JP2022024497A - Method for manufacturing shock absorbing member - Google Patents

Abstract

To provide a method for manufacturing a shock absorbing member that achieves both higher mechanical characteristics and designability, further simplifies the molding process, and reduces waste material.SOLUTION: There is provided a method for manufacturing a shock absorbing member by laminating a first material provided with a first protrusion and a second material provided with a second protrusion, and disposing them in a molding die to mold. The shock absorbing member is provided with a first shock absorbing protrusion on a side that receives shock, and provided with a second shock absorbing protrusion on the opposite side of the side that receives the shock.SELECTED DRAWING: Figure 1

Description

The method for manufacturing a shock absorbing member of the present invention relates to a method for manufacturing a shock absorbing member by laminating a first material and a second material and arranging them in a molding die for molding.

Weight reductions in the automotive, transportation, aerospace, and logistics-based industries are becoming more important to create more fuel efficient vehicles on both ground and air transportation. In particular, materials containing reinforcing fibers and resins have excellent mechanical properties and are attracting attention as structural members for automobiles and the like.

Patent Document 1 discloses a vehicle side door using a beam made of a unidirectional fiber reinforced material.

Patent Document 2 discloses a molded body having a stepped cross-sectional thickness using a material in which carbon fibers are impregnated with a thermosetting resin.

US2016 / 0137038 US2008 / 0217806

However, although the beam described in Patent Document 1 uses unidirectional fibers, the design is not yet sufficient from the viewpoint of impact absorption. Further, the composite material described in Patent Document 2 is manufactured so as to have a stepped cross-sectional shape by laminating the prepreg peel ply once and then peeling and removing the prepreg peel ply, which makes the manufacturing process complicated. Further, since the material is peeled off and removed, a large amount of waste is generated, which is a problem.

Therefore, an object of the present invention is to provide a method for manufacturing a shock absorbing member that achieves both higher mechanical properties and design, simplifies the molding process, and reduces waste.

In order to solve the above problems, the present invention provides the following means.
1. 1. It is a method of manufacturing a shock absorbing member by laminating a first material having a first convex portion and a second material having a second convex portion, arranging them in a molding die, and molding them.
The impact absorbing member is provided with a first impact absorbing convex portion on the impact receiving side and a second impact absorbing convex portion on the side opposite to the impact receiving side.
Manufacturing method of shock absorbing member.
2. 2. When the first material and the second material are laminated, the first convex portion is convex toward the second material, and the second convex portion is convex toward the first material. The method for manufacturing a shock absorbing member according to 1 above.
3. 3. 2. The shock absorbing member according to 2 above, wherein the first convex portion before molding forms the first shock absorbing member convex portion or the second impact absorbing convex portion by reversing the convex direction before and after molding. Manufacturing method.
4. 3. The method for manufacturing a shock absorbing member according to 3, wherein the second convex portion is inverted in the direction opposite to the first convex portion before and after molding.
5. The cross section of the first impact absorbing convex portion and the second impact absorbing convex portion is triangular, trapezoidal, arcuate, other polygonal, mountain-shaped, hemispherical, spherical crown-shaped, or stepped. 4. The method for manufacturing a shock absorbing member according to any one of 4.
6. The first impact absorbing convex portion forms an outward convex from the impact absorbing member, and forms a convex.
The second impact absorbing convex portion forms an outward convex from the impact absorbing member in the direction opposite to the first impact absorbing convex portion.
The method for manufacturing a shock absorbing member according to any one of 1 to 5 above.
7. The first material is a laminate containing at least Sheet 1A and Sheet 1B, wherein Sheet 1A comprises the first convex portion and Sheet 1B comprises a third convex portion.
When the sheet 1A and the sheet 1B are laminated, the third convex portion is convex toward the sheet 1A.
The method for manufacturing a shock absorbing member according to any one of 2 to 6 above.
8. The second material is a laminate containing at least a sheet 2A and a sheet 2B, wherein the sheet 2A comprises the second convex portion and the sheet 2B comprises a fourth convex portion.
When the sheet 2A and the sheet 2B are laminated, the fourth convex portion is convex toward the sheet 2A.
The method for manufacturing a shock absorbing member according to 7.
9. The method for manufacturing a shock absorbing member according to any one of 1 to 8, wherein the first convex portion and / or the cross section of the second convex portion has a stepped surface shape.
10. 8. The method for manufacturing a shock absorbing member according to 8, wherein the third convex portion and / or the cross section of the fourth convex portion has a stepped surface shape.
11. The method for manufacturing a shock absorbing member according to any one of 1 to 10, wherein the first material and / or the second material is a laminate of sheets containing reinforcing fibers and a resin.
12. The first material comprises the sheet 1A and the sheet 1B.
The second material comprises the sheet 2A and the sheet 2B.
11. The method for manufacturing a shock absorbing member according to 11 above, wherein the sheet 1A, the sheet 1B, the sheet 2A, and the sheet 2B are carbon fiber composite materials or glass fiber reinforced composite materials.
13. The shock absorbing member has a beam shape and has a beam shape.
The method for manufacturing a shock absorbing member according to the above 12, wherein the thickness of the first shock absorbing convex portion and / or the second shock absorbing convex portion becomes thicker toward the center of the beam.
14. 12. The method for manufacturing a shock absorbing member according to the above 12, wherein the thickness of the first shock absorbing convex portion and / or the second shock absorbing convex portion becomes thicker toward the center in the longitudinal direction of the beam.
15. The sheet 1A and the sheet 2A are unidirectional carbon fiber composite materials or glass fiber composite materials.
13. The method for manufacturing a shock absorbing member according to 13 or 14, wherein the fibers are oriented toward the longitudinal direction of the first material and the second material.
16. The sheet 1A and the sheet 2A are unidirectional carbon fiber composite materials or glass fiber composite materials.
13. The method for manufacturing a shock absorbing member according to 13 or 14, wherein the fibers are oriented toward the lateral side of the first material and the second material.
17. The method for manufacturing a shock absorbing member according to any one of 1 to 16, wherein the shock absorbing member is a door of an automobile.
18. It is a method of manufacturing a shock absorbing member by laminating a first material and a second material, arranging them in a molding die, and molding them.
The first material and the second material have a layered structure having an uneven thickness structure.
When the first material and the second material are laminated, an uneven thickness structure is formed in which the layer is made smaller toward the inside of the cross section.
A method of manufacturing a shock absorbing member by reversing the uneven thickness structure in a molding die to the outside of a cross section at the time of molding.

