JP2024002299A - Resin injection mold device, method for manufacturing carbon fiber-reinforced resin tubular bodies, and carbon fiber-reinforced resin tubular bodies - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a resin injection mold device capable of producing carbon fiber reinforced resin tubular bodies in which unnecessary portions of resin can be easily removed.

SOLUTION: The molding device 100A as a resin injection mold device includes: housing sections 111, 121 in which a second metal member 50, a carbon fiber layer 31, and an end fixing member 60 are housed; resin accumulation portions 113, 123 provided in a portion corresponding to the end fixing member 60, connected to the housing sections 111, 121; and a first section 130A capable of dividing the resin accumulation portions 113, 123 into a first section that is closer to one end of the carbon fiber in the longitudinal direction and a second section that is closer to the other end of the carbon fiber in the longitudinal direction.

SELECTED DRAWING: Figure 7

COPYRIGHT: (C)2024,JPO&INPIT

Description

The present invention relates to a resin injection molding mold apparatus, a method for manufacturing a carbon fiber reinforced resin tube, and a carbon fiber reinforced resin tube.

As a carbon fiber-reinforced resin tube, Patent Document 1 describes a tube formed by a multi-fiber filament winding method and a resin injection molding method. The multi-filament winding method involves arranging carbon fiber bundles consisting of multiple woven layers on the outer circumferential surface of a mandrel (core material). In addition, with the resin injection molding method, a semi-finished product wound using the multi-filament winding method is placed in a mold, resin is injected, and the tubular body is completed by heating and curing. suitable for production.

Patent No. 6873369

In the multi-fiber filament winding method, carbon fiber bundles woven into a cylindrical shape are placed around the outer periphery of a mandrel, but in order to control the orientation angle of the fibers, the ends of the carbon fiber bundles are placed at the ends of the tube body. It is necessary to firmly fix it to the metal member to be used. For this purpose, a tape is wound around the end of the carbon fiber bundle to fix it.

In the resin injection molding method, a semi-finished product consisting of metal members placed at both ends of a mandrel and carbon fiber bundles placed on the outer peripheral surface of the mandrel to connect the metal parts is placed in a mold. The resin is injected into the vicinity of the end of the carbon fiber bundle on one metal member. The resin flows toward the discharge port formed on the other metal member side under negative pressure, and the entire carbon fiber is impregnated with the resin. Here, the resin injection part surrounds the tape, and a resin reservoir layer is formed whose diameter is larger than the outer diameter of the carbon fibers, but since this part is unnecessary as a product, it is removed by machining.

The present invention was created in view of the above circumstances, and provides a resin injection molding device and a resin injection molding mold capable of manufacturing a carbon fiber-reinforced resin tube body from which unnecessary parts of the resin can be easily removed. It is an object of the present invention to provide a method for manufacturing a carbon fiber reinforced resin pipe using an apparatus and a carbon fiber reinforced resin pipe.

According to the present disclosure, a metal member, a housing part in which a carbon fiber wound around the outer peripheral surface of the metal member, and a fixing member for fixing one longitudinal end of the carbon fiber to the metal member are housed; a resin pool part connected to the part and provided at a part corresponding to the fixing member; a first part that is closer to one end in the longitudinal direction of the carbon fiber; A resin injection mold device is provided, which includes a second section that is closer to the other end in the direction, and a first section that can be sectioned into two.

According to the present invention, it is possible to manufacture a carbon fiber-reinforced resin pipe body in which unnecessary portions of resin can be easily removed.

