JP2023101237A - Fiber-reinforced resin jointed body - Google Patents

Abstract

To provide a fiber-reinforced resin jointed body that is securely fixed without increasing the height of a projecting portion, when a through-hole provided on a counterpart member to be joined is larger than the projecting portion to be caulked.SOLUTION: A fiber-reinforced resin jointed body includes a member A that has at least one projecting portion and includes a fiber-reinforced resin, and a member B that has at least one through-hole h1. The projecting portion penetrates the through-hole h1, and has a caulking portion at a part projected out from the through-hole H1. Assuming a side area of the maximum inscribed column of the through-hole h1 as S1, and the total of an area of a surface parallel with a thickness direction and an area of a surface parallel with a direction inclined by more than 0° and less than 90 with respect to the thickness direction as ST, the expression S1<ST is established.SELECTED DRAWING: Figure 1

Description

TECHNICAL FIELD The present invention relates to a fiber-reinforced resin bonded body containing reinforcing fibers and a thermoplastic resin, and a method for producing the same. More specifically, it relates to a fiber-reinforced resin bonded body having a crimped portion, and can be suitably used for structural parts represented by automobiles.

In recent years, in the field of materials used in automobiles, multi-materials are progressing in consideration of weight reduction, and in addition to steel plates and aluminum alloys, so-called fiber-reinforced resins, which include resins and reinforcing fibers such as carbon fibers, are attracting attention. there is As multi-material progresses, various technologies for joining dissimilar materials are being developed, but chemical joining using adhesives and mechanical fastening using rivets and the like are the mainstream. When joining fiber-reinforced resin using a thermoplastic resin as the matrix resin, it is possible to use a method of joining by crimping by deforming the tip of the protrusion provided in advance with heat, and the peel direction (joining A high bonding strength can be obtained in the direction perpendicular to the surface). In addition, it is widely used in various industrial fields because various methods such as heat and ultrasonic waves can be used as a heating method for crimping.

Patent Literature 1 describes a fiber-reinforced resin bonded body having a crimped portion, which is excellent in bonding strength in the peel direction.

In Patent Document 2, in joining dissimilar materials of a metal-based member and a fiber-reinforced resin-based member, when the resin of the fiber-reinforced resin-based member melts and solidifies and shrinks, the joint on the side of the metal-based member has a role of preventing it from coming off. A joint shape and a joining method are described, which are characterized by providing a hole having a shape to accommodate the joint.

Patent Document 3 discloses a joining method for joining a first member having a through hole formed from one surface to the other surface and a second member having a projection inserted through the through hole, a preparation step of preparing a cylindrical portion having an inner diameter larger than the hole diameter of the through hole and a movable portion slidably arranged inside the cylindrical portion; The two members are arranged on one surface of the first member, and the tubular portion is arranged in contact with the other surface of the first member so that the inside of the tubular portion and the through hole communicate with each other. an arranging step of moving the movable portion toward the projection within the cylindrical portion, causing the movable portion to collide with the projection to deform the projection, thereby locking the second member to the first member; and an anchor portion forming step of forming an anchor portion to be joined.

WO2015/146846 JP 2016-016592 A JP 2015-186870 A

When performing crimping, the projected area of the through-hole provided in the mating member to be joined in the member plate thickness direction is usually 1 with respect to the projected area of the projection, even if it is large with respect to the size of the projection to be crimped. .2 times (in other words, the size of the through-hole is within 1.10 times the thickness of the protrusion), and the gap is made as small as possible. do.
In general, when multiple crimped parts are provided and fixed to a large molded product, in order to avoid the effects of warping and dimensional variations due to individual differences in molded products, protrusions such as bosses and ribs are used to process the crimped parts. The size of the through hole provided in the mating member to be joined needs to be large, and the gap between the two members to be joined becomes large. For this reason, there is a problem that when caulking is performed, the gap cannot be sufficiently filled with the material to be caulked, and the members cannot be firmly fixed to each other.
In addition, in order to fill the gap, it is conceivable to increase the volume of the material to be crimped, and to increase the volume, it is conceivable to design the height of the protrusions such as ribs and bosses to be high. If the height of the molded product is increased, there is a problem that short shots of the protrusions and demolding defects tend to occur during molding, resulting in a high defect rate.

An object of the present invention is to provide a fiber-reinforced resin joined body that is firmly fixed while keeping the height of the protrusions low when the through-holes provided in the mating member to be joined are larger than the protrusions to be crimped. to do.

More specifically, when the projected area of the through-hole in the member plate thickness direction is 1.2 times or more (furthermore, when it is 1.5 times or more) the projected area of the protrusion, the above problem is remarkable. appear as an issue.
For example, if the protrusion is cylindrical and the diameter of the bottom surface is 6 mm, the above problem becomes significant when the size of the through hole exceeds 6.6 mm, and the size of the through hole is 10 mm. When it becomes, it becomes a more remarkable problem.

The present inventors have made intensive studies and found that the above problems can be solved by the following means.

[1]
A fiber-reinforced resin joined body including a member A containing a fiber-reinforced resin having at least one protrusion and a member B having at least one through-hole h1,
The protrusion penetrates through the through hole h1 and has a crimped portion protruding from the through hole h1,
_S1 is the side area of the maximum inscribed cylinder of the through hole h1, and the area of the surface parallel to the thickness direction in the region covered by the crimped portion of the member B and the thickness direction are more than 0° and 90°. A fiber-reinforced resin joined body in which S ₁ < _ST , where S _T is the total area of surfaces parallel to a direction inclined by less than °.
[2]
The fiber-reinforced resin joined body according to [1], wherein the member B has at least one through hole h2 smaller than the through hole h1 in the region covered with the crimped portion.
[3]
The fiber-reinforced resin according to [1] or [2], which has at least one notch c1 on the periphery of the through hole h1, and the notch c1 is present in a region covered with the crimped portion. zygote.
[4]
The fiber-reinforced resin joined body according to any one of [1] to [3], wherein at least part of the region covered with the crimped portion of the member B is roughened.
[5]
The fiber-reinforced resin joined body according to any one of [1] to [4], wherein the member B has a recess in at least part of the region covered with the crimped portion.
[6]
The fiber-reinforced resin joined body according to any one of [1] to [5], wherein the shape of the through hole h1 when viewed in the thickness direction is neither elliptical nor polygonal.

According to the present invention, when the projected area of the through-hole in the member plate thickness direction is 1.2 times or more the projected area of the projection, the projection can be firmly fixed while keeping the height of the projection low. It is possible to provide a fiber-reinforced resin bonded body with high initial rigidity.

BRIEF DESCRIPTION OF THE DRAWINGS Sectional drawing which shows typically an example of the fiber reinforced resin joined body of this invention. FIG. 2 is a plan view of a member B included in an example of the fiber-reinforced resin bonded body of the present invention; FIG. 4 is a schematic diagram of a member Aa corresponding to the member A before forming a crimped portion and a member B stacked on each other so that the protrusion A1 of the member Aa penetrates the through hole h1 of the member B; FIG. 4 is a schematic diagram of the maximum inscribed cylinder of the through hole h1 of the member B included in one example of the fiber-reinforced resin bonded body of the present invention. FIG. 2 is a plan view of a member B included in an example of the fiber-reinforced resin bonded body of the present invention; K3-K4 sectional view of FIG. FIG. 2 is a plan view of a member B included in an example of the fiber-reinforced resin bonded body of the present invention; FIG. 8 is an enlarged view of region T in FIG. 7; FIG. 2 is a plan view schematically showing the through hole h1 of the member B used in the fiber-reinforced resin bonded body of the example and its surroundings. As for (e), the EE sectional view is also shown. FIG. 2 is a cross-sectional view schematically showing an example of a conventional fiber-reinforced resin bonded body. FIG. 2 is a plan view of a member G included in an example of a conventional fiber-reinforced resin bonded body; FIG. 4 is a schematic diagram when a member Fa corresponding to a member F before forming a crimped portion and a member G are stacked so that a projection portion F1 of the member Fa penetrates through a through hole of the member G;

The fiber-reinforced resin bonded body of the present invention is
A fiber-reinforced resin joined body comprising a member A containing a fiber-reinforced resin and having at least one protrusion and a member B having at least one through-hole h1,
The protrusion penetrates through the through hole h1 and has a crimped portion protruding from the through hole h1,
_S1 is the side area of the maximum inscribed cylinder of the through hole h1, and the area of the surface parallel to the thickness direction in the region covered by the crimped portion of the member B and the thickness direction are more than 0° and 90°. It is a fiber-reinforced resin bonded body in which S ₁ < _ST , where S _T is the total area of the surfaces parallel to the direction inclined by less than °.