According to the method for manufacturing a shock absorbing member of the present invention, a shock absorbing member having a protrusion on the side receiving a shock and the opposite side thereof can be easily manufactured. In addition, the loss of waste is extremely small. Further, since the shock absorbing member is provided with convex portions on both sides, the shock absorbing ability is improved.

The schematic diagram which laminated the 1st material (101, the sheet 1A with the 1st convex part), the 2nd material (102, the sheet 2A with the 2nd convex part), and the 3rd material (103). The schematic diagram of the shock absorbing member produced by press-molding the laminated body of FIG. A sheet 1A having a first convex portion, a sheet 1B having a third convex portion, and a sheet 1C are used as the first material (301), and a sheet 2A having a second convex portion and a sheet having a fourth convex portion. 2B and sheet 1C are used as the second material (302), and the schematic diagram in which the first material and the second material are laminated. The schematic diagram of the shock absorbing member produced by press-molding the laminated body of FIG. FIG. 2 is a schematic view of a molding die for creating the shock absorbing member of FIGS. 2 and 4. The schematic diagram which laminated the material (601) which provided the convex part and the material (602) which did not have a convex part. The schematic diagram of the shock absorbing member produced by press-molding the laminated body of FIG. The schematic diagram of the door provided with the shock absorbing member of this invention. The schematic diagram of the door provided with the shock absorbing member of this invention. (A)-(l) Schematic diagram illustrating the relationship of cross-sectional shape between the first material and the second material, the first material and the third material, or the second material and the fourth material. The schematic diagram which laminated the 1st material (1101, the sheet 1A with the 1st convex part), the 2nd material (1102, the sheet 2A with the 2nd convex part), and the 3rd material (1103). FIG. 3 is a schematic view of a shock absorbing member created by press-molding the laminate of FIG. 11. The schematic diagram of the molding die for making the shock absorbing member of FIG. The schematic diagram which laminated with the 1st convex part and the 2nd convex part facing in the direction opposite to FIG.

The present invention is a method for manufacturing a shock absorbing member by laminating a first material and a second material, arranging them in a molding die, and molding them. The first material comprises a first convex portion and the second material comprises a second convex portion.
[First material and second material]
1. 1. The first convex portion and the second convex portion FIG. 10 is a schematic diagram showing the relationship between the first material and the second material. When the first material and the second material are laminated, it is preferable that the first convex portion and the second convex portion are directed toward the second material and the first material, respectively, and it is not always necessary that the first convex portion and the second convex portion are line-symmetrical when facing each other. There is no.
For example, the convex portion may be designed as shown in FIGS. 10 (a) to 10 (l).

Further, as shown in FIGS. 10 (i) to 10 (l), the first material or the second material may have two convex portions. Even if the first material or the second material is designed in the cross-sectional shape as shown in FIG. 10 (i), the warp can be suppressed when the shock absorbing member (molded body) is produced. In the first convex portion and the second convex portion that are designed and laminated in this way, the first convex portion is inverted from the inward direction when pressed, and the first impact absorbing convex portion (or the second impact absorbing convex portion) is formed. The second convex portion is inverted from the inward direction to form the second impact absorbing convex portion (or the first impact absorbing convex portion), and the warp of the impact absorbing member is suppressed. The second convex portion is inverted in the direction opposite to that of the first convex portion to form a shock absorbing convex portion.

2. 2. Shape of convex portion The cross section of the first convex portion and the second convex portion may be triangular, trapezoidal, arcuate, other polygonal, mountain-shaped, hemispherical, spherical crown-shaped, or stepped. Preferably, at least one of the cross sections of the first convex portion and the second convex portion has a stepped surface shape, and more preferably, both the first convex portion and the second convex portion have a stepped surface shape. .. The thickness of the stepped cross section is preferably thicker toward the center in the longitudinal direction of the first material or the second material, and the step direction of the step thickness exists in the longitudinal direction of the first material or the second material. Then it is more preferable. More preferably, it is preferable that the central portion of the first material or the second material in the longitudinal direction is the thickest, and the thickness is gradually reduced toward both sides. The longitudinal direction of the first material and the second material is the X-axis direction in FIGS. 1, 3, and 11.

3. 3. Line symmetry As shown in FIGS. 1, 3, and 11, it is preferable that the first convex portion and the second convex portion face each other. More specifically, the center line (FIG. 1) so as to intersect the center points of all the materials in the molding mold opening / closing direction (Y-axis in FIGS. 1 and 3) in the longitudinal direction of the first material and the second material. 104, 304 in FIG. 3, 1104 in FIG. 11), it is preferable that the first convex portion and the second convex portion are line-symmetric with respect to the center line. In the case of FIG. 1, the material center point is the center point in the Y-axis direction in which the first material (101), the second material (102), and the third material (103) are combined. In the case of FIG. 3, the material center point is the center point in the Y-axis direction in which the first material (301) and the second material (302) are combined. In the case of FIG. 11, the material center point is the center point in the Y-axis direction in which the first material (1101), the second material (1102), and the third material (1103) are combined.

