JP2018153950A - Method of manufacturing composite structure of CFRP member and metal member - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a composite structure of stable quality by integrating a CFRP member and a metal member in a simple process.SOLUTION: In order to integrate a CFRP member 1 and a metal member 2, the CFRP member 1 has a simple shape, an engaging recess 3 having a dimension allowing loose fitting of the CFRP member 1 is formed in the metal member 2, an adhesive injection hole 4 for communicating the engaging recess 3 to an outside is provided. An end portion of the CFRP member 1 is inserted and fitted into the engaging recess 3 of the metal member 2 and an adhesive injected into the engaging recess 3 from the adhesive injection hole 4 is packed between the end portion of the CFRP member 1 and the inner surface of the engaging recess 3 so as to form an adhesive layer 5.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a method of manufacturing a composite structure of different materials by integrating a CFRP member and a metal member.

  In recent years, CFRP made of light weight and excellent strength is sometimes used as a member for automobiles, and the product is often made into a three-dimensional complicated shape.

  As a method for producing such a CFRP product, the following Patent Document 1 describes a method by RTM molding. In this method, as shown in FIG. 3, a fiber preform 51 is formed by laminating a plurality of simple-shaped fiber base sheets 51a and 51b at the end portions and stitching, and the fiber preform 51 is molded into a molding die. The thermosetting resin is set in the cavity between the male mold 53 and the female mold 52 of 52 and exhausted from the exhaust hole 55 of the molding die 52, and the thermosetting resin is injected into the cavity through the injection hole 56 and cured.

  By the way, since it is necessary to disassemble in the member for motor vehicles at the time of a maintenance, there exists a request of making the attachment part with another metal member into the metal which is hard to be damaged at the time of disassembly or reassembly.

  To cope with this, if the above RTM molding is applied and the CFRP member and the metal member are integrated by a metal insert that is molded by inserting the CFRP member and the metal member into the cavity of the molding die, the fiber preform becomes complicated. In the case of a simple shape, the fiber base sheet may be twisted, overlapped, misaligned in the fiber direction, and the required strength may not be exhibited.

  Further, in such a method for producing a composite structure using metal inserts, undercutting may occur, and the molding die may be complicated due to the treatment.

  Furthermore, due to the difference in the coefficient of linear expansion between the CFRP member and the metal member, residual stress may occur during cooling from the molding temperature, causing cracks in the CFRP member, and holes for making nut inserts in the fiber preform. When processing, the fiber direction may be disturbed around the hole, and the required strength and accuracy may not be obtained.

  In addition, the resin flow into the cavity may be hindered, causing voids in the resin and molding defects due to an increase in injection pressure, and smoothing at the polymerization part of the fiber preform during die cutting. It may be difficult to release the mold.

  For this reason, it is also conceivable to employ a connection structure of different materials as described in Patent Document 2. In this connection structure, as shown in FIG. 4, the CFRP member 61 and the metal member 62 are connected via a metal intermediate member 63.

  The intermediate member 63 used for the connection is formed with a fitting recess 64 at one end that has a cylindrical shape, a plate-like contact portion 65 at the other end, and a contact portion 65. It is assumed that a hole 66 is formed in the metal member 62 and a screw hole 67 is formed in the metal member 62.

  Then, an adhesive 68 is applied to the outer periphery of the end portion of the CFRP member 61, the end portion of the CFRP member 61 is inserted into the insertion recess 64, the end portion of the metal member 62 is aligned with the contact portion 65, and the hole 66 is inserted. Then, the bolt 69 is screwed into the screw hole 67. Accordingly, when the adhesive 68 is cured, the CFRP member 61 and the metal member 62 are fixed in a connected state.

JP, 2006-182776, A Japanese Patent No. 5687536

  However, in the connection structure as described in Patent Document 2 above, the adhesive 68 is applied to the outer periphery of the end portion of the CFRP member 61 so as to have a uniform layer thickness, and the intermediate member 63 is kept in that state. It is difficult to insert into the insertion recess 64.

  That is, at the time of this insertion, there is a high possibility that the adhesive 68 is scraped out from the insertion recess 64 of the intermediate member 63 and overflows outside the insertion recess 64.

  For this reason, a stable connection state cannot be obtained, and even when such a connection structure is adopted when manufacturing a complex structure having a complicated three-dimensional shape having a flange or the like like an automobile member, there is a demand. May not be able to produce composite structures of the desired quality.

  Moreover, in the member which attaches importance to the external appearance, such as a member for automobiles, overflow of the adhesive causes a decrease in aesthetics, which is a serious problem.

  Accordingly, an object of the present invention is to provide a method capable of manufacturing a composite structure having a stable quality by integrating a CFRP member and a metal member by a simple process.

In order to solve the above problems, in the present invention, in order to integrate the CFRP member and the metal member, the CFRP member has a simple shape, and the metal member has an insertion recess having a dimension capable of loosely fitting the CFRP member. And forming an adhesive injection hole for communicating the insertion recess to the outside,
Insert and fit the end of the CFRP member into the insertion recess of the metal member,
The adhesive injected into the insertion recess of the metal member from the adhesive injection hole is filled between the end portion of the CFRP member and the inner surface of the insertion recess to form an adhesive layer, and the CFRP member and the metal The composite structure was manufactured by connecting the members.

