JP2018103707A - 接合構造体及びその製造方法 - Google Patents
接合構造体及びその製造方法 Download PDFInfo
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- JP2018103707A JP2018103707A JP2016250703A JP2016250703A JP2018103707A JP 2018103707 A JP2018103707 A JP 2018103707A JP 2016250703 A JP2016250703 A JP 2016250703A JP 2016250703 A JP2016250703 A JP 2016250703A JP 2018103707 A JP2018103707 A JP 2018103707A
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- Prior art keywords
- adhesive
- layer
- bottomed hole
- amorphous structure
- metal member
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Abstract
【解決手段】側方ブラケット22L、22Rの接合部80の表層にアモルファス構造層200が形成される。さらにアモルファス構造層200の表層に複数の有底孔212を有する有底孔層214が形成される。有底孔212は、開口部216と底部218の間に開口部216よりも内周が大きい膨張部220を有する下膨形状である。有底孔212には接着剤130が充填され、側方ブラケット22L、22Rの接合部80の外周面とセンタビーム20の端部66Rの内周面とが接着剤130を介して対向する。
【選択図】図9
Description
図1〜図3を用いて、本発明の一実施形態に係る接合構造体の説明をする。以下で説明する接合構造体は車両10に搭載されるサブフレーム12である。後述するが、サブフレーム12は、異材同士、すなわち金属部材(側方ブラケット22L、22R)と繊維強化プラスチック部材(センタビーム20)とが接着剤で接合された接合構造体である。図1〜図3において、矢印X1、X2、Y1、Y2、Z1、Z2は、車両10を基準とした方向を示す。具体的には、矢印X1、X2は、車両10の前後方向を示し、矢印Y1、Y2は、車両10の幅方向(横方向)を示し、矢印Z1、Z2は、車両10の高さ方向(上下方向)を示す。また、図3において、左ブラケット22Lは省略されているが、右ブラケット22Rと対称の構成を有する。
センタビーム20は、支持ロッド24(図1等)を介してエンジン(図示せず)を支持するものであり、本実施形態では、炭素繊維強化プラスチック(CFRP:carbon-fiber-reinforced plastic)で形成される。
側方ブラケット22L、22Rは、車両10のメインフレーム(図示せず)に固定されてサブフレーム12全体をメインフレームに支持させると共に、図1に示すように、操舵機構14及びサスペンション16を支持する。本実施形態の側方ブラケット22L、22Rは、アルミニウム製の中空部材であり、鋳造によって成形された鋳物である。
側方ブラケット22L、22Rに設けられる接合部80の外周面とセンタビーム20に設けられる端部66L、66Rの内周面は接着接合される。図4は右ブラケット22Rの接合部80とセンタビーム20の端部66Rとの接合箇所のうち、頂面部94と頂面部34との接合箇所を示す。
アモルファス構造層200は金属部材(以下の説明では頂面部94)の電食を防止する役割を果たす。図5A、図5Bを用いてその原理について説明する。ここではアモルファス構造層200が形成されていない頂面部94´(図5A)を想定し、アモルファス構造層200が形成されている頂面部94(図5B)と比較する。上述したように、頂面部94´及び頂面部94は金属部材(アルミニウム)である。金属部材には粒界140が存在する。
図6に示すように、アモルファス構造層200が形成されていない表層206の表面が接合面202に含まれていてもよい。表層206に接着剤130が塗布されていれば、表層206が外気に曝されることはない。このため、表層206の粒界140(図5A、図5B)を起点に電食142(図5A)が発生することはない。また、表層206の表面の周囲にアモルファス構造層200が形成されていれば、周辺から表層206に電食142が侵入することもない。
