JP2017039234A - 接合体、接合体の製造方法、及び車両用構造体 - Google Patents
接合体、接合体の製造方法、及び車両用構造体 Download PDFInfo
- Publication number
- JP2017039234A JP2017039234A JP2015160974A JP2015160974A JP2017039234A JP 2017039234 A JP2017039234 A JP 2017039234A JP 2015160974 A JP2015160974 A JP 2015160974A JP 2015160974 A JP2015160974 A JP 2015160974A JP 2017039234 A JP2017039234 A JP 2017039234A
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- Prior art keywords
- molded body
- fiber
- resin
- molded
- exposed portion
- 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.)
- Pending
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Classifications
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Abstract
Description
また、特許文献2及び特許文献3に記載の技術は樹脂製部品の接合を目的とするものではない。
さらには、樹脂製部品と、樹脂製部品又は金属製部品と、の接合に接着剤又はリベット等の締結部材を用いると、質量又はコストの増加の一因となり、望ましくない。特に、接着剤を用いて樹脂製部品と樹脂製部品又は金属製部品とを接合した場合、接着剤の強度で接合部の強度が決定されるため、樹脂製部品自身の材料強度を生かすことができない場合がある。
<1> 繊維強化樹脂を含み、前記繊維強化樹脂の繊維が露出する繊維露出部を表面の少なくとも一部に有する第一の成形体と、第二の成形体と、前記第一の成形体における前記繊維露出部と前記第二の成形体との接合部と、を有する接合体。
<2> 前記第一の成形体及び前記第二の成形体の少なくとも一方が熱可塑性樹脂を含む<1>に記載の接合体。
<3> 繊維強化樹脂を含み、前記繊維強化樹脂の繊維が露出する繊維露出部を表面の少なくとも一部に有する第一の成形体、及び第二の成形体を準備する工程と、前記第一の成形体と前記第二の成形体とを、前記第一の成形体における前記繊維露出部において接合する工程と、を有する接合体の製造方法。
<4> <1>又は<2>に記載の接合体を有する車両用構造体。
本実施形態の成形体は、繊維強化樹脂を含み、前記繊維強化樹脂の繊維が露出する繊維露出部を表面の少なくとも一部に有するものである。
本実施形態の成形体を用いることで、本実施形態の成形体とその他の成形体とを接合して接合体を得る場合に、接合体の接合強度を向上させることができる。その理由は明確ではないが、以下のように推察される。
本実施形態の成形体は、その表面の少なくとも一部に繊維強化樹脂の繊維が露出する繊維露出部が設けられているため、この繊維露出部において本実施形態の成形体(以下、「第一の成形体」と称することがある)とその他の成形体(以下、「第二の成形体」と称することがある)とを接合する場合に、繊維露出部で露出する繊維が第二の成形体の表面に絡みやすくなると考えられる。その結果、第一の成形体と第二の成形体とを繊維露出部において接合することで、接合体の接合強度を向上させることができるようになるものと推察される。