The present invention will be described below. First, a typical example of a conventional fiber-reinforced resin bonded body will be described.

<Conventional fiber-reinforced resin joined body using caulking>
FIG. 10 is a cross-sectional view schematically showing an example of a conventional fiber-reinforced resin joined body.
A conventional fiber-reinforced resin joined body 30 of FIG. 10 is a joined body of a member F and a member G. Member F contains fiber reinforced resin. Member F has at least one protrusion F1. Member G has at least one through hole. The projecting portion F1 of the member F penetrates through the through hole of the member G and has a crimped portion F2 at a portion protruding from the through hole.

FIG. 11 shows a plan view (viewed from the z direction) of a member G included in a conventional fiber-reinforced resin bonded body 30. As shown in FIG. As shown in FIG. 11, the through hole j1 of the member G has a perfect circular shape when viewed from the z direction (thickness direction).

FIG. 12 shows a schematic diagram when a member Fa corresponding to the member F before forming the caulked portion and the member G are overlapped so that the protrusion F1 of the member Fa penetrates the through hole of the member G. .
In order to manufacture the conventional fiber-reinforced resin joined body 30 shown in FIG. 10, the member Fa and the member G are overlapped so that the protrusion F1 of the member Fa penetrates the through hole of the member G, as shown in FIG. Then, the portion of the protrusion F1 protruding from the through hole is crimped. The shape of the protrusion F1 before crimping is not particularly limited, but is typically cylindrical.

When the projected area Sx of the through-hole in the thickness direction of the member and the projected area Sy of the projection satisfies Sx>Sy×1.2, the conventional fiber-reinforced resin bonded body 30 has the projection F1 of the member F and the projection F1 of the member F and the projected area Sy of the projection. Since the clearance of the through-hole of G becomes too large and the fiber-reinforced resin material cannot be filled in this clearance, there is a problem that the initial stiffness of the member F and the member G in the direction of shear tension is weak.
Further, as described above, it is conceivable to increase the height of the protrusion F1 of the member Fa and fill the gap between the protrusion F1 and the through-hole during caulking. There has been a problem that short shots of the projections during molding of Fa and demolding defects tend to occur, resulting in a high defect rate.

<Fiber-reinforced resin joined body of the present invention>
In contrast, the fiber-reinforced resin joined body of the present invention has members firmly fixed to each other and has excellent initial rigidity in the direction of shear tension. The reason for this will be described in detail below. _S1 is the side area of the maximum inscribed cylinder of the through hole h1 of the member B. This is because S ₁ < _ST , where S _T is the total area of the planes parallel to the direction inclined by more than 0° and less than 90° with respect to the thickness direction.
In the conventional fiber-reinforced resin bonded body 30 of FIG. 10, the side area of the maximum inscribed cylinder of the through-hole j1 of the member G is defined as _S2 , and the area covered by the crimped portion of the member G is When the sum of the area of the parallel surfaces and the area of the surfaces parallel to the direction inclined at more than 0° and less than 90° with respect to the thickness direction is _SU , then S ₂ = _SU .
The shear tensile direction is the direction perpendicular to the plate thickness direction and its opposite direction, for example, the x direction in FIG. 1 and its opposite direction.

In the fiber-reinforced resin joined body of the present invention, the area of the surface parallel to the thickness direction in the region covered with the crimped portion of the member B and the surface parallel to the direction inclined to the thickness direction by more than 0° and less than 60° When the total area of is S _T1 , it is preferable that S ₁ < S _T1 , and the area of the surface parallel to the thickness direction and the surface parallel to the direction inclined to the thickness direction by more than 0 ° and less than 45 ° S _T2 is the total area of S 1 <S _T2 , and it is more preferable that S ₁ < S T2, and the area of the surface parallel to the thickness direction It is more preferable that S ₁ <S _T3 , where S _T3 is the total surface area.

An embodiment of the present invention will be described below, but the present invention is not limited thereto.

Typical embodiments of the fiber-reinforced resin joined body of the present invention include the following aspects.
First mode: A mode in which the member B has at least one through hole h2 smaller than the through hole h1 in the area covered with the crimped portion.
Second mode: A mode in which the member B has a recess in at least part of the area covered with the crimped portion.
Third mode: A mode in which at least one notch c1 is provided in the peripheral edge of the through hole h1, and the notch c1 exists in the area covered with the crimped part.
Fourth mode: A mode in which at least part of the region covered with the crimped portion of the member B is roughened.

(First aspect)
A first embodiment, which is an example of the fiber-reinforced resin bonded body of the present invention, will be described.
A first mode is a mode in which the member B has at least one through hole h2 smaller than the through hole h1 in the area covered with the crimped portion.
The through hole h2 is preferably located around the through hole h1.
FIG. 1 is a cross-sectional view (cross-sectional view taken along K1-K2 in FIG. 2) schematically showing an example (first embodiment) of a fiber-reinforced resin bonded body of the present invention.
A fiber-reinforced resin bonded body 10 in FIG. 1 is a bonded body including a member A and a member B. As shown in FIG. Member A contains a fiber-reinforced resin. Member A has at least one protrusion A1. Member B has at least one through hole h1. The projecting portion A1 of the member A penetrates through the through hole h1 of the member B and has a crimped portion A2 at a portion protruding from the through hole h1. The thickness of member B is _CB . At least one through-hole h2 different from the through-hole h1 is provided in the region of the member B covered with the caulked portion A2. The fiber reinforced resin of the member A enters the through hole h2.

The shape of the through hole h1 of the member B when viewed from the z direction (thickness direction) is not particularly limited, and may be circular (perfectly circular or elliptical) or polygonal. The shape of the through hole h1 of the member B when viewed in the z direction (thickness direction) is preferably neither elliptical nor polygonal, and more preferably a perfect circle.

FIG. 2 shows a plan view (viewed from the z-direction) of the member B included in the fiber-reinforced resin bonded body 10 of FIG.
As shown in FIG. 2, the through-hole h1 of the member B in the first embodiment is a perfect circle when viewed from the z direction (thickness direction) (the diameter of this circle is _Rh1 ).

As shown in FIG. 2, the member B in the first aspect has at least one through hole h2 smaller than the through hole h1 around the through hole h1. Note that the through hole h2 is not connected to the through hole h1, unlike the notch c1 in the third aspect.

Although the number of through-holes h2 is not particularly limited, it is preferably two or more, and may be four or more. Although the upper limit of the number of through-holes h2 is not particularly limited, it can be, for example, 100 or less, 50 or less, or 30 or less.

The shape of the through hole h2 of the member B when viewed from the z direction (thickness direction) is not particularly limited, and may be circular (perfectly circular or elliptical) or polygonal. The through hole h2 may be a long and thin hole (long hole), or may be a long hole along the shape of the through hole h1 (see (b) of FIG. 9).

Of the line segments connecting arbitrary two points on the outline of the through hole h2 when viewed from the z direction (thickness direction), the length L _h2 of the longest line segment is any two points on the outline of the through hole h1. It is preferably smaller than the length L _h1 of the longest line segment among the line segments connecting the points.
L _h1 /L _h2 is preferably greater than 1, can be 1.5 or greater, and can be 2 or greater. Also, L _h1 /L _h2 can be 100 or less, and can be 50 or less.
When there are a plurality of through holes h2, the plurality of L _h2 may be the same or different.
When the through hole h2 has a perfect circular shape, L _h2 is the diameter (R _h2 ) of the through hole h2. When the shape of the through hole h1 is a perfect circle, L _h1 is the diameter (R _h1 ) of the through hole h1.

As shown in FIG. 2, the through hole h2 in the first aspect is a perfect circle (the diameter of this circle is _Rh2 ) when viewed from the z direction (thickness direction). Multiple R _h2 may be the same or different.

R _h1 /R _h2 is greater than 1, can be 1.5 or greater, and can be 2 or greater. Also, R _h1 /R _h2 can be 100 or less, and can be 50 or less.

