 26 with respect to the inner diameter size of the recessed portion 20 at the forming position of the restricting portion 26. . Specifically, in FIG. 3A, the thickness direction and direction of the carbon fiber composite material 10 are matched with the outer shape of the joining component 30 on the peripheral surface between the boundary edge 22 and the bottom 24 of the concave portion 20. The restricting portion 26 is formed by the carbon fiber cloth cured layer 14 projecting in the intersecting direction (inside the recessed portion 20 (on the joining component 30 side)).

The carbon fiber cloth cured layer 14 is formed by curing a carbon fiber prepreg 54 in which the carbon fiber cloth is impregnated with a thermosetting resin. The carbon fiber cloth is formed by forming a carbon fiber into a sheet shape, and can be impregnated with a thermosetting resin, and is light and highly rigid. As the carbon fiber cloth, for example, a carbon fiber woven fabric woven with carbon fibers, a carbon fiber nonwoven fabric in which carbon fibers are combined in a sheet shape, or the like can be employed. Here, the carbon fiber cloth is preferably one in which the fibers are not only in one direction, for example, plain weave composed of warp and weft, twill weave, satin weave, and triaxial weave composed of three-direction yarn. preferable. The carbon fiber cloth preferably has a fiber weight of 90 to 400 g / m ² from the viewpoint of impregnation and rigidity of the thermosetting resin. When the fiber weight is less than 90 g / m ² , it is difficult to ensure sufficient strength and rigidity of the carbon fiber composite material 10. On the other hand, when the weight of the fiber exceeds 400 g / m ² , it becomes difficult to embed the bonding member 30 so as to be in close contact with the carbon fiber cloth cured layer 14 and integrally form the bonding member 30.

  The thermosetting resin impregnated in the carbon fiber cloth is not particularly limited, but in order to increase the rigidity of the carbon fiber composite material 10, the thermosetting resin itself has a certain degree of rigidity when cured. preferable. For example, as the thermosetting resin, a phenol resin, an epoxy resin, an epoxy acrylate resin, a vinyl ester resin, a mixture of a phenol resin and an epoxy resin, or the like can be adopted. In particular, as the thermosetting resin, a phenol resin compound having a high degree of cross-linking in which novolak dinuclear bodies are reduced is suitable. In addition, when the said carbon fiber composite material 10 requires a flame retardance, it is preferable to impregnate resin which shows favorable flame retardance like a phenol resin as the said thermosetting resin. The thermosetting resin is preferably diluted with a diluent such as alcohol in order to easily impregnate the carbon fiber cloth. Further, the amount of the thermosetting resin impregnated into the carbon fiber cloth is set so that the resin weight ratio of the thermosetting resin in the carbon fiber prepreg 54 is in the range of 30 to 80% in order to reduce the weight and increase the rigidity. It is preferable to set, and it is more preferable to set the resin weight ratio in the range of 40 to 70%. The resin weight ratio is (the difference between the total weight of the carbon fiber cloth and the foam before and after impregnation with the thermosetting resin) / (the total weight of the carbon fiber cloth and the foam after impregnating the thermosetting resin). ) × 100 (%). The weight after impregnating the thermosetting resin in the resin weight ratio formula is the weight after removing the solvent by drying after impregnation when the thermosetting resin is dissolved in the solvent. .

The foam forming the foam cured layer 16 is not particularly limited. As this foam, a foam having an open cell structure in which each bubble (cell) communicates is suitable, but a foam having a structure in which bubbles do not communicate can also be used. Here, since the foam has an open cell structure, it can be suitably impregnated with a thermosetting resin and can be molded at a high compression rate. Moreover, the foam of an open cell structure is suitable also for joining the said joining component 30 in the fitting state mentioned later. The foam can be selected from, for example, melamine resin foam, urethane resin foam, polyolefin (polyamide) resin foam, and the like. By selecting these materials as the foam for forming the foam cured layer 16, compression molding is possible to a thickness corresponding to the number of laminated carbon fiber cloths. In particular, the foam is preferably a melamine resin foam or a polyamide resin foam. When the carbon fiber composite material 10 is required to have flame retardancy, the impregnated thermosetting resin is preferably flame retardant, and the melamine resin foam has good flame retardancy. The carbon fiber composite material 10 is suitable. Although the thickness (original thickness) before compression of the foam can be appropriately set, for example, a range of 1 to 25 mm is given. In addition, the density of the foam before compression is preferably 5 to 80 kg / m ³ and more preferably 8 to 12 kg / m ³ from the viewpoints of ease of compression, impregnation, lightness, rigidity, and the like. Is more preferable. That is, when the density of the foam before compression is less than 5 kg / m ³ , it is difficult to sufficiently secure the strength and rigidity of the carbon fiber composite material 10. On the other hand, when the density of the foam before compression exceeds 80 kg / m ³ , it becomes difficult to impregnate the foam with the thermoplastic resin or compress the foam, or the weight of the carbon fiber composite material 10 increases. As a result, handling becomes a factor.