FIG. 1 is a cross-sectional view schematically showing a mandrel according to a first embodiment of the present invention. 1 is a diagram schematically showing a power transmission shaft manufactured using a mandrel according to a first embodiment of the present invention. FIG. 1 is a cross-sectional view schematically showing a power transmission shaft according to a first embodiment of the present invention. FIG. 2 is a diagram schematically showing a first carbon fiber layer of a power transmission shaft according to a first embodiment of the present invention. FIG. 3 is a diagram schematically showing a second carbon fiber layer of the power transmission shaft according to the first embodiment of the present invention. FIG. 3 is a diagram schematically showing a third carbon fiber layer of the power transmission shaft according to the first embodiment of the present invention. 1 is a cross-sectional view schematically showing a molding apparatus according to a first embodiment of the present invention. FIG. 1 is a cross-sectional view schematically showing a molding apparatus according to a first embodiment of the present invention, and a cross-sectional view showing a first section. It is a flowchart for explaining the manufacturing method of the power transmission shaft concerning a first embodiment of the present invention. FIG. 1 is a schematic cross-sectional view for explaining a method of manufacturing a power transmission shaft according to a first embodiment of the present invention. FIG. 1 is a schematic cross-sectional view for explaining a method of manufacturing a power transmission shaft according to a first embodiment of the present invention. FIG. 3 is a cross-sectional view schematically showing a molding device according to a second embodiment of the present invention. FIG. 7 is a schematic cross-sectional view for explaining a method of manufacturing a power transmission shaft according to a second embodiment of the present invention. FIG. 7 is a schematic cross-sectional view for explaining a method of manufacturing a power transmission shaft according to a second embodiment of the present invention. It is a sectional view showing typically a molding device concerning a third embodiment of the present invention. It is a sectional view showing typically a molding device concerning a third embodiment of the present invention, and is a sectional view showing a first section. It is a sectional view showing typically a molding device concerning a third embodiment of the present invention, and is a sectional view showing a first section. FIG. 7 is a schematic cross-sectional view for explaining a method of manufacturing a power transmission shaft according to a third embodiment of the present invention. FIG. 7 is a schematic cross-sectional view for explaining a method of manufacturing a power transmission shaft according to a third embodiment of the present invention.

Embodiments of the present invention will be described in detail with reference to the drawings, taking as an example a case in which a vehicle power transmission shaft (propeller shaft), which is an example of a fiber-reinforced resin tube, is manufactured from carbon fiber-reinforced plastic. In the following description, the same elements are denoted by the same reference numerals, and redundant description will be omitted. Furthermore, the drawings referred to are deformed for ease of understanding.

<First embodiment>
As shown in FIG. 1, a mandrel 1 according to a first embodiment of the present invention is used for manufacturing a fiber-reinforced resin pipe body 30 (see FIG. 2), and includes a mandrel body 10 and an inner A fitting member 20 is provided.

≪Mandrel body≫
The mandrel body 10 is a resin member having a cylindrical shape. The mandrel main body 10 can be made of a material that can withstand heating during resin curing in the fiber-reinforced resin tube 30. Examples of such materials include PP (polypropylene resin), PET (polyethylene terephthalate resin), SMP (shape memory polymer), and the like. The mandrel main body 10A includes a large diameter portion 11 at an axially intermediate portion, a first end portion including a stepped portion 12 and a first small diameter portion 13 in order from the large diameter portion 11 side, and a first end portion including a step portion 12 and a first small diameter portion 13 in order from the large diameter portion 11 side. A second end portion including a tapered portion 14, a second small diameter portion 15, and a protruding portion 16 in this order are integrally provided.

The outer diameter of the stepped portion 12 is smaller than the outer diameter of the large diameter portion 11 by the radial dimension of the first metal member 40 . The outer diameter of the first small diameter portion 13 is smaller than the outer diameter of the stepped portion 12 . The outer diameter of the tapered portion 14 becomes smaller from the large diameter portion 11 side toward the second small diameter portion 15 side. The size relationship between the outer diameters of the first small diameter portion 13 and the second small diameter portion 15 can be set as appropriate. The outer diameter of the protruding portion 16 is smaller than the outer diameter of the second small diameter portion 15 .