[Convex direction and shape of the third convex part and the fourth convex part]
1. 1. Convex parts of various shapes FIG. 10 is also a schematic diagram showing the relationship between the first material and the third material, or the second material and the fourth material. When the sheet 1A and the sheet 1B are laminated, the third convex portion may be directed toward the sheet 1A. Similarly, when the sheet 2A and the sheet 2B are laminated, the fourth convex portion may be directed toward the sheet 2A. It does not necessarily have to be axisymmetric when facing each other. For example, the first convex portion and the third convex portion, and the second convex portion and the fourth convex portion may be designed in the relation as shown in FIGS. 10 (a) to 10 (l). As shown in FIGS. 10 (i) to 10 (l), there may be two convex portions. The third and fourth convex portions designed and laminated in this way are inverted when the impact absorbing member is molded to form a first impact absorbing convex portion or a second impact absorbing convex portion, and shock absorbing. Warpage of members is suppressed.

It is preferable that the first convex portion and the third convex portion face each other. Similarly, it is preferable that the second convex portion and the third convex portion face each other.

2. 2. Shape of convex portion The cross section of the third convex portion and the fourth convex portion may be triangular, trapezoidal, arcuate, other polygonal, mountain-shaped, hemispherical, spherical crown-shaped, or stepped.

Preferably, at least one of the cross sections of the third convex portion or the fourth convex portion has a stepped surface shape, and more preferably, both the third convex portion and the fourth convex portion have a stepped surface shape. Is.

The thickness of the stepped cross section is preferably thicker toward the center of the first material and / or the second material in the longitudinal direction, and the step direction of the step thickness is the longitudinal direction of the first material or the second material. It is more preferable to be present in. More preferably, it is preferable that the central portion of the first material or the second material in the longitudinal direction is the thickest, and the thickness is gradually reduced toward both sides. The longitudinal direction of the first material and the second material is the X-axis direction in FIGS. 1, 3, and 11.

3. 3. Line symmetry More preferably, a center line (305 in FIG. 3) is drawn in the longitudinal direction of the sheets 1A and 1B so as to intersect the center point of the first material in the mold opening / closing direction (Y axis in FIG. 3). Then, it is preferable that the first convex portion and the third convex portion are line-symmetrical with respect to the center line.

Similarly, when a center line (306 in FIG. 3) is drawn in the longitudinal direction of the sheet 2A and the sheet 2B so as to intersect the center point of the second material in the molding mold opening / closing direction (Y axis in FIG. 3). The second convex portion and the fourth convex portion should be line-symmetrical with respect to the center line.

[Fiber-reinforced laminate]
The first material and the second material are preferably a laminate containing reinforcing fibers and a resin. The first material and the second material are more preferably composite materials reinforced with continuous fibers at least in the longitudinal direction, with a layer reinforced with continuous fibers in the longitudinal direction and continuous fibers reinforced in the lateral direction. It is more preferable that the composite material contains the layers. Further, it is more preferable that the composite materials are laminated in a pyramid shape toward the center of the first material and the second material in the longitudinal direction. Specifically, it is sufficient that a step-like step is provided in the X-axis direction of FIGS. 1, 3 and 11 and the composite material reinforced with continuous fibers is laminated.
Further, the third material is also preferably a material containing a reinforcing fiber and a resin.

[Sheets that make up the first and second materials]
1. 1. Configuration The first material is preferably a laminate containing the sheets 1A and 1B, and the second material is preferably a laminate containing the sheets 2A and 2B. The first material may be a laminated body further containing the sheet 1C, and the second material may be a laminated body further containing the sheet 2C.

The sheet 1A and the sheet 1B have a first convex portion and a second convex portion, respectively. The sheet 2A and the sheet 2B have a third convex portion and a fourth convex portion, respectively.

2. 2. Composite Material At least one of Sheet 1A, Sheet 1B, Sheet 1C, Sheet 2A, Sheet 2B, or Sheet 2C is preferably a carbon fiber composite material or a glass fiber reinforced composite material, and all sheets are carbon fibers. More preferably, it is a composite material or a glass fiber reinforced composite material.

It is preferable that the sheet provided with these protrusions is formed by laminating a fiber-reinforced composite material reinforced in one direction to form a stepped cross section. Sheets 1A, 1B, 2A, and 2B having a stepped cross section can be obtained by gradually reducing (or shortening) the fiber-reinforced composite material sheets reinforced in one direction and laminating them. The number of layers contained in each of the sheet 1A, the sheet 1B, the sheet 2A, and the sheet 2B is preferably 2 or more and less than 50 layers, more preferably 2 or more and less than 30 layers, and 2 or more and 10 layers. It is more preferably less than a layer. Further, the thickness per layer is preferably 0.05 mm or more and less than 1.0 mm, and more preferably 0.1 mm or more and 0.5 mm or less. When the thickness of one layer is about 0.15 mm, it is preferable to stack about 5 layers to form a convex portion.

In FIGS. 1, 3 and 11, since the fiber-reinforced composite material sheets reinforced in one direction are gradually and shortly laminated toward the upper side or the lower side in the Y-axis direction, the first material and the second material are laminated. The thickness of the central part of the combined material (in some cases, the third material) is the largest.

3. 3. Orientation Direction Sheet 1A, Sheet 1B, Sheet 2A, and Sheet 2B are preferably unidirectional carbon fiber composite materials or glass fiber composite materials. The orientation direction is not particularly limited, and the longitudinal direction of the first material is 0 degrees (X-axis in FIGS. 1, 3 and 11) and the lateral direction is 90 degrees (Z in FIGS. 1, 3 and 11). Axis), a unidirectional composite material oriented at 0 degrees, 15 degrees, 45 degrees, 60 degrees, or 90 degrees, or a combination thereof may be laminated.