  The thermosetting resin impregnated in the foam is not particularly limited, but in order to increase the rigidity of the carbon fiber composite material 10, it is preferable that the thermosetting resin itself has a certain degree of rigidity when cured. For example, as the thermosetting resin, a phenol resin, an epoxy resin, a mixture of a phenol resin and an epoxy resin, or the like can be adopted. In particular, as the thermosetting resin, a phenol resin compound having a high degree of cross-linking in which novolak dinuclear bodies are reduced is suitable. In addition, when the said carbon fiber composite material 10 requires a flame retardance, it is preferable to impregnate resin which shows favorable flame retardance like a phenol resin as the said thermosetting resin. The thermosetting resin is preferably diluted with a diluent such as alcohol in order to easily impregnate the carbon fiber cloth. Further, the thermosetting resin impregnated in the carbon fiber prepreg 54 and the thermosetting resin impregnated in the foam may be the same type or different types, but the same type of thermosetting resin is impregnated. Preferably, when the laminate 52 is compression-cured, the adhesion between the carbon fiber cloth cured layer 14 and the foam cured layer 16 can be enhanced, and delamination can be remarkably suppressed, and both layers can be firmly integrated.

  As shown in FIGS. 1-3, as said joining component 30, in addition to components used for connection to other components such as screws, nuts and pins used for fastening with other members, it is for decoration Such a decorative part can be employed, and by embedding it in the concave portion 20 of the carbon fiber composite material 10, it is possible to firmly fix the joint part 30. In addition, the material of the said joining component 30 will not be specifically limited if it has the pressure resistance and heat resistance of the grade which can endure the compression and heating which are mentioned later. In the embodiment, a so-called insert nut made of metal having a screw hole 32 opened at one end surface is employed as the joining component 30. That is, the carbon fiber composite material 10 can be easily connected to other constituent members by screwing male screws provided on other constituent members into the screw holes 32 of the joining component 30. .

  In addition, the joining component 30 is provided so as to be fitted into the recessed portion 20 in a state where the opening surface 34 where the screw hole 32 opens from the first outer surface 10A of the carbon fiber composite material 10 is exposed. The joining component 30 is joined to the outermost carbon fiber cloth cured layer 14 that forms the structure. Thus, the joining component 30 is embedded in the thickness direction with respect to the base material 12 including the integrated carbon fiber cloth cured layer 14 and the foam cured layer 16 by fitting into the concave portion 20. It is fixed with. Here, the entire joining component 30 is not limited to a form in which the joining component 30 is embedded in the concave portion 20. For example, a joining component 30 longer than the depth of the concave portion 20 can be fitted so that a part of the joining component 30 protrudes from the concave portion 20 (not shown). In other words, only a portion of the joining component 30 that fits into the concave portion 20 is a joining portion that is joined in a state of being surrounded by the carbon fiber cloth cured layer 14.