In this embodiment, the stepped portion 12 and the first small diameter portion 13 constitute a first end portion of the mandrel body 10. Further, the tapered portion 14, the second small diameter portion 15, and the protruding portion 16 constitute a second end portion of the mandrel body 10. Further, the large diameter portion 11 constitutes a main body portion that expands and deforms (expands in diameter) in the radial direction between both ends and then deforms and deforms (reduces in diameter). The first end and the second end are parts that are not expanded in the expansion process described later, and before the expansion process, the second end (the tapered part 14 (excluding the large diameter part 11 side end) ), the outer diameter of the second small diameter portion 15 and the protruding portion 16) is smaller than the outer diameter of the first end portion (step portion 12), which is the side from which the mandrel body 10 is extracted from the fiber-reinforced resin pipe body 30. It is set.

≪Internal fitting member≫
The internal fitting member 20 is a cylindrical metal member that is internally fitted into the first small diameter portion 13 that is the first end of the mandrel body 10 . The internal fitting member 20 prevents the first small diameter portion 13 from deforming inward in the radial direction, and is configured to prevent pressurizing fluid F (see FIG. 7) (for example, pressurized air) into the mandrel body 10. A flow path 20a is formed for filling the liquid. In this embodiment, the pressurizing fluid F is for pressurizing the inside of the mandrel body 10 to expand (expand the diameter) in the molding apparatus 100A. Further, the pressurizing fluid F is also a heating fluid for heating a thermosetting resin (resin 32 to be described later) disposed on the outer peripheral surface of the mandrel body 10 in order to harden it in the molding apparatus 100A to be described later. Note that the mandrel 1 may be a metal member in which the mandrel body 10 and the internal fitting member 20 are integrally formed.

<Power transmission shaft>
As shown in FIGS. 2 and 3, a power transmission shaft 2 manufactured using a mandrel 1 (see FIG. 1) extends in the longitudinal direction of a vehicle, and converts power generated from a power source into rotation around an axis. It is the axis of transmission. The power transmission shaft 2 includes a fiber-reinforced resin pipe 30, a first metal member 40, a second metal member 50, a first joint member 3, and a second joint member 4. In addition, in FIG. 3, the first joint member 3 and the second joint member 4 are omitted.

<Fiber-reinforced resin tube body>
The fiber-reinforced resin tube 30 is a resin-containing fiber layer formed into a tubular shape along the outer peripheral surface of the mandrel body 10. The fiber reinforced resin tube 30 is integrally molded with the first metal member 40 and the second metal member 50. The fiber-reinforced resin pipe body 30 includes the large diameter portion 11 (see FIG. 1), the tapered portion 14 (see FIG. 1), and the second small diameter portion 15 (see FIG. 1) of the mandrel body 10, and the first metal member 40. It is formed along the outer peripheral surface of one axial end (end on the large diameter portion 11 side) and one axial end (end on the large diameter portion 11 side) of the second metal member 50 . The fiber-reinforced resin pipe body 30 includes, as the carbon fiber layer 31, a first carbon fiber layer 31a (see FIG. 4) and a second carbon fiber layer 31b (see FIG. ) and a third carbon fiber layer 31c (see FIG. 6). Note that the outer peripheral surface of the other axial end of the second metal member 50 (the end located on the opposite side to the large diameter portion 11) is not covered with the fiber reinforced resin tube 30, and is not covered with the fiber reinforced resin tube 30. It protrudes from the resin pipe body 30.

≪First carbon fiber layer≫
As shown in FIG. 4, the first carbon fiber layer 31a is composed of a plurality of carbon fibers provided on the outer peripheral surface of the mandrel body 10 (see FIG. 1), etc., so as to cover the mandrel body 10. ing. More specifically, a carbon fiber aggregate is formed by gathering a plurality of carbon fibers into a band or a bundle, and a plurality of carbon fiber aggregates are provided at equal intervals on the circumference. One carbon fiber layer 31a is formed. The carbon fibers in the first carbon fiber layer 31a extend parallel to the axial direction of the mandrel body 10. That is, regarding the first carbon fiber layer 31a, the orientation angle of the carbon fibers with respect to the axis X of the mandrel body 10 is 0°.