It is preferable to use a composite material sheet layer in which the fibers are oriented in the longitudinal direction of the first material and the second material, and a composite material in which the fibers are oriented in the longitudinal direction of the first material and the second material. It is more preferred to use both the sheet layer and the composite sheet layer in which the fibers are oriented in the lateral direction. By using the composite material sheet oriented in the lateral direction, the composite material easily flows in the longitudinal direction during press molding. In this case, a shock absorbing member having a curved surface rather than a stepped shape can be easily formed (for example, FIG. 12).

By laminating composite materials reinforced with continuous fibers in a staircase pattern and orienting them in the longitudinal direction of the first material or the second material, when a shock absorbing member is produced, a convex portion having a staircase surface shape can be easily formed ( For example, FIGS. 2 and 4).

[Shape of shock absorber]
The impact absorbing member in the present invention is provided with a first impact absorbing convex portion (201, 401, 1201) on the impact receiving side, and a second impact absorbing convex portion (202, 402, 1202) on the side opposite to the impact receiving side. ). More specifically, the first impact absorbing convex portion forms an outward convex from the impact absorbing member, the second impact absorbing convex portion is in the direction opposite to the first impact absorbing convex portion, and the impact absorbing member is outward. It is good to form a convex.

The shape of the shock absorbing convex portion is not particularly limited, and the cross section of the convex portion may be triangular, trapezoidal, arcuate, other polygonal, mountain-shaped, hemispherical, spherical crown-shaped, or stepped. Here, the "spherical cap" means a curved surface portion when a sphere or an ellipsoidal sphere is cut in one plane, and is a sphere when the sphere is cut in a plane at a position separated from the center point of the sphere or the ellipsoidal sphere. It is the part of the small volume that does not include the center of.

When the shock absorbing member has a beam shape, it is preferable that the thickness of the stepped cross section of the first shock absorbing convex portion and the second shock absorbing convex portion becomes thicker toward the center. It is more preferable that the central portion of the beam is the thickest and the thickness becomes thinner toward both sides. This is because when the pole collides with the door, a tensile force acts toward the inside of the door, so that the fiber reinforced material has a structure that utilizes the strength against tensile bending.

When the shock absorbing protrusion is stepped, it is preferable that the step direction of the step thickness is in the longitudinal direction of the beam.

When the shock absorbing member has a beam shape, the longitudinal direction of the first material and the second material is the beam direction of the shock absorbing member. When the longitudinal direction of the first material and the second material is reinforced with continuous fibers, the longitudinal direction of the beam (X-axis direction in FIG. 8) is reinforced with continuous fibers.

[Reversal of convex direction during molding]
In FIGS. 1 and 2, FIGS. 3 and 4, and 11 and 12, the first convex portion is inverted from inward to outward to form the first impact absorbing convex portion, and the second convex portion is inward. It is drawn as if the second impact absorption convex part was formed by reversing from the direction to the outside. At this time, the first convex portion may be inverted from the inward direction to form the second impact absorbing convex portion, and the second convex portion may be inverted from the inward direction to form the first impact absorbing convex portion.

In other words, in the impact absorbing member of the present invention, it is preferable that the first convex portion before molding forms the first impact absorbing member convex portion or the second impact absorbing convex portion, and the convex direction is reversed before and after molding. .. At this time, before and after molding, the second convex portion is inverted in the direction opposite to the first convex portion.

When the impact absorbing member is subjected to a tensile test or a compression test, the most force is applied to the outermost layer (surface) of the impact absorbing member due to the stress distribution. By inverting the first convex portion and the second convex portion at the time of molding, it becomes easy to continuously connect and arrange the outermost layers of the shock absorbing member, and the outer side of the shock absorbing member has a higher mechanical strength. Can be done.

In other words, the first material and the second material have a layer structure of an uneven thickness structure, and when the first material and the second material are laminated, the first material and the second material have an uneven thickness structure in which the layer is made smaller toward the inside of the cross section. This is a method of manufacturing a shock absorbing member by inverting the uneven thickness structure in the molding die to the outside of the cross section at the time of molding.

When inverting, the first convex portion of the first material is arranged so as to enter the concave portion of the molding mold (for example, the upper mold of FIGS. 5 and 13), and the second convex portion of the second material is also the concave portion of the molding mold (for example, the upper mold of FIG. 13). It may be arranged and pressed so as to be in the lower mold of FIGS. 5 and 13. The convex portion is inverted by press molding.

[Comparison with the case where the convex direction during molding is not reversed]
When sheets having different lengths and sheets having a constant length are alternately sandwiched to create an uneven thickness structure, it is also possible to stack the sheets as shown in FIG. However, from the viewpoint of strengthening the outer layer of the shock absorbing member, the laminating method of FIG. 11 is preferable in which the first convex portion and the second convex portion are laminated toward the second material and the first material, respectively. Compared with each layer of 1401 of FIG. 14, the layers of 1Ca, 1Cb, 1Cc, 1Aa, and 1Cd of FIG. 11 are less oriented in the Y-axis direction when they become shock absorbing members, and are oriented in the X-axis and Z-axis directions. This is because the impact strength and tensile strength of the above are increased. In addition, in FIG. 14, even if the uneven thickness structure is slightly deviated from the convex shape of the molding die, the sheet (1402, 1403, 90 degree layer) oriented in the Z-axis direction flows in the X-axis direction, which is a big problem. It does not become.

[Composite material]
1. 1. Resin The type of resin used in one aspect of the present invention is not particularly limited, and a thermosetting resin or a thermoplastic resin is used.
1.1 Thermoplastic resin When the resin is a thermoplastic resin, the type thereof is not particularly limited, and a resin having a desired softening point or melting point can be appropriately selected and used. The thermoplastic resin usually has a softening point in the range of 180 ° C. to 350 ° C., but is not limited thereto.
1.2 Thermosetting resin When a thermosetting resin is used, it is preferably an unsaturated polyester resin, a vinyl ester resin, an epoxy resin, or a phenol resin. As the resin, one type may be used alone, or two or more types may be used in combination.

