JP2022189196A - Structure and method for using the same - Google Patents

Abstract

To provide a structure having high strength with a new constitution, and a method for using the same.SOLUTION: A structure 16 has a structure 17 which has a bead part 30 and is shaped integrally with the bead part 30, and a reinforcing band 50 provided along the bead part 30, wherein the bead part 30 is shaped so as to be recessed on one surface side 17a of the structure part 17 and to be protruded on an opposite surface side 17b thereof, the reinforcing band contains continuous fibers bonded each other by a matrix resin, and is joined integrally with the bead part along the recessed surface and/or the protruded surface of the bead part, and the continuous fibers are installed in the extension direction of the bead part. A method for using the same uses the inside of the recess of the bead part as an installation space where a long article is laid. The method uses the inside of the recess as a flow channel of a flow article.SELECTED DRAWING: Figure 1

Description

The present invention relates to structures and methods of use thereof. More particularly, it relates to a fiber-reinforced structure using continuous fibers and a method of using the same.

In recent years, attempts have been made to substitute structural materials, which have been formed using metals, with resins. Among them, fiber reinforced resins, particularly carbon fiber reinforced resins (CFRP) using carbon fibers as reinforcing fibers, have attracted attention. Fiber-reinforced resins are promising because they are superior in strength and rigidity and can be made lighter than metals. For example, a vehicle seat disclosed in Patent Document 1 below is known as a structure using a fiber-reinforced resin.

JP 2015-193303 A

In Patent Document 1, a reinforcing member 50 protrudes from the occupant seating surface to the opposite surface side through a through hole 36 that communicates with the occupant seating surface side and the opposite surface side of the seat shell (back pan 32). A mounted structure (vehicle seat) is disclosed. The back pan 32 is exemplified by a fiber-reinforced plastic obtained by injection-molding a composite resin with carbon fiber having a fiber length of about 1 mm as a reinforcing material and polypropylene as a matrix resin. A fiber-reinforced plastic with polypropylene as a matrix resin is exemplified. According to Patent Document 1, a high-strength vehicle seat can be obtained, but various high-strength structures with more variations are desired.
SUMMARY OF THE INVENTION It is an object of the present invention to provide a high-strength structure with a novel configuration and a method for using the same.

That is, the present invention is shown below.
[1] The structure of the present invention has a structure integrally formed with one or more beads, and a reinforcing band provided along the beads,
The bead portion is shaped so as to form a concave streak on one side of the structural portion and a protruded streak on the opposite side,
The reinforcing band includes continuous fibers bound by a matrix resin, and is integrally joined to the bead along the concave and/or convex surfaces of the bead,
The gist is that the continuous fibers are laid along the extending direction of the bead portion.
[2] In the structure of the present invention, the reinforcing portion provided with the reinforcing band may be thicker than the circumference of the reinforcing portion not provided with the reinforcing band.
[3] In the structure of the present invention, the structural part is made of a fiber-reinforced resin containing dispersed discontinuous fibers and/or a fiber-reinforced resin containing a woven fabric using continuous fibers. can be
[4] In the structure of the present invention, the reinforcing band includes a fiber bundle obtained by bundling the continuous fibers, a base fabric to which the fiber bundle is sewn, and the fiber bundle and the base fabric impregnated and fixed. and a matrix resin.
[5] In the structure of the present invention, the reinforcing band may have a transition region in the matrix resin on the joint surface side with the bead portion.
[6] In the structure of the present invention, the bead portion may have a fastening structure with another structure.
[7] The structure of the present invention can be a back shell of a vehicle seat.
[8] The gist of the method of using the structure of the present invention is that the inside of the recessed line of the bead portion is used as a laying space for laying a long object.
[9] The gist of another method of using the structure of the present invention is to use the inside of the groove of the bead portion as a flow path for a fluid.

According to the structure of the present invention, a high-strength structure can be obtained with a novel configuration.
According to the method of using the structure of the present invention, the reinforcement structure can be effectively utilized for the purpose of obtaining other effects as well as reinforcement.

The present invention will be further described in the following detailed description by way of non-limiting examples of exemplary embodiments according to the invention and with reference to the mentioned drawings, wherein like reference numerals indicate Similar parts are shown throughout the several figures.
It is explanatory drawing which shows an example of this structure. It is explanatory drawing which shows the other example of this structure. It is explanatory drawing which shows the variation of this structure. It is explanatory drawing which shows the other example of this structure. 1 is a perspective view of a seatback frame (assembled state) according to an embodiment; FIG. It is a perspective view of a seat back frame (disassembled state). FIG. 6 is a cross-sectional view taken along line III-III of FIG. 5; FIG. 8 is an enlarged view of a main portion of FIG. 7; 1 is a side view of a vehicle seat according to an embodiment; FIG. It is explanatory drawing explaining the variation of the extension direction of a bead part.

The material presented herein is intended to be illustrative and illustrative of the embodiments of the invention and is the description that most effectively and readily understands the principles and conceptual features of the invention. It is described for the purpose of providing what is believed to be In this regard, no attempt is made to show structural details of the invention beyond those necessary for a fundamental understanding of the invention, and the description in conjunction with the drawings will illustrate some aspects of the invention. It will be clear to those skilled in the art how it is actually implemented.
In this specification, unless otherwise specified, the description of "XX to YY" means "XX or more and YY or less".

[1] Structure A structure (16) of the present invention comprises a structure (17) having a bead (30) and a reinforcing band (50) provided along the bead (30). . The bead portion (30) is shaped such that one side (17a) of the structural portion (17) is concave and the opposite side (17b) is convex. Further, the bead portion (30) is formed integrally with the structural portion (17) and has one or more streaks.
On the other hand, the reinforcing band (50) comprises a matrix resin (51) and continuous fibers (52), and the continuous fibers (52) are included in the reinforcing band (50) in a state bound by the matrix resin (51). . Furthermore, the reinforcement strip (50) is integrally joined to the bead (30) along the concave surface (30a) and/or convex surface (30b) of the bead (30), and the continuous fibers (52) are: It is laid along the extending direction of the bead portion (30) (see FIGS. 1 to 4).