  Here, the shape of the outer surface of the joining component 30 is not particularly limited, but it is a boundary from the bottom 24 side of the recessed portion 20 to the restricting portion 26 of the recessed portion 20 at the joining portion that fits into the recessed portion 20. It is preferable to provide a retaining portion 38 that abuts in the direction of the edge 22. Such a retaining portion 38 can be provided by forming the outer peripheral surface of the joining component 30 in a concavo-convex shape or by forming the outer shape on the back side of the concave portion 20. For example, in the joining component 30 shown in FIGS. 2 and 3, enlarged portions 38 and 40 having an outer shape larger than that of the shaft-shaped portion 36 are formed at both ends of the shaft-shaped portion 36, and are concave from the shaft-shaped portion 36. An enlarged portion 38 located on the back side of the portion 20 functions as the retaining portion. That is, the restricting portion 26 in which the carbon fiber cloth cured layer 14 and the foam cured layer 16 are formed in a form following the outer shape of the joining component 30 is formed by the shaft-shaped portion 36 and the enlarged portions 38 and 40. When the force acts on the joining part 30 in the direction of being pulled out from the recessed part 20 by fitting in the groove-like part between the enlarged parts 38 and 40 of the joining part 30 to be connected, the back side of the recessed part 20 The enlarged portion 38 located on the (bottom portion 24 side) engages with the restricting portion 26, and effectively prevents the joining component 30 from falling off the concave portion 20. In addition, when a force acts in the direction in which the joining component 30 is pushed into the back side of the concave portion 20, the carbon fiber cloth cured layer 14 is pushed into the restricting portion 26 by the elastic force of the foam cured layer 16, and the joining component 30. And the adhesion of the carbon fiber cloth cured layer 14 and the foam cured layer 16 are enhanced. Further, when a plurality of carbon fiber cloth cured layers 14 are laminated on the surface layer that forms the concave portion 20, the plurality of carbon fiber cloth cured layers 14 and the foam cured layer 16 are matched to the shape of the joining component 30. It is in close contact. Here, the plurality of carbon fiber cloth cured layers 14 follow the shape of the joining component 30 to a certain depth, but are broken in a deeper region. The break here means that the carbon fiber cloth is compressed by the bonding member 30, exceeds the elongation of the fiber cloth, breaks at the compression surface of the bonding member 30, and the bonding member 30 penetrates the fiber cloth. State. In the region compressed to the bottom of the joining component 30, the carbon fiber cloth cured layer 14 and the foam cured layer 16 of the front surface layer and the back surface layer (the first outer surface 10A and the second outer surface 10B) are compressed, and the foam is cured. Layer 16 is solid. Here, the retaining portion can also be formed by forming the joint component 30 in a cone shape, or by providing a recess or protrusion on the outer peripheral surface of the joint component 30. By forming the carbon fiber cloth hardened layer 14 and the foam hardened layer 16 in a form following the outer shape of the joint 30, it is possible to prevent the joining component 30 from being pulled out or pushed.

  Further, as shown in FIG. 3B, the joining component 30 has an axis that is the center line of the concave portion 20 (in the depth direction of the concave portion 20). It is preferable to provide a non-slip portion 42 that restricts rotation in the rotation direction. Such an anti-slip part 42 forms the outer peripheral surface of the joining part 30 in an uneven shape, or forms the cross-sectional shape of the joining part 30 in a direction intersecting the center line of the recessed part 20 in a noncircular shape. Can be provided. For example, in the joining component 30 shown in FIG. 3B and FIG. 2, an inclined groove portion that intersects the rotation direction with the center line of the concave portion 20 as the axis is formed on the outer peripheral surface of the enlarged portions 38 and 40 in the circumferential direction. A plurality of projections 42 formed by the groove portions function as the anti-slip portions. Further, by forming the groove portion so as to intersect with the direction in which the joining component 30 is pulled out from the concave portion 20, the protrusion 42 can be configured to function as the retaining portion.

  Such an anti-slip portion 42 can be formed by various processing methods capable of forming a concavo-convex shape on the outer peripheral surface of the joining component 30 such as so-called knurling or blasting. When forming the protrusions 42 by knurling, an oblique knurl in which the groove portion is inclined with respect to the center line of the concave portion 20, a flat knurling in which the groove portion extends along the center line of the concave portion 20, and the groove portion are used. A twill knurled or the like formed in a mesh shape can be employed. FIG. 2 shows a state in which the grooves are formed in a mesh shape. In other words, the anti-slip portion 42 is formed by fitting the carbon fiber into a gap between the minute protrusions 42 formed so as to protrude from the outer surface of the joining component 30. That is, the carbon fiber cloth cured layer 14 formed in a form following the outer surface shape of the joining component 30 is fitted into the anti-slip portion (projection) 42 of the joining component 30, so that the joining component is formed inside the recessed portion 20. It is possible to effectively prevent the joining component 30 from rotating when a force acts in the direction in which the 30 rotates. Such an anti-slip portion 42 is particularly effective when a component such as a bolt or a nut, on which a force acts in the rotational direction, is embedded as the joining component 30. The anti-slip portion 42 can also be formed by forming the cross-section of the joining component 30 into an ellipse or a polygon.

