JP2019136878A - Composite body of carbon fiber-reinforced thermoplastic plastic and metal shaped material - Google Patents

Abstract

To provide a composite body which is used for automobile components and components such as a building member, is lightweight, and has high rigidity.SOLUTION: A composite body 1 of a carbon fiber-reinforced thermoplastic plastic and a coated metal shaped material having a carbon fiber-reinforced thermoplastic plastic 3 and a coated metal shaped material 2 covers the surface of the coated metal shaped material with an organic resin layer 5.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a composite of a carbon fiber reinforced thermoplastic used for parts such as automobile parts and building members and a metal shape material.

  Among automotive parts, high-strength steel sheets are used for skeletal parts that need to suppress deformation during a collision and maintain rigidity during travel. Also, aluminum alloys having a relatively low density have come to be used for reasons such as improving fuel efficiency. Among these, high-strength steel sheets are difficult to perform complex processing because of high yield stress and tensile strength and low total elongation, and are limited to parts that are subjected to relatively simple processing such as bending. Has been. Moreover, since various alloy elements are included, there is a problem that a hot-crack is likely to occur at the time of fusion welding or resistance welding, and a range of parts that can be applied is narrow. In the case of an aluminum alloy, although it can contribute to the weight reduction of the vehicle body, the tensile strength is lower than that of the steel material. Therefore, it is necessary to increase the thickness for securing the rigidity of the parts. However, because of its high heat conduction performance, it is difficult to make a thick plate by welding, so there are many cases in which extrusion processing is performed, and this causes a problem that the part shape is limited.

  Regarding building members, in particular, weight reduction of roof members is required from the viewpoint of improving earthquake resistance. However, it is necessary for the roof member to ensure rigidity against snow and typhoons. Since the rigidity is preferentially secured, many steel materials are applied, and weight reduction has not yet been achieved.

  In recent years, carbon fiber reinforced plastics have been used for parts in response to the above problems, and in particular, application to automobile parts has spread. This carbon fiber reinforced plastic is made by weaving carbon fiber in various forms to form a cloth, which is covered with plastic to form a plate or coil, and can be made to be highly rigid and lightweight by carbon fiber. There are advantages. However, for joints with parts made of steel or non-ferrous materials, plastic deformation type mechanical joining such as resistance welding, fusion welding, and caulking joining is difficult. It becomes joining with an adhesive. However, in bolt fastening, there is a problem in that the strength of a part made of carbon fiber reinforced plastic is reduced by dividing the carbon fiber woven by the pilot hole processing. In addition, bonding with an adhesive has a problem that production efficiency is lowered because long-time drying is required.

  In order to solve the problem in handling the above-mentioned carbon fiber reinforced plastic, the present invention is a composite of a carbon fiber reinforced plastic and a painted metal shape material, and is joined to other parts at the painted metal shape portion. The present inventors have found that carbon fiber reinforced plastic can be efficiently produced without causing a decrease in strength. Here, the painted metal shape material is a general metal such as a steel material or a non-ferrous material, and the shape is not limited, and includes a plate shape, a coil shape, a processed product, and the like.

    As a method for producing the composite, as shown in Patent Document 1, a method is proposed in which the surface roughness of a metal material is increased and then heat fusion is performed, and the metal material and the plastic are joined by an anchor effect. However, in this method, even if the surface roughness of the material is increased, the surface unevenness dimension changes after processing, so it cannot be applied unless after processing, and the manufacturing process naturally increases. is there.

Japanese Patent No. 5108891

  The present invention solves the problems of the conventional method and realizes a composite of carbon fiber reinforced plastic and painted metal shape material. The composite of a carbon fiber reinforced plastic and a painted metal shape material according to the present invention is a composite in which a carbon fiber reinforced thermoplastic is used as a carbon fiber reinforced plastic and a painted metal shape material made of steel or the like is joined. Is the body.