By including both the bead portion 30 and the reinforcing band 50, the structure 16 can be a high-strength structure.
The shape and size of the structural portion 17 are not limited. The shape of the structure portion 17 can be, for example, a three-dimensional shape having unevenness. Furthermore, curved surface shapes, flat plate shapes, and the like can be included. These shapes may contain only one type, or may contain two or more types at the same time. That is, for example, a three-dimensional shape that includes an uneven shape, a curved surface shape, and a flat plate shape can be used. In addition, it can have a shape such as a cylindrical shape or a polygonal tubular shape.
The structural portion 17 is preferably shell-shaped in terms of both lightness and strength. The shell shape can be said to have a general shape that is broadly concave toward the center. For example, as described below, the back shell of a vehicle seat may be mentioned as a representative example.

Also, the material of the structural portion 17 is not limited, but resin can be used because it is both lightweight and strong. The resin type is not limited, and may be a thermoplastic resin or a curable resin (various curable resins regardless of the curing method), and may be used in combination depending on the purpose. That is, for example, the structure may be injection-molded using a thermoplastic resin. Further, the structural portion 17 may be formed only from resin, but may contain reinforcing fibers from the viewpoint of strength improvement. That is, the structural portion 17 can be formed using a fiber-reinforced resin containing a resin (matrix resin) and reinforcing fibers bound by the resin.

Among resins (matrix resins when reinforcing fibers are included) that can constitute the structural part 17, thermoplastic resins include, for example, polyolefins, polyesters, polyamides, polycarbonates, acrylic resins, fluorine-containing thermoplastic resins, polyimides, Examples include polyamide-imide, resin alloys (composite resins) containing two or more of these thermoplastic resins, and the like. These may use only 1 type and may use 2 or more types together. On the other hand, examples of curable resins include epoxy resins, unsaturated polyester resins, phenol resins, urea resins, melamine resins, diallyl phthalate resins, and vinyl ester resins. These may use only 1 type and may use 2 or more types together.

The reinforcing fibers may be continuous fibers, discontinuous fibers, or both. Generally, continuous fibers have a fiber length of 15 mm or more, and discontinuous fibers have a fiber length of less than 15 mm. When using discontinuous fibers, the mixture of resin and discontinuous fibers can be injection molded. The injection-molded structural portion 17 is a fiber-reinforced resin in which discontinuous fibers are dispersed in the resin. On the other hand, when continuous fibers are used, the fiber-reinforced resin is formed by binding the continuous fibers with a resin. The continuous fibers may be contained in the fiber-reinforced resin in a state of being simply aligned, or may be contained as a woven fabric or the like.

Materials constituting the reinforcing fibers are not limited, and may be inorganic fibers or organic fibers, or may be used in combination.
Examples of inorganic fibers include carbon fibers, activated carbon fibers, glass fibers, ceramic fibers (silicates, titanates, alumina, etc.), metal fibers, boron fibers, and the like. These may use only 1 type and may use 2 or more types together.
Organic fibers include natural fibers and synthetic fibers. These may use only 1 type and may use 2 or more types together. Among these, synthetic fibers include fibers obtained by forming a synthetic resin into a fiber shape. Such synthetic resin fibers include polyamide resin fibers (aliphatic polyamide (nylon fiber, etc.), aromatic polyamide (aramid fiber, trade name "Kevlar", etc.), etc.), polyester resin fibers (aliphatic polyester, aromatic Polyester (polyethylene terephthalate fiber, polyethylene naphthalate fiber, etc.), polyolefin resin fiber (high molecular weight polyolefin (product name "Dyneema", etc.), etc.), polybenzazole resin fiber (polyparaphenylene benzobisoxazole fiber (product name " Zylon”, etc.), etc.).

Further, the reinforcing fibers are preferably fibers having a high tensile strength, for example, fibers having a tensile strength of 7 cN/dtex or more (usually 50 cN/dtex) according to JIS L1015.
Furthermore, the form of the reinforcing fiber is not limited, and may be a spun yarn, a filament yarn, or a combination thereof. Furthermore, monofilaments may be used, multifilaments may be used, and these may be used in combination.

In the present structure 16, carbon fiber is particularly preferable among the above materials. The type of carbon fiber is not limited, and examples thereof include PAN (polyacrylonitrile)-based carbon fiber and pitch-based carbon fiber. These may use only 1 type and may use 2 or more types together.
Carbon fibers can be used as filaments, but they may also be used as bundles (tows). The number of carbon fibers forming the bundle is not limited, and can be, for example, 3000 or more. When the number of continuous fibers constituting the bundle is 3000 or more, it is possible to exhibit excellent strength as a core material while being flexible. In addition, the number of continuous fibers can be, for example, 3,000 or more and 100,000 or less, further can be 5,000 or more and 70,000 or less, further can be 7,000 or more and 50,000 or less, and further can be 10,000. It can be set to 30000 or less.

The bead portion 30 is a portion formed so as to form a groove on one side 17a of the structure portion 17 and a protrusion on the opposite side 17b. The bead portion 30 is a part of the structural portion 17 and is an integrated object formed integrally with the structural portion 17 . Since the structure 16 includes the bead portion 30, the strength and rigidity of the structure 16 are improved compared to when the structure 16 does not include the bead portion 30. FIG. Further, as described above, the bead portion 30 is shaped so that the one surface side 17a of the structure portion 17 is concave and the facing side 17b is convex, so that the bead portion, which is a reinforcing structure, can be formed thin. . Therefore, significant strength reinforcement can be performed while suppressing an increase in the weight of the structure 16 .
The bead portion 30 may be recessed toward either the front or back side of the structure portion 17 and may protrude toward either side. Preferably, the bead portion 30 is also recessed on the side where the shape is recessed, and the bead portion 30 is also projected on the side where the general shape of the structure 17 is projected.