(About the manufacturing method of the carbon fiber composite material 10)
Next, the manufacturing method of the carbon fiber composite material 10 mentioned above is demonstrated. As shown in FIG. 4, the carbon fiber composite material 10 is manufactured using a mold 60. The mold 60 includes a first mold 62 having a first mold surface 62a for molding a first outer surface 10A (also referred to as a first surface layer) of the carbon fiber composite material 10, and a second outer surface 10B of the carbon fiber composite material 10. And a second mold 64 having a second mold surface 64a for molding (also referred to as a second surface layer). A holding means 66 is provided on the mold surfaces 62a and 64a of the mold 60 (first and second molds 62 and 64) to hold the joining component 30 in a state of being removable from the mold 60 after molding. Yes. Here, the joining component 30 may be held in one of the first and second molds 62 and 64, or may be held in both molds. That is, by compressing and heating the laminate 52 with the molding die 60 holding the joining component 30 in one mold, the joining component 30 can be embedded in one side of the carbon fiber composite material 10 obtained. By compressing and heating the laminated body 52 with the molding die 60 holding the joint component 30 on the surface, the joint component 30 can be embedded on both surfaces of the obtained carbon fiber composite material 10. In addition, the number of the joining components 30 held in the molding die 60 can be determined as appropriate, and the carbon fiber obtained by compressing and heating the laminate 52 with the molding die 60 holding a plurality of joining components 30 is obtained. A plurality of joining parts 30 can be embedded in the composite material 10. In FIG. 4, the joining component 30 is held by one holding means 66 formed on the first mold surface 62a. In FIG. 4, the holding means 66 is constituted by a pin inserted into the screw hole 32 of the joining component 30.

  Further, the first mold surface 62a is provided with an unevenness forming portion 68, and is configured to form unevenness at an appropriate position on the first outer surface 10A of the carbon fiber composite material 10 by compressing and heating the laminate 52. ing. The unevenness is not limited to the illustrated convex shape or concave shape, and may be a gentle unevenness formed by a raised curved surface. Furthermore, it is also possible to provide uneven portions having different areas of uneven regions as convex portions on the first mold surface 62a and concave portions on the second mold surface 64a. As described above, the mold surfaces 62 a and 64 a of the mold 60 for compressing and heating the laminate 52 can be formed according to the shape of the necessary carbon fiber composite material 10. In FIG. 4, the first mold surface 62 a is provided with a concavo-convex forming portion 68 that forms the concave portion 18 in the first outer surface 10 </ b> A of the carbon fiber composite material 10. Further, the mold 60 is provided with heating means (not shown) such as an electric heater, and can be heated to a temperature necessary for the curing reaction of the thermosetting resin in a state where the laminate 52 is compressed. It is configured as follows.

  Further, the carbon fiber prepreg 54 is prepared by impregnating the carbon fiber cloth with a thermosetting resin (step of obtaining a carbon fiber prepreg). The carbon fiber prepreg 54 is prepared by immersing the carbon fiber cloth cut into a required plane size in a liquid thermosetting resin solution and impregnating the carbon fiber cloth with the thermosetting resin. Can do. Further, the resin-impregnated foam 56 is prepared by impregnating the foam with a thermosetting resin (step of obtaining a resin-impregnated foam). In the same manner as the carbon fiber prepreg 54, the resin-impregnated foam 56 is obtained by immersing the foam cut into a required plane size in a liquid thermosetting resin solution, and applying the thermosetting resin to the foam. It can be created by impregnation. Further, after impregnating a solution in which a thermosetting resin is dissolved in a solvent, the carbon fiber prepreg 54 and the resin-impregnated foam are removed by drying at a temperature at which the curing reaction of the thermosetting resin does not occur and removing the diluent. 56 can be easily created. In addition, as a method of impregnating a carbon fiber cloth or foam with a thermosetting resin, in addition to the method of immersing in the thermosetting resin solution described above, a method of spraying and impregnating the thermosetting resin solution with a spray, a roll A method of applying a thermosetting resin solution with a coater can be employed.

  Here, the amount of the thermosetting resin impregnated into the carbon fiber cloth and the foam is 30 to 80% by weight of the thermosetting resin in the carbon fiber prepreg 54 in order to reduce weight and increase rigidity. The range is preferably set, and the weight ratio is more preferably set in the range of 40 to 70%. When the thermosetting resin is dissolved in the diluent and impregnated, the resin weight ratio is obtained based on the weight after drying after the impregnation and removing the diluent. Further, by impregnating the carbon fiber cloth or the foam with the same type of thermosetting resin, the carbon fiber cloth cured layer 14 and the foam cured layer 16 are effectively formed when the laminate 52 is compressed and heated. The rigidity of the base material 12 can be increased by integrating.