In order to manufacture the fiber reinforced resin bonded body 10 of FIG. It is preferable that the protrusion A1 is crimped so as to pass through the through hole h1.
FIG. 3 shows a schematic diagram when the member Aa and the member B are overlaid so that the protrusion A1 of the member Aa penetrates the through hole h1 of the member B. As shown in FIG.

The crimping process can be performed by applying heat to the portion protruding from the through hole h1 of the protrusion A1 to compress it.
During the caulking process, part of the fiber reinforced resin of the protrusion A1 melts and flows into at least one through-hole h2. In this way, a structure in which the portion connected to the crimped portion A2 is inserted into the through hole h2 can be obtained, and the fiber-reinforced resin joined body 10 of FIG. 1 is manufactured.
The fiber-reinforced resin bonded body 10 has a high initial rigidity in the shear tensile direction because the fiber-reinforced resin in the through-hole h2 is filled with the fiber-reinforced resin in the portion connected to the crimped portion A2. In FIG. 1, the entire interior of the through hole h2 is filled with the fiber reinforced resin, but compared to the clearance area observed between the through hole h1 and the protrusion A1 when viewed from the plate thickness direction Moreover, since the area of the through hole h2 is small, it is easily filled with the crimped resin, and high initial stiffness (initial shear tensile stiffness) is likely to be exhibited in the shear tensile direction.
In addition, in the present invention, the fiber reinforced resin does not have to be filled entirely inside all of the plurality of through-holes h2, and it is sufficient that at least a portion thereof is filled with the fiber reinforced resin.

Here, consider the maximum inscribed cylinder of the through-hole h1 of the member B in the fiber-reinforced resin joined body 10 of FIG.
FIG. 4 shows a schematic diagram of the maximum inscribed cylinder 20 of the through hole h1 of the member B included in the fiber-reinforced resin joined body 10 of FIG. The height of the maximum inscribed cylinder 20 of the through hole h1 of the member B is _CB , and the diameter of the bottom surface is _Rh1 . Therefore, if the side area of the maximum inscribed cylinder 20 of the through hole h1 of _the member B is _S1 , then _S1 = _πRh1CB . π is the circular constant.
In addition, in the region covered with the crimped portion A2 of the member B, the sum of the area of the surface parallel to the thickness direction and the area of the surface parallel to the direction inclined from 0° to less than 90° with respect to the thickness direction is S _T , S _T is obtained by adding the side area of the maximum inscribed cylinder of the through hole h2 (πR _{h2 CB} × number of through holes h2) to S ₁ . Therefore, S ₁ < _ST .

(Second aspect)
A second aspect, which is an example of the fiber-reinforced resin bonded body of the present invention, will be described.
A second mode is a mode in which the member B has a recess in at least part of the area covered with the crimped portion.
FIG. 5 shows a plan view (viewed from the thickness direction) of an example of the member B included in the second embodiment.

The member B in FIG. 5 has a concave portion d1 instead of the through hole h2 of the member B in FIG. That is, the member B in FIG. 5 has at least one concave portion d1 smaller than the through hole h1 around the through hole h1.

Although the number of recesses d1 is not particularly limited, it is preferably two or more, and may be four or more. Although the upper limit of the number of recesses d1 is not particularly limited, it can be, for example, 100 or less, 50 or less, or 30 or less.

The shape of the recess d1 when viewed in the z direction (thickness direction) is not particularly limited, and may be circular (perfectly circular or elliptical) or polygonal. The recess d1 can be an elongated depression (groove), or an elongated depression (groove) along the shape of the through hole h1.

The length L d1 of the longest line segment among the line segments connecting any two points on the contour line of one recess d1 when viewed from the z direction (thickness direction) is the length L _d1 on the contour line of one through hole h1 It is preferably smaller than the length L _h1 (diameter R _h1 when the shape of the through hole h1 is a perfect circle) of the longest line segment among the line segments connecting any two points.
L _h1 /L _d2 is preferably greater than 1, can be 1.5 or greater, and can be 2 or greater. Also, L _h1 /L _d2 can be 100 or less, and can be 50 or less.
When there are a plurality of concave portions d1, the plurality of L _d1 may be the same or different.

R _h1 /L _d1 is preferably greater than 1, can be 1.5 or greater, and can be 2 or greater. Also, R _h1 /L _d1 can be 100 or less, and can be 50 or less.

FIG. 6 shows a cross-sectional view (schematic view seen from the x direction) taken along the line K3-K4 in FIG. As shown in FIG. 6, the inner wall surface of the recess d1 is not parallel to the thickness direction (z direction), but a plane Sd1 parallel to the direction (f1 direction) inclined at an angle of θ1 with respect to the thickness direction (z direction), and a plane Sd2 parallel to a direction (f2 direction) inclined at an angle of θ2 with respect to the thickness direction (z direction). θ1 is greater than 0° and less than 90°, and θ2 is greater than 0° and less than 90°. θ1 and θ2 may be the same or different.

Assuming that the side area of the maximum inscribed cylinder of the through hole h1 of the member B in FIG. 5 is S ₁ , S ₁ =πR _{h1 CB} . _CB is the height of the maximum inscribed cylinder of the through hole h1 of the member B (the thickness of the member B).
In addition, in the region covered with the crimped portion A2 of the member B, the sum of the area of the surface parallel to the thickness direction and the area of the surface parallel to the direction inclined from 0° to less than 90° with respect to the thickness direction is S _T , S _T is the sum of the area of the inner wall surface of the recess d1 (the sum of the areas of all the inner wall surfaces including the surfaces Sd1 and Sd2) to _S1 . Therefore, S ₁ < _ST .

In the case of manufacturing the fiber reinforced resin bonded body of the second aspect, as in the case of manufacturing the fiber reinforced resin bonded body of the first aspect, during the caulking process, the fiber reinforced resin of the protrusion A1 is A portion melts and flows into at least one recess d1. In this way, a structure in which the portion connected to the crimped portion A2 is inserted into the concave portion d1 can be formed, and the fiber-reinforced resin joined body of the second aspect is manufactured. In the fiber-reinforced resin joined body of the second aspect, since the fiber-reinforced resin in the portion connected to the caulked portion A2 enters the recess d1, the initial rigidity in the shear tensile direction is high. The fiber reinforced resin does not have to be filled in the entire interior of the recess d1, and it is sufficient that at least a portion thereof is filled with the fiber reinforced resin.

(Third aspect)
A third aspect, which is an example of the fiber-reinforced resin bonded body of the present invention, will be described.
A third mode is a mode in which at least one cutout portion c1 is provided on the periphery of the through hole h1, and the cutout portion c1 exists in a region covered with the crimped portion.
The notch portion c1 exists on the periphery of the through hole h1 and is connected (integrated) with the through hole h1.

The number of cutouts c1 is not particularly limited, but is preferably two or more, and may be four or more. The upper limit of the number of notches c1 is not particularly limited, but can be, for example, 100 or less, 50 or less, or 30 or less.

FIG. 7 shows a plan view (viewed from the thickness direction) of an example of the member B included in the third aspect.
The member B in FIG. 7 has at least one notch c1 on the periphery of the through hole h1. The notch portion c1 exists in the area covered with the crimped portion.

The shape of the through hole h1 having the notch c1 when viewed in the z direction (thickness direction) is not particularly limited, and may be, for example, a flower shape or a star shape.
The shape of the notch c1 when viewed in the z direction (thickness direction) is not particularly limited, and may be semicircular or polygonal, for example. Moreover, the notch c1 may be linear (long and narrow).
In FIG. 7, eight triangular cutouts c1 are provided on the periphery of the through hole which has a perfect circular shape (the diameter of this circle is defined as _Rh1 ) when viewed from the z direction (thickness direction), and the through hole The hole and the notch c1 are integrated.

The length L _c1 of the longest line segment among the line segments connecting any two points on the outline of one notch c1 when viewed from the z direction (thickness direction) is the outline of one through hole h1. It is preferably smaller than the length L _h1 of the longest line segment connecting any two points on the line.
FIG. 8 shows an enlarged view of region T in FIG. L _c1 in the notch c1 in FIG. 7 is as shown in FIG.
When there are a plurality of notch portions c1, the plurality of L _c1 may be the same or different.
L _h1 >L _c1 is preferably greater than 1, can be 1.5 or greater, and can be 2 or greater. Also, L _h1 >L _c1 can be 100 or less, and can be 50 or less.