As described above, the bead portion 30 may be a groove on one side 17a of the structural portion 17 and a protrusion on the opposite side 17b. A cup shape, an arc shape, a V shape, and the like can be mentioned.
Of these, the U-shape has a pair of side walls 41 facing each other and a connecting wall 42 connecting the edges of the pair of side walls 41, and the pair of side walls 41 are arranged substantially parallel to each other. A mode is included in which the connecting wall 42 has a substantially flat plate shape and has a curved shape in which the connecting wall 42 is curved inwardly. Also, a mode in which the pair of side walls 41 provided in this U-shape are arranged so that the distance between the side walls 41 increases toward the open end can also be included.
The U-shape has a pair of side walls 41 facing each other and a connecting wall 42 connecting the edges of the pair of side walls 41. The pair of side walls 41 are arranged substantially parallel to each other. It is made into flat plate shape, and the aspect made into substantially flat plate shape by which the connection wall 42 was arrange|positioned at substantially right angle with the side wall is included.
Furthermore, the cup shape (see FIGS. 1 to 4) includes a pair of side walls 41 facing each other and a connecting wall 42 connecting the edges of the pair of side walls 41. The pair of side walls 41 are The side walls 41 are arranged non-parallel and have a substantially flat plate shape. Embodiments arranged to be are included.
In addition, the arc shape includes a pair of side walls and a connecting wall connecting the edges of the pair of side walls, and the side walls and the connecting wall are curved in a series of inwardly concave shapes. An embodiment is included.
Furthermore, the V-shape includes a mode in which a pair of substantially flat side walls are connected at their edges so as to form an inner recess.

Although the size of the bead portion 30 is not limited, the ratio (t4 /t3) can be from 0.1 to 50, preferably from 0.5 to 25, more preferably from 1 to 10. However, the depth (height) of the bead portion 30 may be constant in the longitudinal direction of the bead portion 30, or may be changed.

Also, the bead portion 30 is generally elongated. Therefore, the bead portion 30 can act like a beam in the structure 16, and can reinforce a wide range including regions other than the region where the bead portion 30 is formed. For this reason, the bead portion 30 may be provided only on a part of the structure portion 17 , but it is more preferable to provide the bead portion 30 so as to traverse or longitudinally cut through the structure portion 17 . That is, for example, a bead portion 30 extending in the width direction of the structural portion 17, a bead portion 30 extending in the vertical width direction of the structural portion 17, a bead portion 30 extending along the outer edge of the structural portion 17, and the like. Furthermore, the bead portions 30 can be arranged so as not to cross each other (see FIG. 10(a)), but from the viewpoint of torsional strength, etc., a plurality of bead portions 30 are arranged so as to cross each other (see FIG. 10 ( b) see). For example, a pair of bead portions 30 can be arranged to cross each other in an X shape.
In addition, the bead portion 30 may be formed in a straight line or a curved shape when viewed from above, or may be formed in a composite shape including both a straight portion and a curved portion. good too. In addition, the number of bead portions, arrangement form, etc. are not particularly limited, and are appropriately selected according to the application.

The reinforcing band 50 includes a matrix resin 51 and continuous fibers 52 , and the continuous fibers 52 are included in the reinforcing band 50 in a state of being bound by the matrix resin 51 . Moreover, it is preferable that the continuous fibers 52 are substantially aligned in the same direction.
Further, the reinforcing band 50 is integrally joined to the bead portion 30 along the concave surface 30a and/or the convex surface 30b of the bead portion 30, and the continuous fibers 52 are laid along the extending direction of the bead portion 30. . Specifically, for example, a reinforcing band 50 covering the bottom of the concave surface 30a and/or the top of the convex surface 30b of the bead portion 30 can be provided. Further, for example, as exemplified in FIG. 3A, a reinforcing band 50 covering substantially the entire surface of the convex surface 30b of the bead portion 30 can be provided. Further, as illustrated in FIG. 3B, a reinforcing band 50 that covers only the top surface of the convex surface 30b of the bead portion 30 and the outer surface of one side wall 41 can be provided. Furthermore, as illustrated in FIG. 3C, a reinforcing band 50 covering the bottom surface of the concave surface 30a of the bead portion 30 can be provided. Further, as illustrated in FIG. 3D, a reinforcing band 50 covering substantially the entire concave surface 30a of the bead portion 30 can be provided. Furthermore, as illustrated in FIG. 3E, a reinforcing band 50 covering only the bottom surface of the concave surface 30a of the bead portion 30 and the inner surface of one side wall 41 can be provided.
Also, the structure 17 may be provided with the reinforcing band 50 so as to have the same thickness as the perimeter 17s of the structural portion 17 without the reinforcing band 50, but it may be thicker than the perimeter 17s of the structural portion 17. It is preferable to have reinforcing strips 50 in the . In this aspect, a more pronounced reinforcing effect can be obtained. Similarly, when comparing the thickness t1 of the bead portion 30 (that is, the reinforcing portion) provided with the reinforcing band 50 and the thickness t2 of the bead portion 30 not provided with the reinforcing band 50, both have the same thickness. However, it is preferable to form the thickness t1 so as to be thick. In this aspect, a more pronounced reinforcing effect can be obtained.

That is, the reinforcing band 50 is provided in order to lay the continuous fibers 52 along the extending direction of the bead portion 30 . By laying the continuous fibers 52 along the extending direction of the bead portion 30, more excellent strength reinforcement can be obtained as compared with the case where only the bead portion 30 is provided.
In particular, as described above, the structural portion 17 (including the bead portion 30) is made of a fiber-reinforced resin, and the reinforcing fibers are discontinuous fibers, or when the reinforcing fibers are included as a woven fabric. becomes. When the reinforcing fibers are discontinuous fibers, the structural portion 17 can be molded more easily by injection molding or the like. , is input broadly over the left and right ends, the structure 17 alone cannot have reinforcing fibers extended along the input range. That is, discontinuous fibers are short in length and contained in structure 17 oriented in various directions, and thus cannot have properties that strongly contribute to a specific direction. The same is true when reinforcing fibers are included as a woven fabric, and since the entire amount of the included reinforcing fibers cannot be oriented in the required direction, reinforcing fibers that do not contribute to reinforcement are included. Such a tendency becomes more conspicuous when the structure portion 17 has a shell shape. That is, when an external input is applied to the structural body 16, the input in a wide range where the bead portion 30 is not formed is likely to be collected to the bead portion 30 if the structural portion 17 has a shell shape. This is because there are cases where a larger force acts on the bead portion 30 .