  According to the composite structure manufacturing method of the present invention, after inserting the end portion of the CFRP member having a simple shape into the insertion recess of the metal member, the adhesive is injected and filled into the insertion recess through the adhesive injection hole. Therefore, a uniform adhesive layer can be easily formed as compared with the case where the end portion of the CFRP member to which the adhesive is applied is inserted into the insertion recess of the metal member.

  Further, when the end portion of the CFRP member is inserted into the insertion recess of the metal member, the overflow of the adhesive does not occur.

  Then, after the CFRP member and the metal member are integrated, the adhesive layer acts as a buffer material. Therefore, when assembling into a predetermined composite structure having a flange or the like by, for example, RTM molding, the temperature change during molding No cracking occurs.

  In addition, the temperature change during use of the composite structure is not easily affected by the difference in thermal expansion between the CFRP member and the metal member which are different materials.

Sectional drawing which shows the connection structure of the CFRP member and metal member in the manufacturing method of the composite structure which concerns on this invention The perspective view which shows a CFRP member and a metal member in case a CFRP member same as the above is a simple three-dimensional (2A) U-shape and (2B) hat shape Sectional drawing which respectively shows (3A) the setting process of the fiber preform to the male type | mold in the RTM shaping | molding of patent document 1, (3B) the approaching process of a male type | mold and a female type | mold, and (3C) the resin injection process to a cavity. The perspective view which shows the connection structure of the CFRP member and metal member of patent document 2

  Embodiments of the present invention will be described below with reference to the accompanying drawings.

  As shown in FIG. 1, in the manufacturing method of this composite structure, the CFRP member 1 and the metal member 2 are connected and integrated. At the time of connection, the CFRP member 1 is divided into a simple flat plate-like two-dimensional shape in advance as a component of a three-dimensional shape composite structure as a product, and this is combined with the metal member 2 To do.

  Further, the metal member 2 is provided with a groove-like insertion recess 3 having a dimension allowing the CFRP member 1 to be loosely fitted, and an adhesive injection hole 4 for communicating the insertion recess 3 with the outside behind it. deep.

  Then, the end of the CFRP member 1 is inserted and fitted into the insertion recess 3 of the metal member 2, and the adhesive is injected into the insertion recess 3 from the outside of the adhesive injection hole 4.

  The adhesive injected into the insertion recess 3 is diffused and filled between the end portion of the CFRP member 1 and the inner surface of the insertion recess 3 and cured to form the adhesive layer 5.

  As this adhesive, a polyurethane-based or epoxy-based elastic adhesive that has fluidity when injected and becomes a rubber-like elastic body after curing is used.

  According to the method of connecting and integrating the CFRP member 1 and the metal member 2 as described above, compared with the case where the end portion of the CFRP member 1 coated with the adhesive is inserted into the insertion recess 3 of the metal member 2, The uniform adhesive layer 5 can be easily formed.

  Further, when the end portion of the CFRP member 1 is inserted into the insertion recess 3 of the metal member 2, no overflow of the adhesive occurs.

  Then, after the CFRP member 1 and the metal member 2 are integrated, the adhesive layer 5 acts as a buffer material. Therefore, when assembling into a predetermined composite structure having a flange or the like by RTM molding in the subsequent process, No cracking due to temperature changes.

  In addition, the temperature change during use of the composite structure is not easily affected by the difference in thermal expansion between the CFRP member 1 and the metal member 2 which are different materials.

  Furthermore, since the adhesive injection hole 4 can be connected to a gun for jetting the adhesive at a high pressure, and the adhesive can be injected into the insertion recess 3, it also supports automation of the manufacturing process of the composite structure. It is easy to use and is particularly suitable for mass production of automobile parts and the like.

  In the above embodiment, it is intended to use a carbon fiber reinforced thermoplastic resin (CFRTP) as the CFRP member 1, but the CFRP member 1 may be a carbon fiber reinforced thermosetting resin.

  In addition, the CFRP member 1 has a flat plate-like two-dimensional shape. The CFRP member 1 can be a simple three-dimensional shape as long as the insertion recess 3 having a shape that can be inserted corresponding to the metal member 2 can be formed. It is good. For example, as shown in FIG. 2 (2A), it may be a curved U-shape or a hat shape in which flat plate portions are connected to both ends of the curved portion as shown in FIG. 2 (2B).

  In forming the composite structure, the CFRP member 1 is assumed to have a predetermined shape by RTM molding as described in Patent Document 1, but is not limited thereto, and is not limited to resin, cured An agent, a filler and the like may be blended and processed into a predetermined shape by SMC molding or the like that is heated and pressurized in a mold.

1 CFRP member 2 Metal member 3 Insertion recess 4 Adhesive injection hole 5 Adhesive layer

Claims (1)

In order to integrate the CFRP member (1) and the metal member (2), the CFRP member (1) has a simple shape, and the metal member (2) has a size capable of loosely fitting the CFRP member (1). In addition to forming the recess (3), an adhesive injection hole (4) for communicating the insertion recess (3) to the outside is provided,
Insert and fit the end of the CFRP member (1) into the insertion recess (3) of the metal member (2),
The adhesive injected from the adhesive injection hole (4) into the insertion recess (3) of the metal member (2) is inserted between the end of the CFRP member (1) and the inner surface of the insertion recess (3). A method of manufacturing a composite structure of a CFRP member and a metal member, which is filled into a resin to form an adhesive layer (5).

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