Assuming that the side area of the maximum inscribed cylinder of the through hole h1 of the member B in FIG. 7 is S ₁ , S ₁ =πR _{h1 CB} . _CB is the height of the maximum inscribed cylinder of the through hole h1 of the member B (the thickness of the member B).
In addition, in the region covered with the crimped portion A2 of the member B, the sum of the area of the surface parallel to the thickness direction and the area of the surface parallel to the direction inclined from 0° to less than 90° with respect to the thickness direction is S _T , S _T satisfies S ₁ < S _T in consideration of the area of the inner wall surface of the notch c1.

When manufacturing the fiber reinforced resin bonded body of the third aspect, part of the fiber reinforced resin of the protrusion A1 melts and flows during the caulking process, and contacts the inner wall surface of at least one notch c1. do. In this way, a structure in which the portion connected to the crimped portion A2 is in contact with the inner wall surface of the notch portion c1 can be obtained, and the fiber-reinforced resin joined body of the third aspect is manufactured. The fiber-reinforced resin joined body of the third aspect has high strength in the shear direction because the fiber-reinforced resin at the portion connected to the crimped portion A2 is in contact with the inner wall surface of the notch c1. The fiber reinforced resin does not have to be in contact with the entire inner wall surface of the notch c1, and the fiber reinforced resin may be in contact with at least a portion of the inner wall surface.

Also, the portion between the two cutouts c1 may be bent (raised) in the thickness direction (z direction) (see FIG. 9E).

(Fourth mode)
A fourth aspect, which is an example of the fiber-reinforced resin bonded body of the present invention, will be described.
A fourth aspect is an aspect in which at least a portion of the region of the member B covered with the crimped portion is roughened.
Although the roughening treatment is not particularly limited, it can be performed by sanding, for example. The roughness of the sanding paper is not particularly limited, but since it is more advantageous to get caught in the shear pulling direction, it is preferable to use sandpaper that is rougher than #320, and sandpaper that is rougher than #100 is used. is more preferred. The roughness of the surface of the sandpaper is called the count and is indicated by a number with a "#". The # is also called particle size, which is the size of the abrasive particles. The smaller the number, the coarser the abrasive. In addition to sanding, sandblasting, chemical product treatment, and pore treatment by laser processing can also be used.

Since the member B of the fourth aspect is roughened, fine irregularities and grooves are formed on the surface.

When the shape of the through hole h1 of the member B of the fourth aspect is a perfect circle with a diameter R _h1 , and the side area of the maximum inscribed cylinder of the through hole h1 is S ₁ , then S ₁ =πR _h1 C _B. . _CB is the height of the maximum inscribed cylinder of the through hole h1 of the member B (the thickness of the member B).
In addition, in the region covered with the crimped portion A2 of the member B, the sum of the area of the surface parallel to the thickness direction and the area of the surface parallel to the direction inclined from 0° to less than 90° with respect to the thickness direction is S _T , S _T is the sum of S ₁ and the area of the unevenness and inner wall surfaces of the grooves formed by the roughening treatment. Therefore, S ₁ < _ST .

When manufacturing the fiber-reinforced resin bonded body of the fourth aspect, part of the fiber-reinforced resin of the protrusion A1 melts and flows during the caulking process, and the irregularities and grooves formed by the roughening treatment are formed. contact the inner wall surface. In this way, a structure in which the portion connected to the crimped portion A2 is in contact with the unevenness or the inner wall surface of the groove formed by the surface roughening treatment, and the fiber-reinforced resin joined body of the fourth aspect is manufactured. be done. In the fiber-reinforced resin bonded body of the fourth aspect, since the fiber-reinforced resin in the portion connected to the crimped portion A2 is in contact with the inner wall surface of the unevenness or groove formed by the surface roughening treatment, high initial stiffness. The fiber reinforced resin may not be in contact with the entire inner wall surface of the unevenness or groove formed by the surface roughening treatment, and the fiber reinforced resin may be in contact with at least a portion of the inner wall surface.

Next, matters other than those described above (components included, etc.) regarding the member A and the member B included in the fiber-reinforced resin bonded body of the present invention will be described.

<Member A>
The member A is a member containing a fiber-reinforced resin, and is preferably a fiber-reinforced resin molding.
The member A preferably contains reinforcing fibers and a thermoplastic resin. Specifically, it is preferable to use a thermoplastic resin as a matrix and contain reinforcing fibers in the matrix.
The abundance (content) of the matrix in the member A can be appropriately determined according to the type of matrix and the type of reinforcing fiber described below, and is not particularly limited. It is in the range of 3 parts by mass to 1000 parts by mass with respect to 100 parts by mass of the fiber. More preferably 30 to 200 parts by mass, still more preferably 30 to 150 parts by mass.
The member A is, for example, a flat plate, a prism, a polyhedron, or the like having a flat portion and having a polygonal cross section such as a quadrangle. , a projection is preferred. Although the thickness of the plane portion may be the same or different, it is preferable that the thickness is the same in terms of mechanical strength. The thickness of the flat portion is preferably within the range of 1 to 20 mm.
Further, when the member A is a flat plate, the thickness of the flat plate may be constant within a range of 1 to 20 mm or may vary.

(reinforced fiber)
The type of reinforcing fiber is not particularly limited.
Either inorganic fibers or organic fibers can be suitably used as the reinforcing fibers.
Examples of inorganic fibers include carbon fibers, activated carbon fibers, graphite fibers, glass fibers, tungsten carbide fibers, silicon carbide fibers (silicon carbide fibers), ceramic fibers, alumina fibers, natural fibers, mineral fibers such as basalt, boron fibers, Boron nitride fiber, boron carbide fiber, metal fiber and the like can be mentioned.
Metal fibers include, for example, aluminum fibers, copper fibers, brass fibers, stainless steel fibers, and steel fibers.
Examples of glass fibers include those made of E glass, C glass, S glass, D glass, T glass, quartz glass fiber, borosilicate glass fiber, and the like.
Examples of organic fibers include fibers made of resin materials such as aramid, PBO (polyparaphenylenebenzoxazole), polyphenylene sulfide, polyester, acrylic, polyamide, polyolefin, polyvinyl alcohol, and polyarylate.

In the present invention, two or more types of reinforcing fibers may be used together. In this case, a plurality of types of inorganic fibers may be used together, a plurality of types of organic fibers may be used together, and inorganic fibers and organic fibers may be used together.
Examples of a mode in which a plurality of types of inorganic fibers are used in combination include a mode in which carbon fibers and metal fibers are used in combination, and a mode in which carbon fibers and glass fibers are used in combination. On the other hand, examples of a mode in which a plurality of types of organic fibers are used in combination include a mode in which aramid fibers and fibers made of other organic materials are used in combination. Furthermore, as an embodiment in which inorganic fibers and organic fibers are used in combination, for example, an embodiment in which carbon fibers and aramid fibers are used in combination can be mentioned.

Carbon fibers are preferably used as reinforcing fibers. This is because carbon fibers can provide a fiber-reinforced resin bonded body that is lightweight and has excellent strength.
Carbon fibers generally include polyacrylonitrile (PAN)-based carbon fibers, petroleum/coal pitch-based carbon fibers, rayon-based carbon fibers, cellulose-based carbon fibers, lignin-based carbon fibers, phenol-based carbon fibers, and vapor growth-based carbon fibers. Fibers and the like are known, and any of these carbon fibers can be suitably used in the present invention.
In the present invention, it is preferable to use polyacrylonitrile (PAN)-based carbon fiber because of its excellent tensile strength. When PAN-based carbon fiber is used as the reinforcing fiber, its tensile modulus is preferably in the range of 100 to 600 GPa, more preferably in the range of 200 to 500 GPa, and more preferably in the range of 230 to 450 GPa. is more preferred. Also, the tensile strength is preferably in the range of 2000 to 10000 MPa, more preferably in the range of 3000 to 8000 MPa.

The reinforcing fiber used in the present invention may have a sizing agent attached to its surface. When reinforcing fibers to which a sizing agent is attached are used, the type of the sizing agent can be appropriately selected according to the types of reinforcing fibers and matrix, and is not particularly limited.
The form of the reinforcing fibers used in the present invention is not particularly limited, and may be, for example, woven fabrics, knitted fabrics, unidirectional materials, continuous fibers, discontinuous fibers of a specific length, or combinations thereof.