On the other hand, when the bead portion 30 requiring reinforcement is provided and the reinforcing band 50 is provided so that the continuous fibers 52 are laid along the extension direction of the bead portion 30, the laid continuous fibers 52 The entire amount is available as a stiffening element to counteract the input applied to the bead portion 30 . That is, since the bead portion 30 is a reinforcing structure that is attached after determining the installation direction, the reinforcement carried by the bead portion 30 is the extending direction of the bead portion 30 . Therefore, in the bead portion 30, the reinforcement path is clear, and the reinforcement effect of the reinforcement band 50 can be obtained very significantly.

The reinforcing band 50 may be provided with the matrix resin 51 and the continuous fibers 52, but may be provided with other configurations. Specifically, a base fabric 54 and a sewing thread can be provided (see FIGS. 1 and 2). That is, as described above, it is easier to obtain the effect of arranging the continuous fibers 52 by bundling them rather than using them separately. Therefore, it is preferable to use the continuous fibers 52 as a bundled fiber bundle 53 . Moreover, when using the fiber bundle 53, it is preferable to use a base material for fixing the orientation direction thereof, and the base fabric 54 can be used as this base material.
The base fabric 54 can have a function of consolidating the plurality of fiber bundles 53 so that they can be easily handled collectively. The fiber slivers 53 may be fixed to the base fabric 54 in any manner, but in particular can be fixed by sewing. In this case, a sewing thread can be used to sew and fix the fiber bundle 53 to the base cloth 54 .
In this way, the core material obtained by sewing the fiber bundle 53 with a sewing thread is easy to impregnate the core material with the matrix resin 51, which is convenient for compounding as a fiber-reinforced resin.

That is, for example, the reinforcing band 50 includes a fiber bundle 53 in which continuous fibers 52 are bundled, a base fabric 54 in which the fiber bundles 53 are arranged, and a matrix resin 51 impregnated and fixed in the fiber bundle 53 and the base fabric 54. be prepared.
The fiber bundle 53 may or may not have a twist. Also, the fiber bundle 53 may contain fibers (non-reinforced fibers) other than the continuous fibers 52 (reinforced fibers).
The fiber bundle 53 may be bundled in any way. This bundling can be realized, for example, in a state in which a plurality of continuous fibers 52 are simply aligned. Alternatively, the bundling can be achieved by bundling a plurality of continuous fibers 52 using yarn (bundle yarn). Alternatively, the bundling can be realized by binding the continuous fibers 52 to each other using another agent such as an adhesive, a pressure sensitive adhesive, or a heat-sealing agent.

The material of the continuous fibers 52 forming the reinforcing band 50 is not limited, but the same material as that of the continuous fibers 52 used when forming the structural portion 17 with fiber-reinforced resin can be used. It is the same that carbon fiber is particularly preferable among the above-mentioned materials. The type of carbon fiber is not limited, and examples thereof include PAN (polyacrylonitrile)-based carbon fiber and pitch-based carbon fiber. These may use only 1 type and may use 2 or more types together.
Carbon fibers can be used as filaments, but as described above, when used as the fiber bundle 53, the number of continuous fibers 52 constituting one fiber bundle 53 is not particularly limited. This number can be, for example, 3000 or more. Since the number of continuous fibers 52 constituting one fiber bundle 53 is 3000 or more, it is possible to exhibit excellent strength as a core material while being flexible. In addition, the number of continuous fibers 52 can be, for example, 3000 or more and 100000 or less, further can be 5000 or more and 70000 or less, further can be 7000 or more and 50000 or less, It can be 10,000 or more and 30,000 or less.
Incidentally, the continuous fibers 52 usually have a fiber length of 15 mm or more.

As the fiber bundle 53, a fiber bundle 53 (thick bundle) in which the number of continuous fibers 52 constituting one fiber is increased can also be used. When a thick bundle is used, the number of continuous fibers 52 can be, for example, 30,000 or more, can be 40,000 or more, and further can be 60,000 or more. On the other hand, when a thick bundle is used, the number of continuous fibers 52 can be, for example, 1,500,000 or less, and further 1,000,000 or less.

For example, the fiber bundle 53 may be arranged on the base fabric 54 in one layer, or may be arranged in multiple layers of two or more layers on the base fabric 54 (see FIG. 2).
From the viewpoint of suppressing stress concentration, etc., on both sides in the width direction of the reinforcing band 50, a portion having fewer layers of the fiber bundles 53 and a portion having a larger interval between adjacent fiber bundles 53 than the middle side sandwiched between the two sides are provided. can be provided. This portion is a gradually changing portion where the number of layers of the fiber bundles 53 gradually decreases and a gradually changing portion where the interval between adjacent fiber bundles 53 gradually increases from the middle side in the width direction of the reinforcing band 50 toward both sides. be able to.

The material and the like of the base fabric 54 are not particularly limited. As a material of the base fabric 54, a fiber assembly (woven fabric, knitted fabric, non-woven fabric, etc.), a metal sheet (foil, plate, etc.), a resin sheet (film, plate, etc.), etc. can be used. These may use only 1 type and may use 2 or more types together.
A method for fixing the fiber bundle 53 by the base fabric 54 is not particularly limited. Examples of this fixing method include sewing, adhesion, fusion, and the like. Among these fixing methods, sewing is preferable. An advantage of sewing is that the fiber bundle 53 can be fixed to the base fabric 54 without crimping. Another advantage of sewing is that the degree of restraint of the fiber bundle 53 can be freely controlled by the tension of the sewing thread (not shown). For example, when the fiber bundle 53 is sewn to the base cloth 54, the fiber bundle 53 is firmly fixed to the base cloth 54, and the mobility of the fiber bundle 53 (movability with respect to the base cloth and/or mobility between the fiber bundles 53) can be ensured. Securing the mobility of the fiber bundles 53 imparts flexibility to the reinforcing band 50 .