≪Second carbon fiber layer≫
As shown in FIG. 5, the second carbon fiber layer 31b is provided on the radially outer side of the first carbon fiber layer 31a, and includes a plurality of carbon fibers provided so as to cover the first carbon fiber layer. It is made up of. More specifically, a carbon fiber aggregate is formed by gathering a plurality of carbon fibers into a band or a bundle, and a plurality of carbon fiber aggregates are provided at equal intervals on the circumference. A second carbon fiber layer 31b is formed. The carbon fibers in the second carbon fiber layer 31b are wound one or more turns at an angle of 45° with respect to the axial direction of the mandrel body 10 (see FIG. 1), and are spirally wound with respect to the axial direction of the mandrel body 10. It has been extended to That is, regarding the second carbon fiber layer 31b, the orientation angle of the carbon fibers with respect to the axis X of the mandrel body 10 is 45°.

≪Third carbon fiber layer≫
As shown in FIG. 6, the third carbon fiber layer 31c is provided on the radially outer side of the second carbon fiber layer 31b, and includes a plurality of carbon fibers provided so as to cover the second carbon fiber layer 31b. Composed of fibers. More specifically, a carbon fiber aggregate is formed by gathering a plurality of carbon fibers into a band or a bundle, and a plurality of carbon fiber aggregates are provided at equal intervals on the circumference. Three carbon fiber layers 31c are formed. The carbon fibers in the third carbon fiber layer 31c are wound one or more turns at an angle of −45° with respect to the axial direction of the mandrel body 10 (see FIG. 1), and are wound spirally with respect to the axial direction of the mandrel body 10. It is extended in a shape. That is, regarding the third carbon fiber layer 31c, the orientation angle of the carbon fibers with respect to the axis X of the mandrel body 10 is −45°. Note that the first carbon fiber layer 31a, the second carbon fiber layer 31b, and the third carbon fiber layer 31c may be individually wound around the mandrel body 10, or may be wound simultaneously. .

As shown in FIGS. 2 and 3, the fiber-reinforced resin tube 30 has a tapered portion 30b that decreases in diameter from the large diameter portion 30a at the center in the axial direction toward the small diameter portion 30c at the second end. has been done. The large diameter portion 30a is a main body portion having a shape that follows the outer peripheral surface of the large diameter portion 11 (see FIG. 1) of the mandrel main body 10A. The tapered portion 30b has a shape that follows the outer peripheral surface of the tapered portion 14 (see FIG. 1) of the mandrel body 10. The small diameter portion 30c is an end portion having a shape that follows the second small diameter portion 15 of the mandrel body 10 (see FIG. 1) and the outer peripheral surface of a part of the second metal member 50.

<First metal member and first joint member>
The first metal member 40 is a member having a substantially cylindrical shape. During the manufacturing stage, the first metal member 40 is fitted (externally fitted) into the stepped portion 12 (see FIG. 1). The axial dimension of the first metal member 40 is equal to the axial dimension of the stepped portion 12 .

The first metal member 40 is a member of the first joint member (yoke assembly) 3 that is a universal joint in the power transmission shaft 2 . The first joint member (yoke assembly) 3 is formed by assembling a spider, a needle bearing, and a yoke body to the first metal member 40.

<Second metal member and second joint member>
The second metal member 50 is a member (shaft) having a substantially cylindrical shape. During the manufacturing stage, the second metal member 50 is fitted (externally fitted) into the protrusion 16 (see FIG. 1).

As shown in FIGS. 1 and 3, a bottomed hole 50a into which the protrusion 16 of the mandrel body 10 can be inserted is formed at the other axial end of the second metal member 50.

The second metal member 50 is a part of a second joint member (plunge joint assembly) 4 that is a universal joint in the power transmission shaft 2 . The second joint member (plunge joint assembly) 4 is formed by assembling the boot and the plunge joint body to the second metal member 50.