  Then, as shown in FIG. 4A, a laminated body 52 in which a resin-impregnated foam 56 is laminated between a plurality of carbon fiber prepregs 54 so that the carbon fiber prepregs 54 are located in the outermost layer is joined Arranged between the first mold 62 and the second mold 64 of the mold 60 holding the component 30, and compressed from the stacking direction of the carbon fiber prepreg 54 and the resin-impregnated foam 56 in the laminate 52. Heat with. That is, the step of holding the joining component 30 on the molding die 60, the step of laminating the carbon fiber prepreg 54 on the molding die 60 on which the joining component 30 is held, and the resin impregnated foam 56 on the carbon fiber prepreg 54 A step of laminating, and a step of compressing and heating the laminated body 52 by closing the molding die 60, and a step of laminating the carbon fiber prepreg 54 on the molding die 60 to form a surface layer of the carbon fiber composite material 10. It comes to form. Here, the number of carbon fiber prepregs 54 and resin-impregnated foams 56 to be laminated can be determined as appropriate. For example, even if a plurality of carbon fiber prepregs 54 and resin-impregnated foams 56 are stacked and laminated, the unevenness forming portion 68 of the mold is faithfully inverted by the elastic force of the resin-impregnated foam regardless of the compression amount. This makes it possible to adjust the depth of the concave portion and the height of the convex portion. That is, even if a plurality of carbon fiber prepregs 54 are stacked, the three-dimensional shape of the obtained carbon fiber composite material 10 can be complicated by stacking a plurality of resin-impregnated foams 56. Further, a plurality of carbon fiber prepregs 54 and a plurality of resin-impregnated foams 56 are stacked and laminated between a pair of carbon fiber prepregs 54 forming the outermost layer, so that a carbon fiber cloth is obtained inside the obtained carbon fiber composite material 10. The cured layer 14 can be formed, and there is an advantage that the tensile load and bending load of the carbon fiber composite material 10 can be improved.

  Further, the number of carbon fiber prepregs 54 existing between one outer surface of the carbon fiber composite material 10 and the nearest resin impregnated foam 56 and the resin impregnated foam material closest to the other outer surface of the carbon fiber composite material 10. It is also possible to laminate so that the number of carbon fiber prepregs 54 existing up to the body 56 is equal, or to laminate the carbon fiber prepregs 54 so as to have different numbers. When the carbon fiber prepreg 54 is compressed by the joining component 30 or the concavo-convex forming portion 68 in accordance with the compression of the laminate 52, the carbon fiber depends on the burying position of the joining component 30 or the concavo-convex forming position by the concavo-convex forming portion 68. By adjusting the number of carbon fiber prepregs 54 located on both outer surface sides of the composite material 10, the carbon fiber composite material 10 without warping can be obtained. That is, at least one step of laminating the resin-impregnated foam 56 on the carbon fiber prepreg 54 is included, and the step of laminating the resin-impregnated foam 56 on the carbon fiber prepreg 54 may be provided a plurality of times. Is possible.

  For example, when embedding the joining component 30 so as to be even on both surfaces of the carbon fiber composite material 10 or forming an uneven shape, the number of carbon fiber prepregs 54 positioned on both surfaces of the carbon fiber composite material 10 is equal. By doing so, it is possible to suppress warping of the carbon fiber composite material 10 while satisfactorily embedding the joining component 30 and forming the uneven shape. On the other hand, the bonding component 30 to be embedded and the uneven shape to be formed are not good on both surfaces of the carbon fiber composite material 10 as in the case where the bonding component 30 is embedded in one surface of the carbon fiber composite material 10 or the uneven shape is formed. In such a case, the number of the carbon fiber prepregs 54 positioned on both sides of the carbon fiber composite material 10 is made different so that the joining part 30 is embedded and the uneven shape is formed on the base material 12. The warpage of the carbon fiber composite material 10 can be suppressed while performing the above. That is, by increasing the number of carbon fiber prepregs 54 laminated on the outer surface side opposite to the outer surface that is pressed by the joining component 30 or the like and pulled by the carbon fiber prepreg 54 as the laminate 52 is compressed, It is possible to effectively prevent the carbon fiber composite material 10 from warping to the side where the joining component 30 is embedded. In FIG. 4A, one carbon fiber prepreg 54 is disposed on the first outer surface 10A side where the joining component 30 is embedded in the carbon fiber composite material 10, and the carbon fiber prepreg 54 is disposed on the opposite second outer surface 60B side. A state in which two sheets are stacked is shown.