The fiber length of the reinforcing fibers is not particularly limited. In the present invention, either continuous fibers or discontinuous fibers may be used depending on the purpose. Alternatively, continuous fibers and discontinuous fibers may be used in combination. When discontinuous fibers are used, the average fiber length is preferably in the range of 0.1 mm to 500 mm, particularly preferably in the range of 1 mm to 100 mm.

The fiber-reinforced resin molded article is preferably manufactured by, for example, injection molding, compression molding (press molding), or the like. In the case of injection molding, the length of the reinforcing fibers contained in the molding material (preferably in pellet form) is preferably in the range of 0.1 to 10 mm. In the case of compression molding, the reinforcing fibers contained in the molding material (preferably sheet material) include discontinuous fibers having a length of 1 to 100 mm, continuous fibers such as woven fabrics, knitted fabrics, and unidirectional materials. can. The sheet material may be one sheet, or may be used by laminating a plurality of sheets.

Reinforcing fibers having different fiber lengths may be used in combination. In other words, the reinforcing fibers may have a single peak in the fiber length distribution, or may have multiple peaks.
The average fiber length of the reinforcing fibers can be obtained, for example, by measuring the fiber length of 100 fibers randomly extracted from the fiber-reinforced resin molded body to the nearest 1 mm using a vernier caliper, and calculating the average fiber length based on the following formula. . Reinforcing fibers can be extracted from a fiber-reinforced resin molded article, for example, by heat-treating the fiber-reinforced resin molded article at 500° C. for about 1 hour and removing the resin in a furnace.
Number average fiber length: Ln = ΣLi/j
(Li: fiber length of single yarn of reinforcing fiber, j: number of reinforcing fibers)
Weight average fiber length: Lw = (ΣLi ² )/(ΣLi)
Note that when the fiber length is constant, such as in the case of cutting with a rotary cutter, the number average fiber length and the weight average fiber length have the same value.
In the present invention, either the number average fiber length or the weight average fiber length may be employed, but the weight average fiber length often reflects the physical properties of the fiber-reinforced resin material more accurately.

The fiber diameter of the reinforcing fiber used in the present invention may be appropriately determined according to the type of reinforcing fiber, and is not particularly limited.
For example, when carbon fibers are used as reinforcing fibers, the average fiber diameter is usually preferably in the range of 3 μm to 50 μm, more preferably in the range of 4 μm to 12 μm, and in the range of 5 μm to 8 μm. is more preferable.
On the other hand, when glass fibers are used as reinforcing fibers, the average fiber diameter is preferably within the range of 3 μm to 30 μm.
Here, the average fiber diameter refers to the diameter of a single reinforcing fiber. Therefore, when the reinforcing fibers are in the form of a fiber bundle, the diameter refers to the diameter of the reinforcing fibers (single filaments) forming the fiber bundle, not the diameter of the fiber bundle.
The average fiber diameter of reinforcing fibers can be measured, for example, by the method described in JIS R7607:2000.
Regardless of the type, the reinforcing fibers used in the present invention may be in the form of a single filament, or may be in the form of a fiber bundle consisting of a plurality of single filaments.
The reinforcing fibers used in the present invention may be in the form of single filaments only, may be in the form of fiber bundles alone, or may be a mixture of both. The term "fiber bundle" as used herein means that two or more single yarns are brought close to each other by a sizing agent, electrostatic force, or the like. When a fiber bundle is used, the number of single yarns constituting each fiber bundle may be substantially uniform in each fiber bundle, or may be different.
When the reinforcing fibers used in the present invention are in the form of fiber bundles, the number of single yarns constituting each fiber bundle is not particularly limited, but is usually in the range of 10 to 100,000.

When the carbon fiber bundle is spread and used as the reinforcing fiber, the degree of spreading of the fiber bundle after the spreading is not particularly limited, but the degree of spreading of the fiber bundle is controlled to obtain a specific number or more of carbon fibers. It is preferable to include carbon fiber bundles consisting of and less carbon fibers (single yarns) and/or carbon fiber bundles. In this case, specifically, the carbon fiber bundle (A) composed of the critical single yarn number or more defined by the following formula (1) and the other opened carbon fibers, that is, the single yarn state or the critical It is preferably composed of a fiber bundle composed of less than the number of single yarns.
Critical single yarn number = 600/D (1)
(where D is the average fiber diameter (μm) of the carbon fiber)

The ratio of the carbon fiber bundles (A) to the total amount of carbon fibers in the fiber-reinforced resin molded product is preferably more than 0 Vol% and less than 99 Vol%, more preferably 20 Vol% or more and less than 99 Vol%, and 30 Vol% or more and less than 95 Vol%. More preferably, it is most preferably 50 Vol % or more and less than 90 Vol %.

The degree of opening of the carbon fibers can be set within a desired range by adjusting the opening conditions of the fiber bundle. For example, when blowing air onto the fiber bundle to open the fiber bundle, the degree of fiber opening can be adjusted by controlling the pressure of the air blown onto the fiber bundle. In this case, increasing the air pressure increases the degree of fiber opening (the number of single yarns constituting each fiber bundle decreases), and decreasing the air pressure decreases the degree of fiber opening (the number of fibers constituting each fiber bundle). There is a tendency for the number of single yarns to be used to increase).
When carbon fibers are used as reinforcing fibers in the present invention, the average number of fibers (N) in the carbon fiber bundle (A) can be appropriately determined within a range that does not impair the object of the present invention, and is particularly limited. not a thing

In the case of carbon fibers, the above N is preferably within the range of 1<N<12000, and more preferably satisfies the following formula (2).
0.6×10 ⁴ /D ² <N<1.0×10 ⁵ /D ² (2)
(where D is the average fiber diameter (μm) of the carbon fiber)

When the average fiber diameter of the carbon fibers is 5 μm, the average number of fibers in the carbon fiber bundle (A) is in the range of 240 to less than 4000, preferably 300 to 2500. More preferably 400 to 1600. Further, when the average fiber diameter of the carbon fibers is 7 μm, the average number of fibers in the carbon fiber bundle (A) is in the range of 122 to 2040, preferably 150 to 1500, more preferably 200. ~800.

(matrix)
Thermoplastic resins and thermosetting resins are generally known as typical matrices used in fiber-reinforced resin molded articles, and these are also preferably used in the present invention. Further, in the present invention, a thermosetting resin may be used in combination as the matrix as long as the main component is a thermoplastic resin.
It is preferable to use a thermoplastic resin as a matrix that constitutes the fiber-reinforced resin molding for manufacturing the member A.
The thermoplastic resin is not particularly limited, and a resin having a desired softening point or melting point is appropriately selected while considering excellent mechanical properties and productivity according to the application of the fiber-reinforced resin joined body of the present invention. It can be selected and used.
As the thermoplastic resin, one having a softening point within the range of 180° C. to 350° C. is usually used, but it is not limited to this.

Examples of thermoplastic resins include polyolefin resins, polystyrene resins, thermoplastic polyamide resins, polyester resins, polyacetal resins (polyoxymethylene resins), polycarbonate resins, (meth)acrylic resins, polyarylate resins, polyphenylene ether resins, and polyimide resins. , polyethernitrile resin, phenoxy resin, polyphenylene sulfide resin, polysulfone resin, polyketone resin, polyetherketone resin, thermoplastic urethane resin, fluorine resin, thermoplastic polybenzimidazole resin, and the like.

Polyolefin resins include, for example, polyethylene resins, polypropylene resins, polybutadiene resins, polymethylpentene resins, vinyl chloride resins, vinylidene chloride resins, vinyl acetate resins, polyvinyl alcohol resins, and the like.
Examples of polystyrene resins include polystyrene resins, acrylonitrile-styrene resins (AS resins), acrylonitrile-butadiene-styrene resins (ABS resins), and the like.
Examples of polyamide resins include polyamide 6 resin (nylon 6), polyamide 11 resin (nylon 11), polyamide 12 resin (nylon 12), polyamide 46 resin (nylon 46), polyamide 66 resin (nylon 66), and polyamide 610 resin. (nylon 610) and the like.
Examples of polyester resins include polyethylene terephthalate resin, polyethylene naphthalate resin, polybutylene terephthalate resin, polytrimethylene terephthalate resin, and liquid crystal polyester.
(Meth) acrylic resins include, for example, polymethyl methacrylate.
Modified polyphenylene ether resins include, for example, modified polyphenylene ethers.
Examples of thermoplastic polyimide resins include thermoplastic polyimides, polyamideimide resins, polyetherimide resins, and the like.
Examples of polysulfone resins include modified polysulfone resins and polyethersulfone resins.
Examples of polyetherketone resin include polyetherketone resin, polyetheretherketone resin, and polyetherketoneketone resin.
Examples of fluorine-based resins include polytetrafluoroethylene.