2. 2. Reinforcing fiber 2.1 Types of reinforcing fiber The reinforcing fiber used in the present invention is not particularly limited, but is one or more reinforcing fibers selected from the group consisting of carbon fiber, glass fiber, aramid fiber, boron fiber, and genbuiwa fiber. Is preferable. It is more preferable that the reinforcing fiber is glass fiber. When glass fiber is used as the reinforcing fiber, the average fiber diameter of the glass fiber is preferably 1 μm to 50 μm, more preferably 5 μm to 20 μm. When the average fiber diameter is large, the impregnation property of the resin into the fiber becomes easy, and when it is not more than the upper limit, the moldability and processability are good.
2.2 Continuous fiber The reinforcing fiber used in the present invention may be a continuous fiber. In the case of continuous fibers, it is also preferable that they are contained in the matrix resin in the form of a woven or knitted fabric, a unidirectionally arranged sheet of strands, a sheet of a multiaxial woven fabric, or a non-woven fabric. It is preferable that the reinforcing fibers have a specific fiber orientation.
2.3 Discontinuous fiber The reinforcing fiber in the present invention may include discontinuous fiber. When discontinuous fibers are used, the shapeability is improved as compared with the fiber reinforced plastic using only continuous fibers, and it becomes easy to produce a complicated molded body. In this case, the weight average fiber length of the reinforcing fibers is preferably 1 mm or more and 100 mm or less. The weight average fiber length is more preferably 1 mm to 70 mm, further preferably 1 mm to 50 mm. Further, discontinuous reinforcing fibers having different fiber lengths may be used in combination. In other words, the discontinuous reinforcing fibers used in the present invention may have a single peak in the weight average fiber length distribution, or may have a plurality of peaks.

When the reinforcing fiber is a discontinuous fiber in which the resin is a thermosetting resin, a sheet molding compound (sometimes referred to as SMC) may be used. Due to its high formability, the sheet molding compound can be easily molded even if it has a complicated shape. The sheet molding compound has higher fluidity and formability than continuous fibers, and ribs and bosses can be easily formed.

3. 3. Fiber volume ratio The fiber volume ratio Vf of the reinforcing fiber is not particularly limited, but is preferably 20 to 70%, more preferably 25 to 60%, still more preferably 30 to 55%. The fiber volume ratio (Vf unit: volume%) is the ratio of the volume of the reinforcing fiber to the total volume including not only the reinforcing fiber and the matrix resin but also other additives and the like.

4. Other Agents In the fiber-reinforced resin used in the present invention, various fibrous or non-fibrous fillers of organic fibers or inorganic fibers, inorganic fillers, flame retardants, UV resistant agents, as long as the object of the present invention is not impaired. , Stabilizers, mold release agents, pigments, softeners, plasticizers, surfactants and other additives may be included. When a thermosetting resin is used, it may contain a thickener, a curing agent, a polymerization initiator, a polymerization inhibitor and the like. As the additive, one type may be used alone, or two or more types may be used in combination.

[Other materials]
In addition to the first material and the second material, other materials may be used. Others may be fibers, composites, steels, aluminums, and combinations thereof.

[Integral molding]
The shock absorbing member of the present invention is preferably made by integrally molding the first material and the second material using the fiber-reinforced composite material. Here, the integral molding means that the molding is continuously performed without having a seam, and is not formed by joining separate members to each other. Such integral molding can be realized by forming a molded body (shock absorbing member) by one-time molding, and preferably by press molding.

Since it is created by integral molding, it is possible to process different parts as one part, and it is possible to reduce the unit price of parts. In addition, the number of assembly processes is reduced, and the cost related to inventory can be reduced by reducing the number of parts.

In Patent Document 2 (US2008 / 0217806), the prepreg peel ply is once laminated and then peeled off to form a stepped cross-sectional shape, which complicates the manufacturing process. Further, since the material is peeled off and removed, a large amount of waste becomes a problem. When the shock absorbing member of the present invention is manufactured, the manufacturing process can be reduced and the waste loss of the material can be reduced by integrally molding.

[Molding means]
The molding method of the shock absorbing member is not particularly limited, but it is preferable to use press molding (compression molding). Molds are illustrated in FIGS. 5 and 12.

When press forming is used, forming methods such as hot press forming and cold press forming can be used. When the resin is a thermoplastic resin, press molding using a cold press is particularly preferable. In the cold press method, for example, a composite material heated to a first predetermined temperature is put into a molding die set to a second predetermined temperature, and then pressurized and cooled.

Specifically, when the thermoplastic resin is crystalline, the first predetermined temperature is equal to or higher than the melting point, and the second predetermined temperature is lower than the melting point. When the thermoplastic resin is amorphous, the first predetermined temperature is equal to or higher than the glass transition temperature, and the second predetermined temperature is lower than the glass transition temperature.

[door]
It is preferable that the shock absorbing member of the present invention is provided on the door of an automobile. In other words, the present invention is a method for manufacturing a door provided with a shock absorbing member, and the shock absorbing member is formed by laminating a first material having a first convex portion and a second material having a second convex portion. The shock absorbing member is placed in a mold and molded, and the shock absorbing member is provided with a first shock absorbing convex portion on the shock receiving side and a second shock absorbing convex portion on the opposite side to the shock receiving side, which is a method for manufacturing a door. be.

[Impact side]
The shock absorbing member in the present invention is provided with a first shock absorbing convex portion on the impact receiving side and a second shock absorbing convex portion on the side opposite to the shock receiving side. More specifically, the first impact absorbing convex portion forms an outward convex, and the second impact absorbing convex portion forms an outward convex from the impact absorbing member in the direction opposite to the first impact absorbing convex portion. It is preferable to do so.