  By compressing the laminated body 52, the carbon fiber prepreg 54 and the resin-impregnated foam 56 are formed into the concave and convex portions (the shaft-shaped portion 36 and the enlarged portions 38, 40) on the outer surfaces of the mold surfaces 62a and 64a and the joining component 30. , It is deformed into a shape following the anti-slip portion 42). At this time, the carbon fiber prepreg 54 is pressed from the inner side of the laminate 52 by the force repelling compression (the repulsive force of the resin-impregnated foam 56 and the thermosetting resin flowing along with the compression). The outermost carbon fiber prepreg 54 to be compressed can be made to follow and deform so as to be in close contact with the joint component 30. That is, the restricting portion 26 can be formed by deforming the outermost carbon fiber prepreg 54 into a shape that follows the shaft-like portion 36 and the enlarged portions 38 and 40 of the joining component 30. Further, by pressing the carbon fiber prepreg 54 against the joining component 30, the carbon fiber of the carbon fiber prepreg 54 can be fitted into the gap of the anti-slip portion 42 of the joining component 30.

  Then, the thermosetting resin is reactively cured in a state where the laminate 52 is compressed, so that the carbon fiber cloth cured layer 14 in which the carbon fiber prepreg 54 is cured and the foam cured layer 16 in which the resin-impregnated foam 56 is cured. Are integrated in a form that follows the mold surfaces 62a, 64a and the outer shape of the joining component 30, and a part (opening surface 34) of the joining component 30 is exposed from the carbon fiber cloth cured layer 14. Joined in state. That is, as the laminate 52 is compressed, the outermost carbon fiber prepreg 54 compressed by the joining component is deformed following the outer surface shape of the joining component 30, and the outermost carbon fiber prepreg 54 is followed. The carbon fiber cloth cured layer 14 formed by curing the carbon fiber prepreg 54 that has been deformed following the outer shape of the joining component 30 by curing the resin-impregnated foam 56 by heating in a state of being compressed and deformed, and the carbon fiber The joint part is formed in a state where the concave part 20 into which the joint part 30 is fitted is formed by being integrated with the foam cured layer 16 obtained by curing the resin-impregnated foam 56 that is deformed following the prepreg 54 and exposed to the outer surface. The carbon fiber composite material 10 having 30 embedded therein can be obtained. At this time, the regulation part 26 is formed by the cured carbon fiber cloth cured layer 14 and the foam cured layer 16, and carbon fibers are fitted in the gaps between the anti-slip parts 42 of the joining component 30. By forming the fiber cloth cured layer 14, the joining component 30 is firmly joined to the concave portion 20.

Next, an example of a specific method for manufacturing the carbon fiber composite material 10 will be described. As a thermosetting resin, a novolac phenol resin (Sumitomo Bakelite Co., Ltd. product name; Sumitrite Resin PR-55791B) with a reduced dinuclear substance is used as a diluent (product name of Daishin Chemical Co., Ltd.); A thermosetting resin solution diluted to 91 wt% in neoethanol) is produced. Carbon fiber woven with plain weave (product name: Toho Tex Co., Ltd .; W-3101 fiber weight: 200 g / m ² ) as a carbon fiber cloth is immersed in the thermosetting resin solution and taken out from the solution. The cloth is naturally dried to produce a carbon fiber prepreg 54 impregnated with a thermosetting resin. Similarly, a foamed melamine resin foam (BASF product name; BASOTECT G density 10.3 kg / m ³ ) cut into a thickness of 10 mm and a plane size of 200 × 300 mm as a foam having open cells is the same as the carbon fiber cloth. Then, the resin is immersed in a thermosetting resin solution, the foam taken out from the solution is naturally dried, and a resin-impregnated foam 56 impregnated with the thermosetting resin is produced. At this time, the resin weight ratio calculated by the above-mentioned formula was 93%.

  Next, the joining component 30 is fitted and held on the pin as the holding means 66 formed on the first mold surface 62 a of the first mold 62 in the molding die 60, and is separated from the surfaces of the first mold 62 and the second mold 64. In addition to applying the mold agent, a laminate 52 in which one carbon fiber prepreg 54, one resin-impregnated foam 56, and two carbon fiber prepregs 54 are laminated in order from the first mold 62 side. It arrange | positions between the 2nd type | molds 64. FIG. In this state, as shown in FIG. 4B, the laminate 52 is compressed from the lamination direction by the first die 62 and the second die 64 and heated in a compressed state using the casting heater of the mold 60. Then, the thermoplastic resin (phenol resin) was reaction-cured in the compressed state. The carbon fiber prepreg 54 arranged on the first surface layer (first outer surface 10A) side is deformed flexibly to form a concave portion 20 in a bag shape and is in close contact with the joining member 30, and is attached to the concave portion 20. The periphery of the mold is shortened as much as possible. At this time, the mold 60 was compressed by applying a surface pressure of 18 MPa at 150 ° C. for 15 minutes. The joining component 30 is fitted into the concave portion 20 formed by the outermost carbon fiber cloth cured layer 14 formed by the carbon fiber prepreg 54 facing the first mold 62, and the joining component 30 is joined by the carbon fiber cloth cured layer 14. It is possible to obtain the carbon fiber composite material 10 in which the formation portion of the concave portion 20 in the carbon fiber cloth cured layer 14 and the foam cured layer 16) are integrated while being joined in a state where 30 is surrounded.