Only one type of thermoplastic resin may be used, or two or more types may be used. Examples of a mode in which two or more thermoplastic resins are used in combination include, for example, a mode in which thermoplastic resins having different softening points or melting points are used in combination, and a mode in which thermoplastic resins having different average molecular weights are used in combination. is possible, but not limited to this.

In the fiber-reinforced resin molded article, various fibrous or non-fibrous fillers of organic fibers or inorganic fibers, flame retardants, UV-resistant agents, stabilizers, mold release agents, pigments are contained within the range that does not impair the purpose of the present invention. , softeners, plasticizers, and surfactants.

It is desirable that the adhesion strength between the reinforcing fibers and the thermoplastic resin as the matrix is 5 MPa or more in a strand tensile shear test. This strength can be obtained by changing the surface oxygen concentration ratio (O/C) of the carbon fiber in addition to selecting the matrix resin, or by adding a sizing agent to the carbon fiber to increase the adhesion strength between the carbon fiber and the matrix. etc. can be improved.

(Manufacturing method of fiber reinforced resin molding)
The method for producing the fiber-reinforced resin molding is not particularly limited, and examples thereof include injection molding, extrusion molding, and press molding. In the case of injection molding and press molding, the matrix containing reinforcing fibers is heated to be plasticized immediately before molding, and introduced into a mold. As a heating method, an extruder or the like is used in the case of injection molding, and a hot air dryer, an infrared heater, or the like is used in the case of press molding.

If the thermoplastic resin used as the matrix exhibits high water absorbency, it is preferable to dry it before molding. The temperature of the thermoplastic resin heated during molding is preferably +15°C to the melting temperature and -30°C to the decomposition temperature. If the heating temperature is below that range, the resin will not melt, making molding difficult.

In the case of injection molding, conventionally known methods can be used. For example, continuous fiber-like reinforcing fibers are impregnated with long fiber pellets, that is, molten thermoplastic resin, adjusted to a predetermined viscosity, and then cut. A method of producing a predetermined shape with an injection molding machine using the pellets obtained in the process can be mentioned.

As a method other than the above, for example, a base material such as a unidirectionally arranged sheet (UD sheet) in which continuous fiber strands are arranged in parallel, a woven fabric, or discontinuous reinforcing fibers is placed in a mold, and then a thermoplastic resin is placed. and impregnated by melting, or by injecting and impregnating a thermoplastic resin melted by heating, followed by cooling. Also, as a thermoplastic resin, a method of placing the film or the like together with reinforcing fibers in a mold, heating and pressing can be used. It is also preferable to put the base material containing the thermoplastic resin into a mold set at a predetermined temperature and press it, as described above. The heating temperature is preferably in the range of the melting temperature of the thermoplastic resin +15°C or higher and the decomposition temperature -30°C or lower.

For manufacturing by press molding, for example, woven or knitted fabrics made of reinforcing fibers, unidirectionally arranged sheets (UD materials) in which strands of continuous fibers are arranged in parallel, papermaking sheets made of discontinuous fibers, continuous or discontinuous fibers A sheet or mat (hereinafter sometimes referred to as a reinforcing fiber mat), and if necessary, a powder, fiber, block, film, sheet, or non-woven fabric made of a thermoplastic resin. A base material contained in a woven fabric, a knitted fabric, a UD material, a sheet made of paper, or a reinforcing fiber mat is laminated in a single layer or multiple layers, and then heated and pressurized. Then, the thermoplastic resin is melted and impregnated between the reinforcing fibers, whereby a fiber-reinforced resin molded article having a thermoplastic resin as a matrix can be produced. The thermoplastic resin in this case may be the one supplied during the production of the reinforcing fiber mat, but after the production of the reinforcing fiber mat, a thermoplastic resin layer (film, non-woven fabric, , sheets, etc.), heat-pressing them, and impregnating the reinforcing fiber mat with a thermoplastic resin. That is, the fiber-reinforced resin molded article is manufactured by once forming two or more substrates of the same or different types by press molding, and then laminating other substrates or layers of the same or different types and press molding again. may
To reiterate, the embodiment in which the reinforcing fiber mat contains a thermoplastic resin includes, for example, an embodiment in which the reinforcing fiber mat contains a powdery, fibrous, or lumpy thermoplastic resin, and an embodiment in which the reinforcing fiber mat contains a thermoplastic resin. An embodiment in which a thermoplastic resin layer containing is mounted or laminated can be mentioned. Here, the thermoplastic resin layer may be formed by depositing a powdery, fibrous or lumpy thermoplastic resin, or may be made of a sheet-shaped or film-shaped thermoplastic resin. good.
A reinforcing fiber mat is a sheet or mat formed by accumulating or entangling reinforcing fibers. The reinforcing fiber mat includes a two-dimensional isotropic reinforcing fiber mat in which the long axis direction of the reinforcing fiber is randomly dispersed in the in-plane direction, and a reinforcing fiber mat in which the long axis direction of the reinforcing fiber is entangled in a cotton-like manner. A three-dimensional isotropic reinforcing fiber mat that is randomly distributed in each of the xyz directions is exemplified.

The base material may contain reinforcing fibers in different arrangement states in one base material.
Embodiments in which reinforcing fibers with different alignment states are included in one base material include, for example, (i) an embodiment in which reinforcing fibers with different alignment states are arranged in the in-plane direction of the base material, and (ii) the base material. An embodiment in which reinforcing fibers with different arrangement states are arranged in the thickness direction can be mentioned. Further, when the base material has a laminated structure composed of a plurality of layers, (iii) there is an aspect in which the reinforcing fibers contained in each layer are arranged in different states. Furthermore, an aspect in which each aspect of the above (i) to (iii) is combined can also be mentioned.

A fiber-reinforced resin molded article can be produced by compression-molding (press-molding) at least one substrate. The orientation state of the reinforcing fibers may be either unidirectional arrangement or two-dimensional random distribution. Alternatively, it may be a random arrangement intermediate between the unidirectional arrangement and the two-dimensional random distribution (the long axis direction of the reinforcing fibers is not completely arranged in one direction and is not completely random). Furthermore, depending on the fiber length of the reinforcing fibers, the long axis direction of the reinforcing fibers may be dispersed so as to have an angle with respect to the in-plane direction of the entire base material, and the fibers are arranged so as to be entangled in a cotton-like manner. Furthermore, the fibers may be dispersed in bidirectional fabrics such as plain weaves and twill weaves, multiaxial fabrics, nonwoven fabrics, mats, knits, braids, paper made of reinforcing fibers, and the like.
Among them, reinforcing fibers are unidirectionally arranged substrates in which the long axis direction is arranged in one direction, and isotropic substrates in which the long axis directions are two-dimensionally randomly dispersed in the in-plane direction. preferred.

In molding the protrusions of the fiber-reinforced resin molded body used for manufacturing the member A, from the standpoint of moldability, at least one surface of the base material, particularly the surface having the protrusions, has reinforcing fibers in a two-dimensional random manner. An array is preferred.

For the orientation of the reinforcing fibers in the base material, for example, a tensile test is performed with reference to an arbitrary direction of the base material and a direction perpendicular thereto, and after measuring the tensile modulus, the measured tensile modulus value It can be confirmed by measuring the ratio (Eδ) obtained by dividing the larger one by the smaller one. As the elastic modulus ratio approaches 1, it can be evaluated that the reinforcing fibers are two-dimensionally isotropically dispersed. It is said to be isotropic when the ratio of the larger modulus of elasticity in two orthogonal directions divided by the smaller value does not exceed 2, and isotropic when this ratio does not exceed 1.3. rated as excellent. As the base material in the present invention, when such a base material with excellent isotropy (isotropic base material) is used, it is excellent in moldability, mold followability, mechanical properties, etc., and good bonding is achieved. It is preferably used because it can provide the joined body of the present invention having strength. The orientation of the reinforcing fibers in the case of using the isotropic base material is maintained even in the fiber-reinforced resin molding.