金属部材(以下の説明では頂面部94)の表面にレーザ光を照射すると、表層にアモルファス構造層200が形成される。アモルファス構造層200は所定以上の表面粗さを有する。さらにアモルファス構造層200の表面を含む表層には、図8に示すような有底孔212を複数備える有底孔層214(図9B)が形成される。図8は有底孔層214を走査電子顕微鏡(SEM:Scanning Electron Microscope)で観察した画像である。
有底孔層214は接着剤130の接合強度を向上させる役割を果たす。図9A、図9Bを用いてその原理について説明する。ここでは表面が機械加工された頂面部94´´(図9A)を想定し、アモルファス構造層200の表層に有底孔層214が形成されている頂面部94(図9B)と比較する。なお、図9Aは頂面部94´´の断面を模式化しており、図9Bは頂面部94の断面を模式化している。
センタビーム20と側方ブラケット22L、22Rとを接合する前に、側方ブラケット22L、22Rの接合部80の各表面にレーザ光を照射する。レーザ光の強度、照射時間等の条件は、アモルファス構造層200の厚さや範囲に応じて設定される。レーザ光の照射後、接合部80が冷却される。冷却後の接合部80の各表面にはアモルファス構造層200が形成される。さらにその表層には有底孔層214が形成される。なお、接合部80の冷却は、例えば空冷等による自然冷却、任意の冷却装置の利用等による強制冷却により実施される。
本実施形態では接合構造体としてのサブフレーム12について説明した。しかし、金属部材と繊維強化プラスチック部材とを接着接合する他の構造体に本発明を使用することも可能である。また、インロウ構造でない他の構造体の接着接合箇所に本発明を使用することも可能である。また、インロウ構造の内側の部材と外側の部材のいずれが金属部材であってもよい。
本実施形態に係るサブフレーム12(接合構造体)は、側方ブラケット22L、22R(金属部材)の接合部80の表層にアモルファス構造層200が形成される。さらにアモルファス構造層200の表層に複数の有底孔212を有する有底孔層214が形成される。有底孔212は、開口部216と底部218の間に開口部216よりも内周が大きい膨張部220を有する下膨形状である。有底孔212には接着剤130が充填され、有底孔層214の表面、すなわち側方ブラケット22L、22Rの接合部80の外周面とセンタビーム20(繊維強化プラスチック部材)の端部66Rの内周面とが接着剤130を介して対向する。
20…センタビーム(繊維強化プラスチック部材)
22L、22R…側方ブラケット(金属部材)
80…接合部 130…接着剤
200…アモルファス構造層 212…有底孔
214…有底孔層 216…開口部
218…底部 220…膨張部
222…鉤状部 224…頭部
Claims (5)
- 金属部材と繊維強化プラスチック部材とが接着剤で接合される接合構造体であって、
前記金属部材の表層にアモルファス構造層が形成され、
さらに前記アモルファス構造層の表層に複数の有底孔を有する有底孔層が形成され、
前記有底孔は、開口部と底部の間に前記開口部よりも内周が大きい膨張部を有する下膨形状であり、
前記有底孔に接着剤が充填され、
前記有底孔層の表面と前記繊維強化プラスチック部材側の接合面とが前記接着剤を介して対向する
ことを特徴とする接合構造体。 - 請求項1に記載の接合構造体において、
前記有底孔は前記開口部に鉤状部を備える
ことを特徴とする接合構造体。 - 請求項2に記載の接合構造体において、
前記鉤状部には、前記金属部材の延在面に対して非平行に延びる100μm以下の頭部が形成される
ことを特徴とする接合構造体。 - 金属部材と繊維強化プラスチック部材とを接着剤で接合する接合構造体の製造方法であって、
前記金属部材にレーザ光を照射して前記金属部材の表層にアモルファス構造層を形成すると共に、前記アモルファス構造層の表層に複数の有底孔を有する有底孔層を形成し、
前記有底孔は、開口部と底部の間に前記開口部よりも内周が大きい膨張部を有する下膨形状であり、
前記有底孔に接着剤を充填し、
前記有底孔層の表面と前記繊維強化プラスチック部材側の接合面とを前記接着剤を介して対向させて、前記金属部材と前記繊維強化プラスチック部材とを接合する
ことを特徴とする接合構造体の製造方法。 - 第1部材と第2部材の少なくとも一方が金属部材であり、前記第1部材と前記第2部材とが接着剤又はシーリング部材で接合される接合構造体であって、
前記金属部材の表層にアモルファス構造層が形成され、
さらに前記アモルファス構造層の表層に複数の有底孔を有する有底孔層が形成され、
前記有底孔は、開口部と底部の間に前記開口部よりも内周が大きい膨張部を有する下膨形状であり、
前記有底孔に接着剤が充填され、
前記有底孔層の表面と前記第2部材側の接合面とが前記接着剤又は前記シーリング部材を介して対向する
ことを特徴とする接合構造体。
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