(Operation of Example)
Next, the effect | action of the carbon fiber composite material mentioned above and its manufacturing method is demonstrated. The carbon fiber composite material 10 is bonded to a concave concave portion 20 formed by integrating a carbon fiber cloth cured layer 14 formed by curing a carbon fiber cloth and a foam cured layer 16 formed by compressing and curing the foam. Since the components 30 are joined in the fitted state, the carbon fiber cloth cured layer 14 can be provided uniformly around the joined components 30. That is, the carbon fiber cloth cured layer 14 obtained by curing the carbon fiber cloth having excellent mechanical properties (high specific strength and high specific elasticity) surrounds the joining component 30 and the carbon fiber cloth cured layer 14 is cured by foam. By supporting with the layer 16, the joining component 30 can be prevented from falling off from the carbon fiber cloth cured layer 14, and the joining strength of the joining component 30 can be increased. Further, the carbon fiber composite material 10 is configured such that a retaining portion (enlarged portion) 38 provided in the joining component 30 is engaged with the regulating portion 26 of the concave portion 20. For this reason, when a force is applied in a direction in which the fitting with respect to the joining component 30 is shallow (a direction in which the joining component 30 is pulled out from the concave portion 20), the restriction portion 26 interferes with the retaining portion (enlarged portion) 38. Therefore, the joining component 30 is more difficult to come off. Further, in the carbon fiber composite material 10, the bonding strength of the bonded component 30 is further increased by fitting the carbon fiber cloth cured layer 14 into the uneven shape of the anti-slip portion 42 provided in the bonded component 30. In particular, even when a force in the direction of rotation about the screw hole 32 acts on the joint component 30, the concave portion 20 is fitted to the anti-slip portion 42, so the joint component 30 is within the concave portion 20. Can be effectively prevented.

  Further, the carbon fiber composite material 10 includes the outermost carbon fiber prepreg compressed by the joining component 30 by compressing the laminate 52 with the molding die 60 in which the joining component 30 is held on the first mold surface 62a. 54 in accordance with the outer surface shape of the joining component 30, the resin impregnated foam 56 is compressed and deformed following the outermost carbon fiber prepreg 54, and the laminate 52 is heated in a compressed state, A carbon fiber cloth cured layer 14 obtained by curing a carbon fiber prepreg 54 that has been deformed following the outer shape of the joining component 30 as the thermosetting resin is cured, and a resin-impregnated foam that is deformed following the carbon fiber prepreg 54. It can be obtained by integrating the cured foam layer 16 formed by curing 56 and embedding the joining component 30 in a state of being exposed to the outer surface. As described above, when the laminate 52 is compressed, the carbon fiber cloth prepreg 54 bends in accordance with the shape of the joining member 30, and at the same time, the resin-impregnated foam 56 conforms to the shape of the joining member 30 due to its elastic characteristics. Thus, the bonded component 30 can be firmly fixed to the carbon fiber composite material 10. Moreover, since the joining component 30 is embedded while integrating the carbon fiber cloth cured layer 14 and the foam cured layer 16, the step of joining the joining component 30 to the base material 12 of the carbon fiber composite material 10 is performed. There is no need to provide it separately from the step of forming the hardened layer 14 or the foam hardened layer 16, and the joining workability of the joining component 30 can be improved.

  And the carbon fiber cloth cured layer 14 integrated with the foam cured layer 16 in a form following the outer surface shape of the joined component 30 by compressing and curing the laminate 52 with the mold 60 holding the joined component 30. The carbon fiber cloth hardened layer 14 can be provided uniformly around the joining component 30. That is, the carbon fiber cloth cured layer 14 obtained by curing a carbon fiber cloth having excellent mechanical properties (high specific strength, high specific elasticity) surrounds the joining component 30 and the carbon fiber cloth cured layer 14 is used as the foam cured layer. By supporting with 16, it is possible to easily obtain the carbon fiber composite material 10 in which the joining component 30 is prevented from falling off the carbon fiber cloth cured layer 14 and the joining strength of the joining component 30 is increased.