The basis weight of the reinforcing fibers in the substrate is not particularly limited, but is usually 25 g/m ² to 10000 g/m ² .

Although the thickness of the substrate is not particularly limited, it is usually preferably in the range of 0.01 mm to 100 mm, preferably in the range of 0.01 mm to 10 mm, and more preferably in the range of 0.1 to 5 mm.
When the base material has a structure in which a plurality of layers are laminated, the above thickness does not refer to the thickness of each layer, but refers to the total thickness of the base material, which is the sum of the thicknesses of the respective layers.

The substrate may have a single-layer structure consisting of a single layer, or may have a laminated structure in which multiple layers are laminated.
The aspect in which the substrate has a laminated structure may be an aspect in which a plurality of layers having the same composition are laminated, or an aspect in which a plurality of layers having mutually different compositions are laminated.
Moreover, as an aspect in which the base material has a laminated structure, an aspect in which layers having mutually different arrangement states of reinforcing fibers are laminated may be used. Examples of such a mode include a mode in which a layer in which reinforcing fibers are arranged in one direction and a layer in which reinforcing fibers are arranged two-dimensionally at random are laminated.
When three or more layers are laminated, a sandwich structure consisting of an arbitrary core layer and skin layers laminated on the front and back surfaces of the core layer may be employed.

(Projections of Fiber Reinforced Resin Moldings)
The fiber-reinforced resin molding used for manufacturing the member A has at least one protrusion. This projecting portion is inserted into the through hole h1 of the member B, and the portion protruding above the through hole h1 is crimped to form a crimped portion.

The crimped portion is a portion protruding above the through hole h1 of the fiber reinforced resin molded article inserted into the through hole h1 of the member B (the portion protruding upward from the fiber reinforced resin molded article) is heated, It refers to a part that is deformed like an umbrella shape by being pressurized. Since the crimped portion is usually shaped like an umbrella, it is sometimes called an “umbrella portion”.

The shape of the protrusions is not particularly limited, but specific examples include columnar, conical, prismatic, pyramidal, and trapezoidal shapes. Among them, cylindrical, conical, pyramidal, and trapezoidal shapes can be preferably used because there are few factors that depend on the draft angle of the mold during molding. For example, if the protrusion is cylindrical, the diameter should be selected from the range of 4 to 12 mm, and the height of the portion protruding from the through hole h1 of the member B should be selected from the range of 6 to 15 mm. Since the protrusion protrudes from the through hole h1 of the member B and is crimped, the height of the portion protruding from the through hole h1 of the member B at this time is, for example, when the protrusion is cylindrical, A range of 0.8 to 1.2 times the diameter of the cylinder is preferred.

<Member B>
The material of the member B is not particularly limited, but examples thereof include metals, resins, and ceramics. Examples of metals include iron, aluminum, copper, titanium and alloys thereof. Resins include synthetic resins and non-synthetic resins (natural macromolecules), and synthetic resins may be either thermoplastic resins or thermosetting (mold) resins. Specific examples of thermoplastic resins include general-purpose plastics such as polyethylene, polyvinyl chloride, polystyrene, ABS, and acrylic resins, engineering materials such as polyamides, polycarbonates, polyphenylene ethers, polyesters (PET, PBT, etc.), and cyclic polyolefins (COP). Plastics, polyphenylene sulfide (PPS), polyetherketone (PEK), polyetheretherketone (PEEK), polytetrafluoroethylene, thermoplastic polyimide, polyarylate, polysulfone, polyethersulfone (PES), liquid crystal polymer (LCP) ), and super engineering plastics such as polyamideimide. Specific examples of thermosetting resins include epoxy resins, phenol resins, unsaturated polyester resins, melamine resins, urea resins, and curable polyimide resins.
The resin may contain, as reinforcing fibers, inorganic fibers such as glass fibers and carbon fibers, and organic fibers such as aramid fibers, polyester fibers and polyamide fibers.
The member B may be a fiber-reinforced resin molded body, and the same fiber-reinforced resin molded body as described in the explanation of the member A can be used.

(Through hole h1 of member B)
Member B has at least one through hole h1. The size and shape of the through hole h1 may be such that the protruding portion of the fiber-reinforced resin molded body, which is the member A, can be completely inserted and protruded from the through hole h1 to the extent that it can be crimped. The shape of the through hole h1 may be selected in accordance with the shape of the protrusion, and is preferably designed to be larger than the protrusion.
The method for obtaining the through hole h1 is not particularly limited, but for example, a method of drilling with a drill, an end mill, a water jet, a laser, etc., or a method of punching a portion corresponding to the through hole h1 in advance in a mold and cutting the base material using a blade. A method of press molding and the like can be mentioned.

The shape of the through hole h1 of the member B when viewed in the thickness direction is not particularly limited, and may be circular (perfectly circular or elliptical) or polygonal. The shape of the through hole h1 of the member B when viewed in the thickness direction is preferably neither elliptical nor polygonal, and more preferably a perfect circle.

Next, matters other than those described above about the fiber-reinforced resin joined body and the method for producing the same of the present invention will be described.

<Fiber-reinforced resin joint>
The fiber-reinforced resin bonded body of the present invention is not particularly limited in its shape, and may be composed of, for example, a planar (plate-shaped) or rod-shaped member A and a member B of the same shape. Further, the member A may have two or more protrusions, and all of the protrusions may be inserted into the two or more through holes h1 of the member B and crimped. Furthermore, one protrusion of the member A having one or more protrusions is inserted into one through hole h1 in the member B having one or more protrusions and one or more through holes h1 and crimped. and one or more protrusions of the member B may be inserted into the through holes of the third compact and crimped.

The crimped portion is preferably crimped by heating and compressing the protruding portion of the fiber-reinforced resin molded body, which is the member A. As shown in FIG. By heating and compressing, the portion (protruding portion) of the fiber-reinforced resin molded article protruding from the through hole h1 of the member B is melted and crimped to form an umbrella-shaped crimped portion.
Since the fiber-reinforced resin bonded body of the present invention is crimped as described above, it has excellent bonding strength. You may
The crimped portion is preferably in contact with the surface of the member B, but may not be in contact as long as the bonding strength can be maintained. Moreover, the protrusion may or may not be in contact with the inner surface of the through hole h1 of the member B. As shown in FIG.

<Method for producing a fiber-reinforced resin bonded body>
The fiber-reinforced resin bonded body of the present invention can be manufactured by inserting the protrusion of the fiber-reinforced resin molding into the through hole h1 of the member B and crimping the protruding portion (projection). When crimping, it is preferable to apply pressure while heating the protruding portion, and the protruding portion can be manufactured by cooling and solidifying after the deformation is completed.
The method of heating the projecting portion is not particularly limited, but there are, for example, a method of heating by contact with a heater such as a hot plate, a method of heating by infrared rays, and a method of heating by vibrating with ultrasonic waves. Among them, in the method of heating with infrared rays, it is possible to selectively heat the portion of the projecting portion that is desired to be deformed. Moreover, the method of heating with ultrasonic waves can be preferably used because crimping can be performed in a short period of time. At this time, when fixing the positions of the fiber-reinforced resin molding and the member B and fixing the caulking position, a jig called an anvil is often used.
The umbrella shape of the caulked portion after caulking can be determined by the shape of a jig used for caulking. The volume of the jig is determined by adjusting the volume of the protrusion used for caulking. Specifically, it is preferable that the crimpable portion of the protruding portion is 1.1 to 1.2 times the size of the jig used for crimping.
The fiber-reinforced resin joined body of the present invention may have one crimped portion, or may have two or more crimped portions.

EXAMPLES The present invention will be specifically described below using Examples, but the present invention is not limited to these.