When the shock absorbing member is provided on the door of an automobile, the shock receiving side is the outside of the door. In this case, the side opposite to the side receiving the impact means heading into the automobile living space. More specifically, it receives an impact from the Y-axis direction of FIG.

[Embodiment of the Invention]
Hereinafter, embodiments of the invention will be described with reference to FIGS. 1, 2, 3, 4, 11, and 12, but the present invention is not limited thereto.

[Example of the first form (FIGS. 1 and 2)]
The laminated structure of FIG. 1 and the impact absorbing member of FIG. 2 will be described as an example.

In FIG. 1, the sheet 1A of the first material (101) has a first convex portion, and when the first material and the second material are laminated, the first convex portion faces the second material (102). There is.

The sheet 1B of the second material (102) has a second convex portion, and when the first material and the second material are laminated, the second convex portion faces the first material (101). When observing the cross section in which the first material and the second material are laminated, the first convex portion and the second convex portion face each other.

Further, as a material other than the first material (101 in FIG. 1) and the second material (102 in FIG. 1), the third material (103) is laminated between the first material and the second material.

When the laminated materials as shown in FIG. 1 are placed on the molding die shown in FIG. 5 and press-molded, the shock absorbing member shown in FIG. 2 can be manufactured. When pressed, the first convex portion and the second convex portion are inverted from the inward direction of the material and become convex toward the outside of the shock absorbing member. As a result, the impact absorbing member depicted in FIG. 2 is provided with a first impact absorbing convex portion on the side receiving the impact and a second impact absorbing convex portion on the side opposite to the side receiving the impact.
Further, by providing convex portions on both sides of the created shock absorbing member, it is possible to suppress the warp of the molded body.

[Example of the second form (FIGS. 3 and 4)]
The laminated structure of FIG. 3 and the impact absorbing member of FIG. 4 will be described as an example.

In FIG. 3, the first material (301) is a laminated sheet 1A, sheet 1B, and sheet 1C. The sheet 1A has a first convex portion, and when the first material and the second material are laminated, the first convex portion faces the second material (302). The sheet 1B has a third convex portion, and when the sheet 1A and the sheet 1B are laminated, the third convex portion faces the sheet 1A.

The second material (302) is a laminated sheet 2A, sheet 2C, and sheet 2B. The sheet 2A has a second convex portion, and when the first material and the second material are laminated, the second convex portion is convex toward the first material. The sheet 2B has a fourth convex portion, and when the sheet 2A and the sheet 2B are laminated, the fourth convex portion faces the sheet 2A.

When observing the cross section in which the first material and the second material are laminated, the first convex portion and the second convex portion face each other, and the first convex portion and the third convex portion, and the second convex portion and the fourth convex portion also face each other. , Similarly heading towards each other. In FIG. 3, there is no laminated material other than the first material and the second material.

When the laminated materials as shown in FIG. 3 are placed on the molding die shown in FIG. 5 and press-molded, the shock absorbing member depicted in FIG. 4 can be manufactured. When pressed, the first convex portion and the second convex portion are inverted from the inward direction of the material and become convex toward the outside of the shock absorbing member. The third convex portion and the fourth convex portion become convex outward as they are. As a result, the shock absorbing member depicted in FIG. 4 is provided with a first shock absorbing convex portion on the side receiving the impact and a second impact absorbing convex portion on the side opposite to the side receiving the impact. By providing convex portions on both sides of the created shock absorbing member, it is possible to suppress the warp of the molded body.

[Example of the third aspect (FIGS. 11 and 12)]
The laminated structure of FIG. 11 and the impact absorbing member of FIG. 12 will be described as an example.

1. 1. Layer structure 1.1 First material In FIG. 11, the first material (1101) includes a sheet 1A, and the sheet 1A has a first convex portion. Here, the sheet 1A for forming the first convex portion is described as five unidirectional composite material sheets (sheet 1Aa, sheet 1Ab, sheet 1Ac, sheet 1Ad, sheet 1Ae, hereinafter simply "1Aa" and the like. Sheet 1C (Sheet 1Cd, Sheet 1Ce, Sheet 1Cf, Sheet 1Cg, hereinafter simply It may be described as "1Cd" etc.). In other words, the sheets 1A and the sheets constituting the sheet 1C (1Aa, 1Ab, 1Ac, 1Ad, 1Ae, 1Cd, 1Ce, 1Cf, 1Cg) are alternately laminated. The unidirectional composite material sheets (1Aa, 1Ab, 1Ac, 1Ad, 1Ae) constituting the sheet 1A are not in direct contact with each other, but form a first convex portion. The sheets 1Aa, 1Ab, 1Ac, 1Ad, and 1Ae are laminated in a stepped manner so that the central portion of the first material is at the top to form the first convex portion.

When the first material (1101) and the second material (1102) are laminated, the first convex portion faces the second material (1102).

1.2 Second Material In FIG. 11, the second material (1102) includes a sheet 2A, and the sheet 2A has a second convex portion. Here, the sheet 2A for forming the second convex portion is described as five unidirectional composite material sheets (sheet 2Aa, sheet 2Ab, sheet 2Ac, sheet 2Ad, sheet 2Ae, hereinafter simply "2Aa" and the like. Sheet 2C (Sheet 2Cd, Sheet 2Ce, Sheet 2Cf, Sheet 2Cg, etc.) between these five unidirectional composite material sheets (Sheet 2Aa to Sheet 2Ae). It may be simply described as "2Cd" etc.). In other words, the sheets 2A and the sheets constituting the sheet 2C (2Aa, 2Ab, 2Ac, 2Ad, 2Ae, 2Cd, 2Ce, 2Cf, 2Cg) are alternately laminated. The unidirectional composite material sheets (2Aa, 2Ab, 2Ac, 2Ad, 2Ae) constituting the sheet 2A are not in direct contact with each other, but form a second convex portion. The sheets 2Aa, 2Ab, 2Ac, 2Ad, and 2Ae are laminated in a stepped manner so that the central portion of the second material is at the top to form the second convex portion.