本実施形態において、繊維強化樹脂を構成する樹脂としては、熱可塑性樹脂であってもよく、熱硬化性樹脂であってもよい。繊維強化樹脂を構成する樹脂が熱硬化性樹脂である場合、樹脂は硬化されていても未硬化又は半硬化の状態であってもよい。
本実施形態において用いられる熱可塑性樹脂としては、例えば、ポリカーボネート樹脂、ポリアミド(PA)樹脂、ポリウレタン(PU)樹脂、ポリ塩化ビニル樹脂、アクリロニトリル−ブタジエン−スチレン共重合体(ABS)樹脂及びポリプロピレン(PP)樹脂が挙げられる。これらの中でも、PA樹脂及びPP樹脂が好ましい。
特に繊維として炭素繊維が用いられる場合、炭素繊維の状態としては、例えば、紡績糸、織布、編物、組物、フェルト、マット、ペーパー、チョップド糸、フィラメント及びミルドが挙げられる。
繊維強化樹脂を構成する樹脂として熱可塑性樹脂を用いる場合、例えば、繊維に熱可塑性樹脂の溶液または融液を含浸させ、必要に応じて乾燥してシート状に成形する方法、繊維と熱可塑性樹脂フィルムとを交互に積層した後に加熱加圧成形する方法、及び繊維強化熱可塑性樹脂フィルムを積層した後に加熱加圧成形する方法等が挙げられる。
繊維強化樹脂を構成する樹脂として熱硬化性樹脂を用いる場合、樹脂として熱可塑性樹脂を用いる場合と同様にして未硬化の成形体を作製し、必要に応じて当該成形体を加熱加圧して硬化又は半硬化の成形体を得る方法が挙げられる。熱硬化性樹脂を用いた成形体を加熱加圧する条件は、熱硬化性樹脂及び必要に応じて用いられる樹脂硬化剤の種類、量等に応じて適宜設定することができる。
繊維露出部において本実施形態の成形体(第一の成形体)と第二の成形体とが接合されることから、本実施形態の成形体の形状、本実施形態の成形体と第二の成形体との接合位置等を勘案して、繊維露出部の設けられる場所を設定することができる。
例えば、コロナ放電処理装置における電極の電圧としては、1kV〜50kVが好ましく、5kV〜20kVがより好ましい。処理時間としては、電極の電圧値等にもよるが、1秒〜10分が好ましく、10秒〜5分がより好ましい。処理ヘッドと被処理物との距離としては、電極の電圧値等にもよるが、1mm〜20mmが好ましく、2mm〜10mmがより好ましい。
コロナ放電処理により繊維露出部を形成する場合、繊維としてカーボン繊維を用いることが好ましい。カーボン繊維を含む成形体に対してコロナ放電処理を実施することで、カーボン繊維に電流が流れてカーボン繊維が発熱し、カーボン繊維周辺の樹脂が効率的に除去される。
カーボン繊維と同様の観点から、繊維としてガラス繊維が用いられてもよい。
例えば、バーナーの発熱量としては、0.1kW〜10kWが好ましく、0.5kW〜5kWがより好ましい。火炎温度としては、バーナーの発熱量等にもよるが、1000℃〜2000℃が好ましく、1000℃〜1500℃がより好ましい。処理時間としては、バーナーの発熱量等にもよるが、1秒〜1分が好ましく、2秒〜30秒がより好ましい。
なお、以下において、同一の部材には同一の符号を付し、重複した説明を省略することがある。また、各図における部材の大きさは概念的なものであり、部材間の大きさの相対的な関係はこれに限定されない。
図2は、コロナ放電処理により繊維露出部を設けた成形体の、繊維露出部における模式断面図を表す。図2に表されるように、成形体1の表面にポーラス状の凹凸が存在し、繊維3が成形体1の表面に露出している。
図3は、フレーム処理により繊維露出部を設けた成形体の、繊維露出部における模式断面図を表す。図3に表されるように、成形体1の表面の樹脂層が消失し、繊維3が成形体1の表面に露出している。
図4は、サンディング処理により繊維露出部を設けた成形体の、繊維露出部における模式断面図を表す。図4に表されるように、成形体1の表層と繊維3の一部が削り取られており、繊維3が成形体1の表面に露出している。
成形体に繊維露出部を設ける方法の違いにより、繊維露出部の状態が各々異なる傾向にある。