Carbon fiber reinforced thermoplastics soften the plastic part when heated, so plasticizing such as drawing can be realized by joining this softened state, and bonding to the surface of the metal shape material If the treatment layer is provided, heat fusion can be performed. That is, the process of providing irregularities on the surface of the metal shaped material as in Patent Document 1 can be omitted.
The contents of the present invention having the above-described features are as follows.
(1) A composite having carbon fiber reinforced thermoplastic and painted metal shape material, wherein the surface of the painted metal shape material is covered with an organic resin layer and the carbon fiber reinforced thermoplastic plastic and painted metal shape. Composite with material.
(2) A composite of a carbon fiber reinforced thermoplastic and a painted metal shape material, wherein the organic resin layer coated on the surface of the painted metal shape material contains acid-modified polypropylene.
(3) A composite of a carbon fiber reinforced thermoplastic and a painted metal shape material, wherein the organic resin layer coated on the surface of the painted metal shape material contains a polycarbonate unit-containing polyurethane resin.
(4) The composite material of carbon fiber reinforced thermoplastic plastic, which is a steel material or non-ferrous metal, and a painted metal material.
(5) A composite of a carbon fiber reinforced thermoplastic and a painted metal shaped material characterized in that at least one of a painted metal shaped material and a carbon fiber reinforced thermoplastic is processed.
(6) A composite of a carbon fiber reinforced thermoplastic and a painted metal material, wherein at least one of the painted metal material and the carbon fiber reinforced thermoplastic is in a flat plate shape.
(7) A composite having a carbon fiber reinforced thermoplastic plastic, a coated metal base material having a surface coated with an organic resin layer, and a hot melt film, wherein the hot melt film is made of carbon fiber reinforced thermoplastic. A composite of a carbon fiber reinforced thermoplastic and a painted metal material, characterized in that the resin layer is fused to an organic resin layer on the surface of the painted metal material.

  ADVANTAGE OF THE INVENTION According to this invention, even if various kinds of coating metal shape materials are joined, the composite of the carbon fiber reinforced thermoplastic plastic and the coating metal shape material excellent in the adhesiveness is provided.

It is sectional drawing concerning an example of the composite_body | complex of this invention. It is sectional drawing which concerns on the other example of the composite_body | complex of this invention.

1. Composite The composite of the present invention comprises a coated metal base material having an organic resin layer formed on one or both sides, a carbon fiber reinforced thermoplastic resin, a resin layer of the painted metal base material, and a resin layer of the carbon fiber reinforced plastic. It is joined with.

  FIG. 1 is an example of the composite of the present invention. As shown in FIG. 1, the composite 1 has a painted metal base material 2 and a carbon fiber reinforced thermoplastic plastic 3. The painted metal base material 2 has a metal base material 4 and an organic resin layer 5. In the composite 1, the organic resin layer 5 and the carbon fiber reinforced thermoplastic resin layer are bonded together by fusing.

  FIG. 2 is another example of the composite of the present invention. As shown in FIG. 2, the composite 1 has a painted metal preform 2 and a carbon fiber reinforced thermoplastic plastic 3, but the organic resin layer 5 of the painted metal preform 2 and the carbon fiber reinforced heat. The hot melt film 6 is inserted between the resin layers of the plastic plastic 3, and the hot melt film 6, the organic resin layer 5 of the painted metal base material 2, and the resin layer of the carbon fiber reinforced thermoplastic plastic 3 are fused. It is joined.

2. Painted Metal Shape Material A painted metal shape material 2 of the present invention includes a metal shape material 4 and an organic resin layer 5. The organic resin layer 5 is formed on the surface of the metal base material 4. In addition, the shape of the painted metal shaped member 2 is not particularly limited, and may be a processed shape such as a flat plate or a drawn shape. The method of coating the organic resin layer 5 on the surface of the metal base material 4 is also not particularly limited, and a roll coating method, a curtain flow method, a spin coating method, a spray method, a dip pulling method, or the like can be applied.

  The material of the metal base material 4 is not particularly limited as long as it is a metal. For example, steel materials such as galvanized steel sheet, Zn-Al alloy plated steel sheet, Zn-Al-Mg alloy plated steel sheet, Zn-Al-Mg-Si alloy plated steel sheet, aluminum plated steel sheet, stainless steel sheet, special steel, aluminum alloy, Non-ferrous metal materials such as copper alloy, magnesium alloy and titanium are included.

3. Organic Resin Layer The organic resin layer 5 is a layer containing an organic resin and improves the adhesion between the painted metal preform 2 and the carbon fiber reinforced thermoplastic plastic 3. The organic resin layer 5 is formed on the surface of the metal base material 4. The organic resin layer 5 is firmly adhered by being fused to the resin layer of the carbon fiber reinforced thermoplastic plastic 3.