  The laminated body 52 is compressed and heated with a mold 60 that holds the joining component 30 provided with the anti-slip portion 42, so that the carbon fiber cloth cured layer 14 fits into the uneven shape of the anti-slip portion 42. In the state, the carbon fiber cloth cured layer 14 and the foam cured layer 16 are integrated. Furthermore, by compressing and heating the laminate 52 with a mold 60 holding the joining component 30 provided with the retaining portion (enlarged portion) 38, the carbon fiber cloth cured layer 14 and the foam cured layer 16 Are integrated in a form along the retaining portion (enlarged portion) 38. That is, the joining component 30 can be firmly joined to the base material 12 of the carbon fiber composite material 10 simply by compressing and curing the laminate 52 with the molding die 60 holding the joining component 30. The carbon fiber composite material 10 that can be suitably used as the fastening part 30 can be obtained.

(Example of change)
The carbon fiber composite material and the manufacturing method thereof according to the present invention are not limited to those described above, and various modifications can be made.
(1) In the examples, the carbon fiber composite material is formed in a flat plate shape, but can be formed into a bent or curved carbon fiber composite material by appropriately adjusting the cavity of the mold. .
(2) The joining component embedded in the base material of the carbon fiber composite material does not have to be the nut shown in the embodiment, and may be a bolt or pin-shaped component. Moreover, it is not restricted to the form which embeds one location of joining components in the base material of a carbon fiber composite material, For example, it comprises so that both ends of the joining components formed in the U shape may be embedded in the base material of carbon fiber composite material. Thus, it is possible to form a gripping portion on the carbon fiber composite material.
(3) The joining component is not limited to the configuration embedded in one surface of the carbon fiber composite material, but may be configured to be embedded in both surfaces of the carbon fiber composite material. For example, it can be realized by compressing and heating the laminated body while holding the joining parts in the first mold and the second mold of the mold shown in the embodiment. At this time, it is a matter of course that the joining parts on each surface can be different parts.

DESCRIPTION OF SYMBOLS 10 Carbon fiber composite material, 14 Carbon fiber cloth cured layer, 16 Foam cured layer, 20 Concave part 30 Joining part, 38 Enlarged part (uneven shape part), 42 Retaining part (uneven shape part)
52 Laminated body, 54 Carbon fiber prepreg, 56 Resin-impregnated foam 60 Mold, 62a First mold surface (mold surface)

Claims (4)

A plurality of carbon fiber cloth cured layers in which the carbon fiber cloth is cured;
The foam cured layer is laminated between the carbon fiber cloth cured layers and integrated with the carbon fiber cloth cured layer, and the foam is cured in a compressed state.
A joining component joined in an embedded state in which a part is exposed from the carbon fiber cloth cured layer forming the outermost layer,
The joining component joined in an embedded state to the concave portion formed by the outermost carbon fiber cloth cured layer is surrounded by a carbon fiber cloth cured layer integrated with the foam cured layer in the concave portion forming portion. Carbon fiber composite material characterized by being made.   The carbon fiber composite material according to claim 1, wherein the carbon fiber cloth cured layer forming the concave portion is engaged with the bonded component in a direction in which the joint component is pulled out from the concave portion. A layered product obtained by laminating a resin-impregnated foam obtained by impregnating a thermosetting resin into a foam having open cells and laminating between a plurality of carbon fiber prepregs obtained by impregnating a carbon fiber cloth with a thermosetting resin, The outermost carbon fiber prepreg compressed by the joining part is compressed by a molding die holding the joining part on the outer surface and deformed following the outer surface shape of the joining part, and the outermost carbon fiber is compressed. Following the prepreg, the resin-impregnated foam is compressed and deformed,
A carbon fiber cloth cured layer formed by curing the carbon fiber prepreg that is heated in a compressed state and is deformed following the outer surface shape of the joining component as the thermosetting resin is cured, and the carbon A carbon fiber composite material comprising: a foam cured layer formed by curing the resin-impregnated foam that has been deformed following a fiber prepreg, and the embedded component being embedded in an exposed state on the outer surface. Production method.   A state in which the outermost layer carbon fiber prepreg is deformed following the concavo-convex shape portion of the joint component by heating the laminate with the molding die holding the joint component provided with the concavo-convex shape portion. The method for producing a carbon fiber composite material according to claim 3, wherein the carbon fiber cloth cured layer and the foam cured layer are integrated.

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