<End fixing member>
As shown in FIG. 6, the end fixing member 60 used in the manufacturing stage of the power transmission shaft 2 is wound on the outer circumferential surface of the end of the carbon fiber layer 31 on the outer circumferential surface of the second metal member 50. This is a metal tape or band that temporarily fixes the ends of the carbon fiber layer 31. The end fixing member 60 fixes the carbon fiber layer 31 to the second metal member 50 so as to at least restrict movement of the end of the carbon fiber layer 31 in the axial direction.

<Forming equipment>
As shown in FIGS. 7 and 8, a resin injection mold device (hereinafter referred to as a molding device) 100A according to the first embodiment of the present invention has divided molds (an upper mold 110A and a lower mold 120A). This is an apparatus for manufacturing a power transmission shaft 2 by impregnating a resin 32 into a carbon fiber layer 31 wound around the outer peripheral surface of a mandrel 10 and hardening the resin 32. The molding device 100A includes an upper mold 110A, a lower mold 120A, and a first section 130A.

<Upper mold>
The upper mold 110A is formed with a housing portion 111, an introduction gate 112, a resin reservoir portion 113, a discharge gate 114, a communication path 115, and a first dividing portion gate 116.

The housing portion 111 is a recess formed in the surface of the upper mold 110A that faces the lower mold 120A. The housing portion 111 accommodates a portion of the mandrel 10 around which the carbon fiber layer 31 is wound, the first metal member 40, and the second metal member 50.

The introduction gate 112 is a passage for introducing the resin 32 into the accommodating parts 111 and 121, and is a hole that penetrates so as to connect the accommodating part 111 and the surface of the upper mold 110A on the opposite side from the accommodating part 111. .

The resin reservoir 113 is formed at a connecting portion between the accommodating portion 111 and the introduction gate 112. The resin reservoir portion 113 is provided on the second metal member 50 side.

The discharge gate 114 is a passageway for discharging the resin 32 introduced into the housing parts 111 and 121 to the outside, and is passed through so as to connect the housing part 111 and the surface of the upper mold 110A on the opposite side from the housing part 111. This is the hole where the The discharge gate 114 is provided on the first metal member 40 side.

The communication passage 115 is a passage for filling the pressurizing fluid F into the inside of the mandrel 10 housed in the housing parts 111 and 121, and is connected to the surface of the housing part 111 and the upper die 110A on the side opposite to the housing part 111. It is a hole that penetrates to connect the two. The communication path 115 is provided on the first metal member 40 side.

The first division gate 116 is a hole that passes through the housing part 116a in which the first division part 130A is accommodated, and connects the housing part 116a and the surface of the upper mold 110A opposite to the housing part 116a. 116b.

<Lower mold>
A housing portion 121, a resin reservoir portion 123, and a first dividing portion gate 126 are formed in the lower mold 120A.

The housing portion 121 is a recess formed in the surface of the lower mold 120A that faces the upper mold 110A. The housing portion 121 accommodates the other part of the mandrel 10 around which the carbon fiber layer is wound.

The resin reservoir 123 is formed at a location corresponding to the resin reservoir 113.

The first division gate 126 is a hole that passes through the housing part 126a in which the first division part 130A is accommodated, and connects the housing part 126a and the surface of the lower mold 120A opposite to the housing part 126a. 126b.

<First division>
The first section 130A divides the resin reservoir 113 into a first part including the end fixing member 60 and a side closer to the other longitudinal end of the carbon fiber 31 than the first part (the first metal member 40 It is configured so that it can be divided into a second part, which is a side). The first section 130A forms an annular groove having an opening on the outer peripheral surface side of the resin 32 cured in the resin reservoirs 113 and 123, thereby allowing the resin 32 to be transferred to the first section. It is divided into the first part and the second part. Such a groove functions as a fragile portion that makes the resin 32 more brittle than when there is no groove when partially removing the resin 32. That is, the first section 130A can be said to be an entry part that enters the resin reservoir 113 from the outside in the radial direction, and can also be said to be a fragile part forming part that forms a fragile part in the resin 32 in the resin reservoir 113.