When the first material (1101) and the second material (1102) are laminated, the second convex portion faces the first material (1102). When observing the cross section in which the first material and the second material are laminated, it is preferable that the first convex portion and the second convex portion face each other.

1.3 Third material As a material other than the first material (1101 in FIG. 11) and the second material (1102 in FIG. 11), the third material (1103) is laminated between the first material and the second material. There is.

2. 2. Unidirectional Composite Material and Orientation Direction The sheets 1A, sheet 1C, sheet 2A, and sheet 2C constituting the first material, the second material, and the third material drawn in FIG. 11 are unidirectionally reinforced composite materials. It is a material.
Hereinafter, the longitudinal direction of the first material and the second material will be described as 0 degrees, and the lateral direction will be described as 90 degrees.

2.1 First Material Sheets 1Aa, 1Ab, 1Ac, 1Ad, and 1Ae constituting the first material sheet 1A are layers one by one oriented in the lateral direction of the first material (90 degree layer, 1 ply). May be described as).

Sheets 1Ca and 1Cc, which are a part of Sheet 1C, are two layers oriented in the longitudinal direction of the first material (2 ply of 0 degree layer).

Sheet 1Cb, which is a part of Sheet 1C, is a single layer oriented in the lateral direction of the first material (1 ply of 90 degree layer).

Sheets 1Cd, 1Ce, 1Cf, 1Cg, and 1Ch, which are a part of the sheet 1C, are layers (1 ply) oriented in the longitudinal direction of the first material. (It may be described as 0 degree layer).

2.2 Second material The sheets 2Aa, 2Ab, 2Ac, 2Ad, and 2Ae constituting the second material sheet 2A are layers one by one oriented in the lateral direction of the second material (90 degree layer 1 ply). ..

Sheets 2Ca and 2Cc, which are part of the sheet 2C, are two layers oriented in the longitudinal direction of the second material (2 ply of 0 degree layer).

Sheet 2Cb, which is a part of Sheet 2C, is a single layer oriented in the lateral direction of the second material (1 ply of 90 degree layer).

Sheets 2Cd, 2Ce, 2Cf, 2Cg, and 2Ch, which are a part of the sheet 2C, are layers one by one oriented in the longitudinal direction of the second material. (1 ply of 0 degree layer).

3. 3. Molding 3.1 Manufacture of Impact Absorbing Member When the laminated materials as shown in FIG. 11 are placed on the molding die shown in FIG. 13 and press-molded, the impact absorbing member depicted in FIG. 12 can be manufactured.

When pressed, the first convex portion and the second convex portion are inverted from the inward direction of the material (the first convex portion faces the second material and the second convex portion faces the first material). However, it becomes convex toward the outside of the shock absorbing member. As a result, the shock absorbing member drawn in FIG. 12 is provided with a first shock absorbing convex portion on the side receiving the impact and a second shock absorbing convex portion on the side opposite to the side receiving the impact. The first impact absorbing convex portion and the second impact absorbing convex portion include a mountain-shaped convex portion having a central portion in the longitudinal direction as a peak. By providing convex portions on both sides of the created shock absorbing member, it is possible to suppress the warp of the molded body.

3.2 Press molding The molding die shown in FIG. 13 is different from the one drawn in FIG. 5, and the cross-sectional shape is not stepped. In general, from the viewpoint of processing a molding die, an egg-shaped molding die (FIG. 13) is easier to form than a stepped molding die (FIG. 5).

However, when the sheet 1A and the sheet 2A laminated in a stepwise manner in the longitudinal direction of the material as shown in FIG. 11 are used and pressed using the molding die drawn in FIG. 13, the sheet 1A and the sheet 2A are pressed. It is necessary to flow the material in the longitudinal direction (X-axis direction in FIGS. 11 and 13). Therefore, the sheets 1Aa, 1Ab, 1Ac, 1Ad, 1Ae constituting the sheet 1A, and the sheets 2Aa, 2Ab, 2Ac, 2Ad, and 2Ae constituting the sheet 2A are oriented in the lateral direction of the first material and the second material. I let you. Fibers are not oriented in the longitudinal direction These sheets tend to flow in the longitudinal direction.

[Reference comparative example (Figs. 6 and 7)]
A reference comparative example will be described by taking the laminated structure of FIG. 6 and the impact absorbing member of FIG. 7 as examples.

In FIG. 6, the material (601) has a convex portion, but the material (602) does not have a convex portion.

When the laminated material as shown in FIG. 6 is placed on a molding die (not shown) and press-molded to manufacture the shock absorbing member depicted in FIG. 7, the convex portion of the material (601) is manufactured. Is inverted from the inward direction of the material and becomes convex toward the outside of the shock absorbing member. In this case, since the material is asymmetric, the shrinkage rate becomes asymmetric with the site where the molding shrinkage occurs, and the shock absorbing member warps.