When the fiber bundle 53 is sewn to the base cloth 54, it is preferable to use a fiber assembly as the material of the base cloth 54. As shown in FIG. That is, when the fiber aggregate is used for the base cloth 54, the fiber bundle 53 can be easily sewn and the reinforcing band 50 can be made flexible. The fiber aggregate may be any of woven fabric, knitted fabric, and non-woven fabric. Among these, woven fabrics are preferred. Advantages of the woven fabric include that it is easy to obtain a balance between flexibility and rigidity, and that the binding force of the sewing thread used for sewing is high.
The weave of the woven fabric is not particularly limited, but a plain weave such as 1×1, 2×2, 3×3, etc. is preferable. The flat weave is preferably finer than 5x5, more preferably 4x4 or finer, more preferably 3x3 or finer, and particularly preferably 2x2 or finer.
Constituent yarns of the fiber assembly are not particularly limited. The same fibers as the continuous fibers 52 forming the fiber bundle 53 can be used as the constituent threads, or different fibers can be used. Specifically, various resin fibers, vegetable fibers, and the like can be used for the constituent threads. Specific examples of the resin constituting the resin fiber include polyamide (aliphatic polyamide, aromatic polyamide, etc.), polyester (polyester having a structural unit derived from aromatic dicarboxylic acid, etc.), and the like. Specific examples of vegetable fibers include cotton fibers and hemp fibers. The fineness of the constituent threads is not particularly limited. This fineness is preferably smaller than that of the fiber bundle 53 .

The reinforcing band 50 is formed by arranging the fiber bundles 53 in parallel on one surface of the base fabric 54 . The form of the reinforcing band 50 is not particularly limited. This form can be, for example, a structure in which the fiber bundles 53 are arranged over the entire surface of the base cloth 54 , or a structure in which the fiber bundles 53 are arranged only in necessary portions on one surface of the base cloth 54 .
The reinforcing band 50 may be composed of only one fiber bundle 53 or may be composed of a plurality of fiber bundles 53 . When the reinforcing band 50 is composed of only one fiber bundle 53, it can be realized by folding and arranging one fiber bundle 53 so as to fill one surface of the base cloth 54. FIG. In this case, the folded form of the fiber bundle 53 is not particularly limited. Examples of the folded form include a bellows shape, a spiral shape (a circular spiral, a polygonal spiral, etc.) and the like in plan view. Further, when the reinforcing band 50 is composed of a plurality of fiber bundles 53, it can be realized by aligning and arranging the plurality of fiber bundles 53 so as to fill one surface of the base cloth 54. FIG. In addition, one layer of the reinforcing band 50 is formed by folding one fiber bundle 53 and arranging a plurality of other fiber bundles 53 so as to fill one surface of the base fabric 54 . can also be formed.

Since the reinforcing band 50 is not formed by weaving or knitting the fiber bundles 53, the fiber bundles 53 can be planarly arranged without providing crimps. That is, the reinforcing band 50 suppresses the orientation of the fiber bundles 53 in the thickness direction, and can improve the flatness of the fiber bundles 53 . As a result, the propagation of force through the orientation of the fiber bundle 53 in the thickness direction is suppressed, and excellent shock absorbing power can be exhibited.

The reinforcement band 50 may be arranged, for example, such that the base fabric 54 faces the structural portion 17 or the fiber bundle 53 faces the structural portion 17 . Moreover, the reinforcing band 50 may have only one layer, or may have a plurality of layers laminated with two or more layers. Furthermore, in the case of having a plurality of layers of reinforcing strips 50, for example, in a portion where the plurality of bead portions 30 do not intersect, the arrangement direction of the fiber bundles 53 of each reinforcing strip 50 is parallel, and the plurality of bead portions 30 intersect. At the site, the arrangement direction of the fiber bundles 53 of each reinforcing band 50 can intersect. This crossing angle is preferably more than 0 degrees and 90 degrees or less (0 degrees<θ≦90 degrees).

When the reinforcing band 50 has a plurality of layers, for example, it is preferable that the base fabrics 54 of the reinforcing band 50 are laminated so as to face each other. This is because the force propagation in the thickness direction of the reinforcement band 50 can be more highly controlled. That is, since the fiber bundle 53 does not have crimps, it is possible to highly suppress force propagation in the thickness direction. On the other hand, between the layers and the interlayers in which the base fabrics 54 are arranged to face each other, there is a structure in which the two layers of the base fabrics 54 are arranged side by side. It has an enlarging effect. That is, by facilitating the formation of cracks in the layer direction, the impact force applied in the thickness direction can be efficiently dispersed in the layer direction, and the magnitude of the impact force in the thickness direction can be weakened.
The reinforcing belts 50 are not limited to the configuration in which the base fabrics 54 are stacked facing each other, and the fiber bundles 53 are stacked facing each other. 50 fiber bundles 53 may be stacked facing each other.

The matrix resin 51 is a resin that serves as the base material of the reinforcing band 50 . That is, the matrix resin 51 is a resin that is impregnated and fixed (hardened if it is a curable resin, or hardened if it is a thermoplastic resin) so as to spread over the inside of the fiber bundle 53 and the base fabric 54 . be. As a method for impregnating and fixing the matrix resin 51, various conventionally known methods can be used.
The matrix resin 51 constituting the reinforcing band 50 is also the same as the resin capable of constituting the structural portion 17 (the matrix resin when reinforcing fibers are included).
When both the structural portion 17 and the reinforcing band 50 are made of fiber-reinforced resin, the matrix resins used for them may be different, but preferably of the same quality, and more preferably the same resin. preferable. When the materials are of the same quality or the same resin, the bondability at the interface between the structural portion 17 and the reinforcing band 50 can be improved, and a stronger reinforcing structure can be obtained.
The same quality is exemplified when both matrix resins are polyolefins, polyamides, polyesters, and epoxy resins. That is, there is a case where the resin species are the same. On the other hand, examples of the case where the resins are the same include the case where the specific resins themselves are the same, such as the case where they are polypropylenes and the case where they are polyamide 6s.