[Example 1]
(1.1 Production of fiber-reinforced resin molding)
Carbon fiber (CF) “Tenax” (registered trademark) STS40-24K (average fiber diameter 7 μm, number of single fibers 24,000) manufactured by Teijin Limited, cut to a fiber length of 20 mm, is used as the carbon fiber, and as the resin, Using nylon 6 resin (PA6) A1030 manufactured by Unitika Ltd., a composite material of carbon fiber and nylon 6 resin in which carbon fibers are randomly oriented two-dimensionally was prepared according to the method described in US Pat. No. 8,946,342. The resulting composite material was heated at 2.0 MPa for 5 minutes in a press heated to 270° C. to obtain a plate-like fiber-reinforced resin molded body having a width of 250 mm, a length of 250 mm, and an average thickness of 2.5 mm. .
Analysis of the carbon fibers contained in the plate-shaped fiber-reinforced resin molded product revealed that the carbon fiber volume ratio (Vf) was 35%, the fiber length of the carbon fibers was constant, and the weight average fiber length was 20 mm. rice field.

(1.2 Manufacture of fiber-reinforced resin molding having protrusions)
A mold capable of producing a flat plate of 200 mm × 100 mm having cylindrical projections (diameter of bottom of cylinder 6 mm, height of cylinder 12 mm) was prepared, and a flat plate having cylindrical projections was formed by cold press molding. . From this flat plate, a test piece of a flat plate with protrusions having a size of 25 mm×100 mm was cut out. As molding conditions for the cold press, the fiber-reinforced resin molded article produced above was heated to 300° C., charged into a mold heated to 150° C., and held at a molding pressure of 20 MPa for 30 seconds.

(2 Manufacture of member B)
A plate having a size of 25 mm×100 mm was prepared by cutting SPCC (Steel Plate Cold Commercial) having a thickness of 1 mm. A through hole h1 having a diameter of 10 mm was formed 25 mm from the end of the plate in the longitudinal direction and centered at the center in the transverse direction. Further, as shown in FIG. 9A, eight through holes h2 having a diameter of 1.5 mm were formed around the through hole h1. The shortest distance from the periphery of the through hole h1 to the periphery of the through hole h2 was set to 1 mm.

(3 Production of fiber-reinforced resin bonded product)
The protrusions of the fiber-reinforced resin moldings were passed through the through-holes h1 of the member B and overlapped. Specifically, the axis of the cylinder that is the protrusion and the axis of the through hole h1 are superimposed so that they are on the same straight line, fixed with a jig, and the portion of the protrusion that protrudes from the through hole h1 is crimped. rice field. The crimping process was carried out using an ultrasonic welding device (Branson 2000Xd, manufactured by Emerson Japan, Ltd.) under the conditions of a vibration frequency of 20 kHz, an amplitude of 60 μm, and a pressure of 1300 N to a predetermined position. The maximum diameter of the canopy of the caulked portion was 16 mm.

(4 Evaluation method)
For the evaluation, the fiber-reinforced resin joined body manufactured as described above was subjected to a shear tensile test using a universal testing machine (manufactured by Instron), and the initial stiffness during the test was evaluated. Specifically, the stress was measured when the displacement was 0.2 mm, and the initial stiffness was calculated by the following formula (1).
An initial rigidity of less than 1000 N/mm was evaluated as "C", 1000 N/mm or more and less than 2000 N/mm as "B", and 2000 N/mm or more as "A".
Initial rigidity [N/mm] = Stress [N]/Displacement [mm] Equation (1)

[Example 2]
Instead of the through hole h2 with a diameter of 1.5 mm, as shown in FIG. A fiber-reinforced resin bonded body was produced in the same manner as in Example 1 and evaluated.

[Example 3]
Instead of the through-hole h2 with a diameter of 1.5 mm, the surface around the through-hole h1 was roughened with #80 sanding paper as shown in FIG. A reinforced resin bonded body was manufactured and evaluated.

[Example 4]
Instead of the through hole h2 having a diameter of 1.5 mm, as shown in FIG. The notch c1 (the length of the longest line segment connecting any two points on the outline of one notch c1 when viewed from the thickness direction is 2.5 mm.) A fiber-reinforced resin bonded body was produced and evaluated in the same manner as in Example 1, except that 8 pieces were provided.

[Example 5]
Instead of the through hole h2 with a diameter of 1.5 mm, as shown in FIG. 9E, eight cuts (the length of the cut was 2.5 mm) were made outward from the periphery of the through hole h1. A fiber-reinforced resin bonded body was produced and evaluated in the same manner as in Example 1, except that the cut portion was bent in the plate thickness direction and raised. When manufacturing the fiber-reinforced resin bonded body, the fiber-reinforced resin molded body and the member B are aligned so that the direction in which the protrusions of the fiber-reinforced resin molded body protrude and the direction in which the notched portion of the member B protrudes are aligned. and superimposed.

[Comparative Example 1]
A fiber-reinforced resin joined body was produced and evaluated in the same manner as in Example 1, except that the height of the projection of the fiber-reinforced resin molded body was 9 mm and the through hole h2 having a diameter of 1.5 mm was not provided in the member B. bottom.

[Comparative Example 2]
A fiber-reinforced resin bonded body was produced and evaluated in the same manner as in Example 1, except that the through hole h2 with a diameter of 1.5 mm was not provided.

_S1 is the side area of the maximum inscribed cylinder of the through hole h1, and the area of the surface parallel to the thickness direction and the inclination of more than 0° and less than 90° with respect to the thickness direction in the region covered by the crimped portion of the member B S ₁ <S _T in Examples 1 to 5 _, and S 1 =S _T in Comparative Examples 1 to 2, where S ₁ is the total area of the planes parallel to the direction in which they are drawn.

The results are shown in Table 1 below.

From the results shown in Table 1, the fiber-reinforced resin joined bodies of Examples 1 to 5 had high initial rigidity.

INDUSTRIAL APPLICABILITY The fiber-reinforced resin bonded body of the present invention has excellent bonding strength, and can be used for applications requiring excellent welding strength, such as structural parts of automobiles.
In particular, when joining the member A and the member B containing the fiber reinforced resin, when joining by caulking and joining by an adhesive are used together, stable dimensional accuracy is achieved without fixing the member A and the member B to a jig. The adhesive can be cured at high temperature, and the cost can be greatly reduced.

A: Member A
B: Member B
A1: Protruding portion A2: Crimped portion h1: Through hole h1
h2: through hole h2
_CB : Thickness of member B 10: Fiber reinforced resin joined body Aa: Member Aa
R _h1 : diameter of through hole h1 20: maximum inscribed cylinder of through hole h1 d1: recess Sd1: inner wall surface of recess Sd2: inner wall surface of recess f1: direction parallel to inner wall surface Sd1 of recess f2: inner wall surface of recess Direction parallel to Sd2 θ1: Angle between thickness direction and f1 direction θ2: Angle between thickness direction and f2 direction c1: Notch L _c1 : Any two points on the outline of one notch c1 Length of the longest segment among the connected segments F: Member F
G: Member G
F1: Protruding part F2: Crimping part 30: Conventional fiber reinforced resin joined body j1: Through hole Fa: Member Fa

Claims (6)

A fiber-reinforced resin joined body including a member A containing a fiber-reinforced resin having at least one protrusion and a member B having at least one through-hole h1,
The protrusion penetrates through the through hole h1 and has a crimped portion protruding from the through hole h1,
_S1 is the side area of the maximum inscribed cylinder of the through hole h1, and the area of the surface parallel to the thickness direction in the region covered by the crimped portion of the member B and the thickness direction are more than 0° and 90°. A fiber-reinforced resin joined body in which S ₁ < _ST , where S _T is the total area of surfaces parallel to a direction inclined by less than °. The fiber-reinforced resin joined body according to claim 1, wherein said member B has at least one through-hole h2 smaller than said through-hole h1 in a region covered with said crimped portion. The fiber-reinforced resin joined body according to claim 1 or 2, wherein at least one cutout portion c1 is provided on the periphery of said through hole h1, and said cutout portion c1 is present in a region covered with said crimped portion. . The fiber-reinforced resin joined body according to any one of claims 1 to 3, wherein at least part of the region covered with the crimped portion of the member B is roughened. The fiber-reinforced resin joined body according to any one of claims 1 to 4, wherein said member B has a recess in at least part of the region covered with said crimped portion. The fiber-reinforced resin joined body according to any one of claims 1 to 5, wherein the shape of said through-hole h1 when viewed in the thickness direction is neither elliptical nor polygonal.

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