  The type of organic resin of the organic resin layer 5 is not particularly limited as long as it has a functional group (hydrogen-bonding functional group) capable of hydrogen bonding with the metal base material 4 and has fusion properties to the hot melt film 6. Not. Examples of the hydrogen bonding functional group include a carboxyl group and an amino group. Examples of the resin having a hydrogen bonding functional group and also having a fusing property with the hot melt film 6 include an acid-modified polypropylene resin and a polycarbonate unit-containing polyurethane resin, and these have a particularly high fusing property. In addition, polyethylene resins, polypropylene resins, polystyrene resins and the like are included. These resins may be used alone or in combination of two or more.

4). Carbon Fiber Reinforced Thermoplastic Plastic Carbon fiber reinforced thermoplastic plastic 3 is obtained by mixing carbon fiber and thermoplastic plastic and solidifying them. Carbon fibers include continuous long fibers and short fibers cut to a certain length. In particular, continuous continuous fibers are used in a cloth type in which fibers are aligned only in one direction and a fabric type in which fibers are crossed in the longitudinal direction and the transverse direction. These types may be processed shapes such as a drawing shape as well as a plate shape. The thermoplastic is not particularly limited as long as it has thermoplastic performance. For example, acid-modified polypropylene resin, polycarbonate unit-containing polyurethane resin, polyethylene resin, polypropylene resin, polystyrene resin and the like are included. These resins may be used alone or in combination of two or more.

5). Hot-melt film The type of hot-melt film 6 is a film that is produced by an existing method such as stretching or extrusion molding of a thermoplastic resin composition, and is composed of a component that melts by heating and expresses bonding strength with various members. If it is a sheet-like thing, it will not specifically limit. For example, polyurethane, polyester, and polyolefin can be applied.

1. Preparation of painted metal shape material (1) Metal shape material As the metal shape material 4, a molten Zn-6 mass% Al-3 mass% Mg alloy-plated steel sheet with a coating adhesion amount per side of 45 g / m ² is used. did. The base material of this plated steel plate is a cold rolled steel plate (SPCC). Moreover, the dimension of this metal raw material 4 is width 100mm, length 200mm, and plate | board thickness 1.6mm.

(2) Preparation of organic resin paint Organic resin emulsion, polyethylene wax and crosslinking agent were added to water to prepare an organic resin paint having a nonvolatile component of 20% by mass. As the organic resin emulsion, an urethane resin emulsion and a polypropylene resin emulsion (Adekabon titer HUX-386: ADEKA Corporation) were used. For the urethane resin emulsion, a polyurethane resin emulsion containing a commercially available polycarbonate unit was used. A commercially available acid-modified polypropylene resin emulsion (Hardlen NZ-1005: Toyobo Co., Ltd.) was used for the polypropylene resin emulsion.

(3) Formation of Organic Resin Layer The surface of the metal preform 4 was degreased by immersing it in an alkaline degreasing aqueous solution (SD-270: Nippon Paint Co., Ltd.) having a liquid temperature of 40 ° C. and a pH of 12 for 1 minute. Next, the organic resin paint prepared in the above (2) is applied to the surface of the degreased metal base material 4 with a roll coater and dried with a hot air dryer so that the ultimate temperature is 150 ° C., and the organic resin layer 5 Formed. The adhesion amount of the organic resin layer 5 was about 1.2 g / m 2 regardless of the kind of the organic resin paint. Thus, a painted metal preform 2 was obtained.

2. Carbon Fiber Reinforced Thermoplastics (1) Types of Carbon Fiber Reinforced Thermoplastics Carbon fiber reinforced thermoplastics 3 are made of woven carbon fiber with the same organic resin as the organic resin paint of “1. (2)” above. A plate-shaped product mixed and solidified was prepared. The dimensions are a width of 100 mm, a length of 200 mm, and a thickness of 1 mm. Moreover, what mixed the short fiber of length 10mm with the same organic resin as the organic resin coating material of said "1. (2)" was also prepared.