101, 301, 1101: First material 102, 302, 1102: Second material 103: Third material 104, 304, 1104: In the longitudinal direction of the first material and the second material, in the molding mold opening / closing direction (Y axis) A center line was drawn so as to intersect the center points of all materials.
305: A center line was drawn in the longitudinal direction of the sheet 1A and the sheet 1B so as to intersect the center point of the first material in the mold opening / closing direction (Y axis).
306: A center line was drawn in the longitudinal direction of the sheet 2A and the sheet 2B so as to intersect the center point of the second material in the mold opening / closing direction (Y axis).
201, 401, 1201: First impact absorption convex part 202, 402, 1202: Second impact absorption convex part 501, 1301: Molding mold (upper side)
502: 1302: Molding mold (lower mold)
801 and 901: Door 802, 902: Impact absorbing member 1A: Sheet 1A
1B: Sheet 1B
1C: Sheet 1C
2A: Sheet 2A
2B: Sheet 2B
2C: Sheet 2C
1Ca, 1Cc: 0 degree layer (2py), unidirectional composite material sheet constituting sheet 1C.
1Cb: 90 degree layer (1py), unidirectional composite material sheet constituting sheet 1C.
1Cd, 1Ce, 1Cf, 1Cg, 1Ch: 0 degree layer (1 ply), unidirectional composite material sheet constituting sheet 1C.
1Aa, 1Ab, 1Ac, 1Ad, 1Ae: 90 degree layer (1py), unidirectional composite material sheet constituting sheet 1A.
2Ca, 2Cc: 0 degree layer (2py), unidirectional composite material sheet constituting sheet 2C.
2Cb: 90 degree layer (1 ply), unidirectional composite material sheet constituting sheet 2C 2Cd, 2Ce, 2Cf, 2Cg, 2Ch: 0 degree layer (1 ply), unidirectional composite material sheet constituting sheet 2C ..
2Aa, 2Ab, 2Ac, 2Ad, 2Ae: 90 degree layer (1py), unidirectional composite material sheet constituting the sheet 2A.
1103: 90 degree layer (1 ply), third material 1402: 90 degree layer, unidirectional composite material sheet constituting sheet 1A.
1403: A one-way composite material sheet constituting the 90 degree layer, sheet 2A.

Claims (18)

It is a method of manufacturing a shock absorbing member by laminating a first material having a first convex portion and a second material having a second convex portion, arranging them in a molding die, and molding them.
The impact absorbing member is provided with a first impact absorbing convex portion on the impact receiving side and a second impact absorbing convex portion on the side opposite to the impact receiving side.
Manufacturing method of shock absorbing member. When the first material and the second material are laminated, the first convex portion is convex toward the second material, and the second convex portion is convex toward the first material. The method for manufacturing a shock absorbing member according to claim 1. The impact absorption according to claim 2, wherein the first convex portion before molding forms the first impact absorption member convex portion or the second impact absorption convex portion by reversing the convex direction before and after molding. Manufacturing method of parts. The method for manufacturing a shock absorbing member according to claim 3, wherein the second convex portion is inverted in the direction opposite to the first convex portion before and after molding. 1. The cross section of the first impact absorbing convex portion and the second impact absorbing convex portion is triangular, trapezoidal, arcuate, other polygonal, mountain-shaped, hemispherical, spherical crown-shaped, or stepped. The method for manufacturing a shock absorbing member according to any one of 4 to 4. The first impact absorbing convex portion forms an outward convex from the impact absorbing member, and forms a convex.
The second impact absorbing convex portion forms an outward convex from the impact absorbing member in the direction opposite to the first impact absorbing convex portion.
The method for manufacturing a shock absorbing member according to any one of claims 1 to 5. The first material is a laminate containing at least Sheet 1A and Sheet 1B, wherein Sheet 1A comprises the first convex portion and Sheet 1B comprises a third convex portion.
When the sheet 1A and the sheet 1B are laminated, the third convex portion is convex toward the sheet 1A.
The method for manufacturing a shock absorbing member according to any one of claims 2 to 6. The second material is a laminate containing at least a sheet 2A and a sheet 2B, wherein the sheet 2A comprises the second convex portion and the sheet 2B comprises a fourth convex portion.
When the sheet 2A and the sheet 2B are laminated, the fourth convex portion is convex toward the sheet 2A.
The method for manufacturing a shock absorbing member according to claim 7. The method for manufacturing a shock absorbing member according to any one of claims 1 to 8, wherein the first convex portion and / or the cross section of the second convex portion has a stepped surface shape. The method for manufacturing a shock absorbing member according to claim 8, wherein the third convex portion and / or the cross section of the fourth convex portion has a stepped surface shape. The method for manufacturing a shock absorbing member according to any one of claims 1 to 10, wherein the first material and / or the second material is a laminate of sheets containing reinforcing fibers and a resin. The first material comprises the sheet 1A and the sheet 1B.
The second material comprises the sheet 2A and the sheet 2B.
The method for manufacturing a shock absorbing member according to claim 11, wherein the sheet 1A, the sheet 1B, the sheet 2A, and the sheet 2B are carbon fiber composite materials or glass fiber reinforced composite materials. The shock absorbing member has a beam shape and has a beam shape.
The method for manufacturing a shock absorbing member according to claim 12, wherein the thickness of the first shock absorbing convex portion and / or the second shock absorbing convex portion becomes thicker toward the center of the beam. The method for manufacturing a shock absorbing member according to claim 12, wherein the thickness of the first shock absorbing convex portion and / or the second shock absorbing convex portion becomes thicker toward the center in the longitudinal direction of the beam. The sheet 1A and the sheet 2A are unidirectional carbon fiber composite materials or glass fiber composite materials.
The method for manufacturing a shock absorbing member according to claim 13 or 14, wherein the fibers are oriented toward the longitudinal direction of the first material and the second material. The sheet 1A and the sheet 2A are unidirectional carbon fiber composite materials or glass fiber composite materials.
The method for manufacturing a shock absorbing member according to claim 13 or 14, wherein the fibers are oriented toward the lateral side of the first material and the second material. The method for manufacturing a shock absorbing member according to any one of claims 1 to 16, wherein the shock absorbing member is a door of an automobile. It is a method of manufacturing a shock absorbing member by laminating a first material and a second material, arranging them in a molding die, and molding them.
The first material and the second material have a layered structure having an uneven thickness structure.
When the first material and the second material are laminated, an uneven thickness structure is formed in which the layer is made smaller toward the inside of the cross section.
A method of manufacturing a shock absorbing member by reversing the uneven thickness structure in a molding die to the outside of a cross section at the time of molding.

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