The first dividing portion 130A is configured to be divided in the circumferential direction, and in this embodiment includes a first dividing member 131 for the upper mold and a first dividing member 132 for the lower mold. The first dividing member 131 for the upper mold is a metal plate-like member that is accommodated in the accommodating portion 116a of the first dividing portion gate 116 so as to be movable in the radial direction. A semicircular recess 131a is formed at the lower edge of the first dividing member 131 for the upper mold. The recess 131a has a V-shape when viewed from the side. The first dividing member 132 for the lower mold is a metal plate-like member that is accommodated in the accommodating portion 126a of the first dividing portion gate 126 so as to be movable in the radial direction. A semicircular recess 132a is formed at the upper edge of the first dividing member 132 for the lower mold. The recess 132a has a V-shape when viewed from the side.

<Manufacturing method>
Next, a method for manufacturing the power transmission shaft 2 using the mandrel 1 and the forming apparatus 100A according to the first embodiment of the present invention will be described using the flowchart of FIG. 9 (see FIGS. 1 to 8 as appropriate). The method for manufacturing the power transmission shaft 2 includes a mandrel body forming step (step S1), an internal fitting member installation step (step S2) performed after the mandrel main body forming step, and a second internal fitting member installation step performed after the internal fitting member installation step. The process includes one connection process (step S3) and a second connection process (step S4) executed after the first connection process. Further, the method for manufacturing the power transmission shaft 2 includes a fiber installation step (steps S5A to S5C) performed after the second connection step, a fiber end fixing step (step S6) performed after the fiber installation step, including. The method for manufacturing the power transmission shaft 2 also includes an in-mold installation step (step S7) performed after the fiber end fixing step, an expansion step (step S8) performed after the in-mold installation step, including. Furthermore, the method for manufacturing the power transmission shaft 12 includes a resin impregnation step (step S9) performed after the expansion step, and an advancing step of advancing the first section (step S10). Furthermore, the method for manufacturing the power transmission shaft 2 includes a resin curing step (step S11) performed after the advancing step, and an exit step (step S12) performed after the resin curing step. Furthermore, the method for manufacturing the power transmission shaft 2 includes a pressure reduction step (step S13) that is performed after the exit step, and a take-out step (step S14) that is performed after the pressure reduction step. Furthermore, the method for manufacturing the power transmission shaft 2 includes a pressure reduction step (step S15) executed after the extraction step, and an extraction step (step S16) executed after the pressure reduction step. Furthermore, the method for manufacturing the power transmission shaft 2 includes a resin removal process (step S17) that is executed after the extraction process, and a joint assembly process (step S18) that is executed after the resin removal process.

Step S1 is a step of forming the mandrel body 10 made of resin shown in FIG. 1 using a molding device (not shown).

Following step S1, in step S2, the internal fitting member 20 is press-fitted into the first small diameter portion 13 of the mandrel main body 10 to be internally fitted. Note that step S2 only needs to be executed before step S7.

Following step S2, in step S3, a first metal member (collar) 40 is provided at the first end of the mandrel body 10 (see FIG. 1).

Following step S3, in step S4, a second metal member 50 is provided at the second end of the mandrel body 10A (see FIG. 1). Here, the order of steps S3 and S4 can be changed as appropriate, and step S4 may be performed first or may be performed simultaneously.

Following step S4, the first carbon fiber layer 31a is formed on the outer peripheral surfaces of the mandrel body 10, the first metal member 40, and the second metal member 50 in step S5A. Following step S5A, in step S5B, a second carbon fiber layer 31b is formed on the outer peripheral surface of the first carbon fiber layer 31a in the mandrel body 10, the first metal member 40, and the second metal member 50. Ru. Following step S5B, in step S5C, a third carbon fiber layer 31c is formed on the outer peripheral surface of the second carbon fiber layer 31b in the mandrel body 10, the first metal member 40, and the second metal member 50. Ru.