本実施形態の接合体は、繊維強化樹脂を含み、前記繊維強化樹脂の繊維が露出する繊維露出部を表面の少なくとも一部に有する第一の成形体と、第二の成形体と、前記第一の成形体における前記繊維露出部と前記第二の成形体との接合部と、を有する。
本実施形態の接合体は、第一の成形体と第二の成形体とが、第一の成形体における繊維露出部において接合部で接合される。繊維露出部において第一の成形体と第二の成形体とを接合する場合に繊維露出部で露出する繊維が第二の成形体の表面に絡みやすい。そのため、本実施形態の接合体は接合強度に優れるものと推察される。
本実施形態の接合体に用いられる第二の成形体は特に限定されるものではない。第二の成形体としては、例えば、熱可塑性樹脂を含む成形体、熱硬化性樹脂を含む成形体及び金属製の成形体が挙げられる。
熱可塑性樹脂を含む成形体又は熱硬化性樹脂を含む成形体は、繊維を含んでいてもよい。第二の成形体中に含まれてもよい繊維の具体例は、本実施形態の成形体の欄で挙げられた繊維が挙げられる。
熱可塑性樹脂を含む成形体又は熱硬化性樹脂を含む成形体を構成する樹脂は、熱可塑性樹脂であってもよいし、熱硬化性樹脂であってもよい。熱硬化性樹脂を用いる場合、樹脂は硬化されていても未硬化又は半硬化の状態であってもよい。
一方、第一の成形体が熱硬化性樹脂を含む場合、第二の成形体としては、例えば、熱可塑性樹脂を含む成形体が挙げられる。
第二の成形体が繊維強化熱可塑性樹脂を含む場合、第二の成形体は第一の成形体と同様に製造することができる。
また、第二の成形体として、本実施形態の成形体を用いることもできる。
第二の成形体が金属製の成形体である場合、第一の成形体に含まれる熱可塑性樹脂が金属製の成形体と強固に溶着可能となるように、金属製の成形体の少なくとも第一の成形体と接合する部分は粗面化処理が施されていてもよい。
粗面化処理としては、乾式で粒子を吹き付けるブラスト加工法、湿式で粒子を吹き付けるホーニング加工法、あるいは砥石研削法、サンドペーパーで粗す方法等の機械的粗面化処理、電解液中で電気分解を行なう電気化学的粗面化処理、薬液中に浸漬する化学的粗面化処理などが挙げられる。
本実施形態の接合体の製造方法によれば、第一の成形体と第二の成形体とを、第一の成形体における繊維露出部において接合することができる。繊維露出部では繊維が露出しているため、繊維露出部において第一の成形体と第二の成形体とを接合することで、繊維露出部で露出する繊維が第二の成形体の表面に絡みやすい。そのため、接合体の接合強度を向上させることができるものと推察される。
例えば、振動の周波数は100Hz〜300Hzが好ましく、210Hz〜260HZがより好ましい。
また、第一の成形体及び第二の成形体に対する荷重としては、0.1MPa〜5MPaが好ましく、0.1MPa〜2MPaがより好ましく、0.1MPa〜1MPaが更に好ましい。
また、振動振幅は0.5mm〜5mmが好ましく、1mm〜3mmがより好ましく、1.5mm〜2.5mmが更に好ましい。
例えば、超音波を発生させる超音波発生装置を構成するホーンのホーン加圧力は100N〜2000Nが好ましく、300N〜1000Nがより好ましく、500N〜800Nが更に好ましい。
超音波振動の振幅としては、10μm〜100μmが好ましく、15μm〜50μmがより好ましい。
第一の成形体及び第二の成形体に対する加圧としては、0kN〜5kNが好ましく、0kN〜3kNがより好ましく、0kN〜1kNが更に好ましい。
本実施形態の車両用構造体は、上述した本実施形態の接合体を有するものである。本実施形態の車両用構造体の種類は特に限定されるものではなく、例えば、サイドドア、フード、ルーフ、バックドア、ラゲージドア、バンパ及びクラッシュボックスが挙げられる。
本実施形態の車両用構造体では、第一の成形体と第二の成形体とが、第一の成形体における繊維露出部において接合される。繊維露出部において第一の成形体と第二の成形体とを接合する場合に、繊維露出部で露出する繊維が第二の成形体の表面に絡みやすい。そのため、接合体の接合強度が向上し、接合強度に優れる接合体を有する車両用構造体が得られる。