In the structure 16, the structure 17 having the bead portion 30 having the reinforcing band 50 and the similar structure 48 similarly formed of a wire-reinforced resin are arranged to face each other, and then both of them are arranged to face each other. It can be used as a structure in which the core layer 47 is provided in the gap between. In this case, by using a foamed resin as the core layer 47, weight reduction can be achieved.

Furthermore, the reinforcement band 50 can have a transition region in the matrix resin 51 on the joint surface side with the bead portion 30 . By having the transition region, the bonding strength between the bead portion 30 and the reinforcing band 50 can be improved. Specifically, there is a transition region between the constituent materials of both. That is, for example, when the structure portion 17 is made of a fiber-reinforced resin using discontinuous fibers, the region in which the discontinuous fibers are included in the interface of the reinforcing band 50 can be used as the transition region. Also, a region where both matrix resins are mixed can be used as a transition region.

Also, the bead portion 30 can have a fastening structure with another structure 18 (see FIG. 3). Other structures 18 include metal parts. The function, shape, size, etc. of the metal parts are not particularly limited. Metal parts include, for example, metal fittings for connecting, fastening, welding, or the like the structural portion 17 to other members. Examples of such metal fittings include hinge metal fittings that are rotatable with respect to other members, connecting metal fittings such as bracket metal fittings and joint metal fittings that are fixed to other members, stay metal fittings that are supported with respect to other members, and others. Angle metal fittings that are fixed at a predetermined angle to a member, fasteners that are fastened to other members, and the like are exemplified.
Moreover, the material constituting the metal parts is not limited, and examples thereof include iron, steel, aluminum, aluminum alloys, copper, and stainless steel.
Furthermore, examples of the form of joining the metal parts to the structural portion 17 include fastening using fasteners 64 such as screws and rivets, insert molding, bonding with an adhesive, laser welding, vibration welding, and the like. Of these, the fastening using the fastener 64 is preferable from the viewpoint of joint strength and the like.

The use of this structure is not particularly limited. This structure can be used, for example, as an automobile part. Automotive supplies include exterior materials for automobiles, interior materials for automobiles, structural materials for automobiles, shock absorbers for automobiles, parts in engine compartments, and the like.
Specifically, bumpers, spoilers, cowlings, front grilles, garnishes, bonnets, trunk lids, cowl louvers, fender panels, rocker moldings, door panels, roof panels, instrument panels, center clusters, door trims, quarter trims, roof linings, Pillar garnish, deck trim, tonneau board, package tray, dashboard, console box, kicking plate, switch base, seat back board, seat frame, armrest, sun visor, intake manifold, engine head cover, engine under cover, oil filter housing, automotive Examples include housings for electronic parts (ECU, TV monitor, etc.), energy absorbers such as air filter boxes and rush boxes, and body shell components such as front end modules.

Examples of the structure include interior materials, exterior materials and structural materials such as buildings and furniture, in addition to automobile parts. That is, door covering materials, door structural materials, covering materials for various types of furniture (desks, chairs, shelves, chests of drawers, etc.), structural materials, unit baths, septic tanks, and the like can be mentioned. In addition, packaging bodies, containers (trays, etc.), protective members, partition members, and the like can also be used. In addition, molded bodies such as housings and structures of home electric appliances (flat TVs, refrigerators, washing machines, vacuum cleaners, mobile phones, portable game machines, laptop computers, etc.) can also be mentioned.

[2] Method of using the structure In the structure 16 described above, the inside of the recessed line of the bead portion 30 can be used as a laying space for laying a long object. Examples of such elongated objects include functional parts such as harnesses (electrical wiring, etc.) and tubes (pump tubes, etc.). These may use only 1 type and may use 2 or more types together.
Furthermore, in the structure 16 described above, the inside of the grooves of the bead portion 30 can be used as a flow path for the fluid. Such fluids include gases and liquids. More specifically, gases such as cold air and warm air are included. That is, it can be used as ventilation. Moreover, a refrigerant|coolant etc. are mentioned as a liquid.

<Vehicle seat>
A vehicle seat according to the present embodiment includes a seat back frame configured with the structure according to the above embodiment. The seat back frame can include, for example, a seat back shell made up of the structural portion and an upper arm made up of the metal part.

It should be noted that the reference numerals for each configuration described in the above embodiment indicate the corresponding relationship with the specific configuration described in the following examples.

Hereinafter, the present invention will be specifically described by way of examples with reference to the drawings.
In this embodiment, a seatback frame of a vehicle seat is exemplified as the "structure" according to the present invention (see FIG. 5).

A vehicle seat 1 according to this embodiment includes, as shown in FIG. 9, a seat cushion 2 that serves as a seating portion for a seated person, and a seat back 3 that serves as a backrest for the seated person. The seat cushion 2 includes a seat cushion frame 5 forming a skeleton. A cushion pad 6 and a skin cover 7 are attached to the seat cushion frame 5 . The seat cushion frame 5 also includes a pair of left and right side frames 11, a front pipe 12 connecting the front ends of the side frames 11, and a rear pipe 13 connecting the rear ends of the side frames. ing. Each of these side frames 11 is provided with a lower arm portion 14 used for connecting the cushion frame 5 and a seat back frame 16 which will be described later. The lower arm portion 14 is formed by projecting the upper edge portion of the rear end portion of the side frame 11 upward in a semi-disc shape.

The seatback 3 includes a seatback frame 16 that forms a skeleton. The seatback frame 16 includes a seatback shell 17 (exemplified as a "structure" according to the present invention) and a pair of left and right upper arms 18 (exemplified as a "metal component" according to the present invention). (See Figure 5). A back pad 21 and an upholstery cover 22 are attached to the seat back shell 17 (see FIG. 7). In addition, the seat back shell 17 is formed in a concave three-dimensional shape as a whole so as to match the outer shape of the rear side of the upper body of the seated person so as to enhance the feeling of holding the backrest. Further, the upper arms 18 are provided so as to protrude downward from the lower end of the seat back shell 17 at both left and right end portions of the seat back shell 17 in the width direction. Further, the upper arm 18 is a metal fixture (for example, iron fittings) used for connecting the seat cushion frame 5 and the seatback frame 16 and is fastened to the seatback shell 17 .