3. Bonding Method of Painted Metal Shape and Carbon Fiber Reinforced Thermoplastic (1) Thermal Fusion Method The above-mentioned “2. (1)” woven fabric type carbon fiber reinforced thermoplastic 3 is replaced with “1.” The painted metal body 2 was placed in a region having a width of 100 mm and a length of 30 mm on one end side in the longitudinal direction, and was pressed and joined with a heated mold. The heat fusion conditions are a pressure of 1 MPa, a temperature of 150 ° C., and a mold holding time after heating of 5 seconds. The upper and lower mold dimensions are rectangular with a width of 120 mm, a length of 50 mm, and a height of 20 mm.

(2) Injection molding method Carbon fiber reinforced thermoplastic plastic in which the coated metal shaped material 2 of the above "1." is inserted into an injection mold, and short fibers melted at 120 ° C and an organic resin are mixed. 3 was injected into the cavity of the injection mold. The shape of the cavity is 100 mm wide, 200 mm long, and 4 mm thick. A joint region between the painted metal raw material 2 and the carbon fiber reinforced thermoplastic plastic 3 was formed in a region having a width of 100 mm and a length of 30 mm on one end side in the longitudinal direction of the painted metal raw material 2. As injection molding conditions, the pressure is 50 MPa, the speed is 10 mm / s, and the holding time after injection is 10 seconds.

4). Types of Hot Melt Films As the hot melt film 6, there are SHM107-PUR (Seadom Co., Ltd.) having a polyurethane type thickness of 70 μm and a melting point of 110 ° C., and Admer QE060 having a polypropylene type thickness of 40 μm and a melting point of 139 ° C. (Mitsui Chemicals Tosero Co., Ltd.) was used.

5). Evaluation Method of Bonding Force Table 1 shows the composite 1 produced in the above “1.” to “4.”. As a comparative example, a carbon fiber reinforced thermoplastic plastic 3 was joined using a metal base material 4 that did not cover the organic resin layer 5. The bonding strength of each composite 1 was measured by measuring the strength when the coated metal base material 2 and the carbon fiber reinforced thermoplastic plastic 3 were gripped and pulled in a direction opposite to each other at a speed of 100 mm / min and broken. When the strength was less than 1.0 kN, “x”, when the strength was 1.0 kN or more, “◯” was given, and “◯” was accepted.

  Table 1 also shows the results of the bonding force evaluated in the above “5.”. The composites 1 of the present invention all passed with sufficient bonding strength, but the composite of the comparative example failed with a strength of less than 1.0 kN.

  Since the composite of the present invention has an excellent bonding force, it is suitable for parts that require weight reduction and rigidity such as automobile parts and building members.

DESCRIPTION OF SYMBOLS 1 ... Composite 2 ... Paint metal shape material 3 ... Carbon fiber reinforced thermoplastic 4 ... Metal shape material 5 ... Organic resin layer 6 ... Hot melt film

Claims (7)

  A carbon fiber reinforced thermoplastic and a coated metal, characterized in that it is a composite comprising a carbon fiber reinforced thermoplastic and a painted metal base material, and the surface of the painted metal base material is coated with an organic resin layer. Complex with raw material.   2. The composite of carbon fiber reinforced thermoplastic and coated metal material according to claim 1, wherein the organic resin layer coated on the surface of the painted metal material comprises acid-modified polypropylene.   2. The composite of carbon fiber reinforced thermoplastic and painted metal material according to claim 1, wherein the organic resin layer coated on the surface of the painted metal material comprises a polycarbonate unit-containing polyurethane resin. .   The composite of a carbon fiber reinforced thermoplastic and a painted metal preform according to claim 1, wherein the painted metal preform is a steel material or a non-ferrous metal.   The carbon fiber reinforced thermoplastic material and the painted metal shape material according to claim 1, wherein at least one of the painted metal shape material and the carbon fiber reinforced thermoplastic material is processed. Complex.   5. The composite of carbon fiber reinforced thermoplastic and painted metal shape material according to claim 1, wherein at least one of the painted metal shape material and the carbon fiber reinforced thermoplastic material has a flat plate shape. body. A composite comprising a carbon fiber reinforced thermoplastic, a coated metal base material having a surface coated with an organic resin layer, and a hot melt film, the hot melt film comprising a carbon fiber reinforced thermoplastic resin layer A composite of a carbon fiber reinforced thermoplastic and a painted metal shape material, which is fused to an organic resin layer on the surface of the painted metal shape material.

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