樹脂材料として、以下のものを用いた。
・三菱レイヨン株式会社製 繊維強化熱可塑性樹脂(CFRTP、連続繊維材)
・東レ株式会社製 繊維強化熱可塑性樹脂(CFRTP、ランダム材)
・三菱レイヨン株式会社製 C−SMC(Carbon−Sheet Molding Compound、熱硬化性樹脂材)
本実施例では、C−SMCを用いた成形体を第一の成形体とし、連続繊維材又はランダム材を用いた成形体を第二の成形体とした。
試験片の大きさは、長さ175mm、幅25mm、厚み3mmとした。
C−SMCを用いた成形体の一端における離型剤を、クリーナーを使用して除去した。これを比較例として使用した。なお、離型剤除去処理では、繊維露出部は形成されなかった。
離型剤除去処理後の成形体の表面の写真を、図5に示す。
C−SMCを用いた成形体の一端を、JIS R6252:2006におけるP60相当の研磨紙をオービタルサンダーに装着し、約0.6MPaのエアー圧力で処理し、繊維露出部を形成した。
サンディング処理により形成された成形体の繊維露出部の写真を、図6に示す。
C−SMCを用いた成形体の一端を、火炎温度約1300℃、発熱量2.1kWのバーナーで加熱処理した。処理時間は7秒とした。バーナーの口元から50mmの距離に成形体を配置し、3mm/secの速度でフレーム処理を実施した。
フレーム処理により形成された成形体の繊維露出部の写真を、図7に示す。
ナビタス株式会社製マルチダイン1のコロナ処理装置を用いて、C−SMCを用いた成形体の一端に対してコロナ放電処理を実施した。処理条件は以下のように設定した。コロナ放電処理を実施した箇所の濡れ性は48dyne以上であった。
電極電圧 12kV(×2個)
最大処理面積65mm×40mm
処理距離(処理ヘッドと対象物との距離) 5mm
処理時間 1min
コロナ放電処理により形成された成形体の繊維露出部の写真を、図8に示す。
C−SMCを用いた第一の成形体における、上記処理を施した箇所と、連続繊維材又はランダム材を用いた第二の成形体とを超音波溶着して接合体を形成した。
超音波溶着機として、ブランソン社製の2000Xdtを用いた。この超音波溶着機の公称周波数は20kHzであり、最大出力は300Wである。先端がφ15のフラットホーンを使用し、振幅28μm、沈み込み量0.5mm、加圧力650Nとした。
図9に、コロナ放電処理後のC−SMCを用いた第一の成形体と、連続繊維材を用いた第二の成形体と、を超音波溶着して形成された接合部の断面写真を示す。
図9から明らかなように、C−SMCと連続繊維材との界面に繊維が存在していることがわかる。図9中、点線を付した箇所は、C−SMCと連続繊維材との界面を示す。
株式会社島津製作所製 オートグラフ AG−X100KNを用い、接合体についてせん断試験を実施した。得られた結果を表1に示す。
以上の結果から、成形体を、繊維露出部において接合することにより、接合強度に優れる接合体が得られることがわかる。
2 樹脂
3 繊維
Claims (4)
- 繊維強化樹脂を含み、前記繊維強化樹脂の繊維が露出する繊維露出部を表面の少なくとも一部に有する第一の成形体と、
第二の成形体と、
前記第一の成形体における前記繊維露出部と前記第二の成形体との接合部と、
を有する接合体。 - 前記第一の成形体及び前記第二の成形体の少なくとも一方が熱可塑性樹脂を含む請求項1に記載の接合体。
- 繊維強化樹脂を含み、前記繊維強化樹脂の繊維が露出する繊維露出部を表面の少なくとも一部に有する第一の成形体、及び第二の成形体を準備する工程と、
前記第一の成形体と前記第二の成形体とを、前記第一の成形体における前記繊維露出部において接合する工程と、
を有する接合体の製造方法。 - 請求項1又は請求項2に記載の接合体を有する車両用構造体。
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