A recliner mechanism 24 (gear mechanism) that rotatably connects the seat back frame 16 to the seat cushion frame 5 is assembled between the upper arm 18 and the lower arm portion 14 . When the recliner mechanism 24 is operated by the reclining motor 25, the seat back frame 16 is rotated with respect to the seat cushion frame 5, and the backrest angle is adjusted to an arbitrary angle. Further, the left and right recliner mechanisms 24 are connected by a shaft 15 (see FIG. 6).

As shown in FIGS. 5 to 7, the seat back shell 17 has a three-dimensional shell shape concave toward the surface side as described above. A back pad 21 is arranged on the surface of the seat back shell 17 (see FIG. 7). Further, the seat back shell 17 is formed with holes 63a and 64a through which fasteners 63 and 64, which will be described later, are inserted (see FIG. 6). In addition, the seat back shell 17 is made of a fiber-reinforced resin (eg, epoxy resin, etc.) in which discontinuous fibers (eg, carbon fibers, etc.) are dispersed and/or continuous fibers (eg, carbon fibers, etc.). The woven fabric is made of fiber-reinforced resin (eg, epoxy resin, etc.). Further, the seat back shell 17 normally faces the front side of the vehicle and the back side of the seat back shell 17 to the rear side of the vehicle when the vehicle seat 1 is mounted on the vehicle.
5 indicates a hole penetrating from the front and back of the seat back shell 17. As shown in FIG. Further, reference numeral "29" in FIG. 7 denotes a cover made of resin or the like that covers the upper arm 18. As shown in FIG.

The seat back shell 17 has a plurality of bead portions 30A, 30B, 30C, and 30D (see FIG. 6). Each of these bead portions 30A to 30D has a pair of side walls 41 facing each other and a connecting wall 42 connecting the tips of the pair of side walls 41 to each other.
6 indicate the extending direction of the bead portions 30A to 30D.

The bead portion 30</b>A (also referred to as “wide bead”) is arranged to extend in the lateral width direction A of the seat back shell 17 . More specifically, the bead portions 30A are arranged so as to connect the portions of the seat back shell 17 that support the shoulders and back of the seated person. The bead portion 30B (also referred to as “main bead”) extends in the longitudinal width direction B (vertical direction) of the seat back shell 17 and is arranged to intersect in an X shape. More specifically, the bead portion 30B is arranged so as to connect the parts of the seat back shell 17 that support the waist, back and head of the seated person. The bead portions 30</b>C (also referred to as “side beads”) are arranged to extend along the left and right edge sides of the seat back shell 17 . Further, a bead portion 30</b>D (also called “connecting bead”) is arranged extending along the lower edge side of the seat back shell 17 . More specifically, the bead portion 30D is arranged so as to connect left and right hollow cross-sectional portions 70, which will be described later.

The bead portions 30A, 30B, and 30D are provided so as to form a groove on the front side 17a of the seat back shell 17 and a protrusion on the rear side 17b (see FIG. 1). A pair of side walls 41 of each of the bead portions 30A, 30B, 30D are raised from the back surface of the surface portion of the seat back shell 17 that supports the backpack 22. As shown in FIG. Further, concave surfaces 30a of the bead portions 30A, 30B, and 30D form hollow portions 40. As shown in FIG. Furthermore, the height of the ridge of the bead portion 30D is higher than the height of the ridge of the bead portion 30B (see FIG. 6). That is, the bead portion 30D protrudes farther toward the back side of the seat back shell 17 than the bead portion 30B. Therefore, a stepped portion 43 is formed at the intersection of the bead portion 30B and the bead portion 30D.

The bead portion 30C is provided so as to form a groove on the back side 17b of the seat back shell 17 and a convex line on the front side 17a. The bead portion 30C is located closer to the surface of the seat back shell 17 than the other bead portions 30A, 30B, and 30D. A side wall 41 inside the bead portion 30</b>C continues to the side edge of the seat back shell 17 . Further, an extension portion 44 extending toward the back side of the seat back shell 17 is provided on the outer side wall 41 of the bead portion 30C.

On each of the bead portions 30A-30D, a continuous fiber (eg, carbon fiber, etc.) 52 bound with a matrix resin 51 (eg, epoxy resin, etc.) and laid along the extending direction of the bead portions 30A-30D. A reinforcing strip 50 is provided integrally (see FIG. 1). The reinforcing band 50 is arranged along the connecting wall 42 of the bead portions 30A, 30B, 30D. Further, the reinforcement band 50 is arranged along the extended portion 44 together with the outer side wall 41 and the connecting wall 42 of the bead portion 30C.

As shown in FIG. 1, the reinforcing band 50 includes a fiber bundle 53 in which continuous fibers 52 are bundled, a base cloth (for example, a woven fabric) 54 in which the fiber bundle 53 is arranged, and the fiber bundle 53 and the base cloth 54 impregnated. and a fixed matrix resin 51 . The fiber bundle 53 is arranged in one layer on the base fabric 54 along the extension direction of the bead portions 30A to 30D by sewing. Also, the fiber bundles 53 are arranged so as to form the holes 63a, 64a (see FIG. 6) of the seat back shell 17 (the portion including the reinforcing band 50). Furthermore, in the seat back shell 17, the thickness t1 of the reinforcing portion provided with the reinforcing band 50 is larger than the thickness t3 of the circumference 17s of the reinforcing portion not provided with the reinforcing band 50. As shown in FIG.

The fiber bundles 53 may be arranged on the base fabric 54 in a plurality of layers of two or more layers by sewing (see FIG. 2). In this case, from the viewpoint of suppressing stress concentration, etc., it is preferable that both sides of the reinforcing band 50 in the width direction are provided with portions 56 having fewer layers of the fiber bundles 53 than the middle side sandwiched between the two sides. .

As shown in FIGS. 5 to 7, the upper arms 18 are arranged on both left and right sides in the lateral width direction A under the seat back shell 17 . The upper arm 18 has a first surface portion 61 and a second surface portion 62 that cross each other. The first surface portion 61 is formed with a hole portion 63b through which the fastener 63 is inserted, and the second surface portion 62 is formed with a hole portion 64b through which the fastener 64 is inserted (see FIG. 6).

As shown in FIG. 8, the first surface portion 61 is fastened with a fastener (specifically, a screw and nut) 63 to an extension portion 61 extending from the outer side wall 41 of the bead portion 30C. The first surface portion 61 has an engaged portion (specifically, a hole portion) 66 to which an engaging portion (specifically, a hook portion) 22a provided on the outer cover 22 covering the surface of the seat back shell 17 is hooked. is provided. The locked portion 66 is arranged at a bent portion 67 formed by hemming on the outer edge side of the upper arm 18 . The bent portion 67 is thicker than the portion of the first surface portion 61 connected thereto.

In this embodiment, the seat back shell 17 has bead portions 30B and 30D, and the upper arm 18 is fastened to the bead portions 30B and 30D. As a result, the bead portions 30B and 30D reinforce the fastening portion between the seat back shell 17 and the upper arm 18, further improving the strength and rigidity.
In particular, in this embodiment, the upper arm 18 includes a stepped portion 69 that is applied to the intersection (stepped portion 43) of the bead portions 30B and 30D having different heights of the ridges, and the beads on both sides that straddle the stepped portion 69. It is fastened to each of the portions 30B and 30D. As a result, the gap between the fastening portions of the seat back shell 17 and the upper arm 18 is more strongly reinforced by the stepped portion 69 .

In this embodiment, the bead portions 30B and 30D are integrally provided with a reinforcing band 50 including continuous fibers 52 bound by a matrix resin 51 and laid along the extending direction of the bead portions 30B and 30D. ing. As a result, the fastening portion between the seat back shell 17 and the upper arm 18 is further reinforced by the reinforcing band 50 .

In this embodiment, the upper arms 18 are arranged on both left and right sides of the seat back shell 17 in the width direction A, and connect hollow cross-sectional portions 70 formed on both left and right sides of the seat back shell 17 in the width direction A. It is fastened to the bead part 30D which carries out. As a result, the fastening portion between the seat back shell 17 and the upper arm 18 is further reinforced by the bead portion 30D.

Further, in this embodiment, the upper arm 18 is provided with a locked portion 66 to which the locking portion 22a provided on the outer cover 22 is hooked. As a result, the upper arm 18 can be used to form a hooking structure for the outer cover 22 .

Furthermore, in this embodiment, the seat back shell 18 is made of fiber reinforced resin. As a result, further weight reduction can be achieved without impairing strength and rigidity.

It should be noted that the present invention is not limited to the above-described examples, and may be variously modified examples within the scope of the present invention according to the purpose and application.
FIG. 10(b) is an explanatory view showing the bead portions 30A, 30B, and 30D shown in FIG. 6 described above in a simplified plan view. 2 shows a crossed aspect at . On the other hand, FIG. 10(a) shows a modified example, and is an explanatory diagram showing a simplified plan view of the bead portions 30A, 30B and 30D. It shows a mode in which the two bead portions 30A are crossed with each other.

The foregoing examples are for illustrative purposes only and are not to be construed as limiting the invention. While the present invention has been described by way of examples of exemplary embodiments, it is understood that the words used in describing and illustrating the invention are words of description and illustration, rather than words of limitation. Changes may be made within the scope of the appended claims without departing from the scope or spirit of the invention in its form, as detailed herein. Although reference has been made herein to specific structures, materials and embodiments in describing the invention, it is not intended that the invention be limited to the disclosure herein, but rather the invention as set forth in the appended claims. It covers all functionally equivalent structures, methods and uses within its scope.

The present invention is not limited to the embodiments detailed above, and various modifications and changes are possible within the scope of the claims of the present invention.

INDUSTRIAL APPLICABILITY The present invention is widely used as a technique related to a structure formed by joining metal parts to a structure. In particular, it is suitably used as a seat back frame for a vehicle seat.

16; structure (seat back frame),
17; structure (seat back shell), 17a; one side (front side), 17b; facing side (back side), 17s;
30; bead portion, 30A, 30B, 30C, 30D; bead portion,
30a; concave surface, 30b; convex surface,
41; side wall, 42; connecting wall,
50; reinforcing band, 51; matrix resin, 52; continuous fiber.

Claims (9)

Having a structural part integrally formed with one or more beads, and a reinforcing band provided along the bead,
The bead portion is shaped so as to form a concave streak on one side of the structural portion and a protruded streak on the opposite side,
The reinforcing band includes continuous fibers bound by a matrix resin, and is integrally joined to the bead along the concave and/or convex surfaces of the bead,
The structure, wherein the continuous fibers are laid along the extending direction of the bead portion. 2. The structure according to claim 1, wherein the reinforcing portion provided with the reinforcing band has a greater thickness than the circumference of the reinforcing portion not provided with the reinforcing band. 3. The structure according to claim 1 or 2, wherein the structural part comprises a fiber-reinforced resin containing dispersed discontinuous fibers and/or a fiber-reinforced resin containing a woven fabric using continuous fibers. The reinforcing band includes a fiber bundle in which the continuous fibers are bundled, a base fabric to which the fiber bundle is sewn, and the matrix resin impregnated and fixed in the fiber bundle and the base fabric. 4. A structure according to any one of 3. 5. The structure according to any one of claims 1 to 4, wherein the reinforcing band has a transition region in the matrix resin on the side of the joint surface with the bead portion. The structure according to any one of claims 1 to 5, wherein the bead portion has a fastening structure with another structure. 7. The structure according to any one of claims 1 to 6, which is a back shell of a vehicle seat. 8. The method of using the structure according to claim 7, wherein the inside of the groove of the bead portion is used as a laying space for laying a long object. 8. The method of using the structure according to claim 7, wherein the inside of the groove of the bead portion is used as a flow path for a fluid.

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