In steps S5A to S5C, the carbon fiber layer 31 is not resin-impregnated fiber but so-called raw silk. Further, the carbon fiber layer 31 is arranged on the outer circumferential surfaces of the mandrel main body 10, the first metal member 40, and the second metal member 50, respectively, by a multi-filament winding method. The carbon fiber layer 31 fed by the multi-fiber filament winding method exhibits a so-called non-crimp structure in which the layers are independent without being interwoven with each other.

Following step S5C, in step S6, the end of the carbon fiber layer 31 disposed on the outer peripheral surface of the second metal member 50 is fixed by the end fixing member 60.

Following step S6, in step S7, as shown in FIG. , installed in the molding device (mold) 100A.

Following step S7, the mandrel body 10 is expanded in step S8. As shown in FIG. 7, in the molding apparatus 100A according to the first embodiment, a communication path 115 is provided so as to communicate with the inside of the mandrel body 10A via the flow path 20a. In step S8, the hollow portion of the mandrel body 10 is filled with pressurizing fluid F (for example, pressurized air at 140° C. or higher) via the communication path 115 connected to a supply device (not shown). The mandrel body 10 heated by the high-temperature pressurizing fluid F softens when the temperature reaches a temperature lower than the temperature at which the resin 32 hardens (80° C., which is the transformation temperature), and is pressurized from the inside by the pressurizing fluid F, forming the mold. It expands and deforms to follow the inner peripheral surface of the device 100A. Such pressurization can prevent the mandrel body 10 from being deformed in the diametrical direction by the filled resin 32. In addition, since the space volume formed between the mandrel body 10 and the upper mold recess 131a and the lower mold recess 132a is maintained appropriately by this pressurization, the filling amount of the resin 32 is suppressed, and the finished product is An increase in the weight of a certain fiber-reinforced resin pipe body 30 can be prevented.

Following step S8, resin 32 is supplied into the molding apparatus 100A in step S9. As a result, the carbon fiber layer 31 disposed on the outer peripheral surface of the mandrel body 10 is impregnated with the resin 32. Following step S9, in step S10, the first dividing member 131 for the upper die and the first dividing member 132 for the lower die are advanced inward in the radial direction by a device (not shown) (hydraulic pressure, pneumatic pressure, motor power, etc.). let Here, the first dividing member 131 for the upper mold and the first dividing member 132 for the lower mold advance before the resin 32 is filled into the molding apparatus 100A and hardened. Following step S10, in step S11, the resin 32 is cured by applying heat to the molding device 100A, and the fiber reinforced resin tube 30 is formed, and the fiber reinforced resin tube 30, the first metal member 40 and the second metal member 50 are integrally molded. Following step S11, in step S12, the first section 130A is withdrawn radially outward.

The resin 32 is, for example, a thermosetting resin. In this embodiment, the mold of the molding apparatus 100A is divided into a plurality of parts. In step S9, heat is applied to the assembly, a mold closing operation is performed to close the mold of the molding apparatus 100A, and then a mold clamping operation is performed to apply pressure to the closed mold. By increasing the internal pressure, curing of the resin 32 is promoted. Note that in this embodiment, the mold is divided into a plurality of parts, so a mold closing operation and a mold clamping operation are performed, but the mold clamping operation is not essential. Moreover, when the mold is not divided into a plurality of parts, such mold closing operation and mold clamping operation are not essential. In the molding apparatus 100A, a space (resin reservoirs 113, 123) is formed on the exit side of the introduction gate 112 into which the molten resin 32 is introduced. The resin 32 introduced into the molding apparatus 100A is stored in the resin reservoirs 113 and 123 located on the side of one end of the carbon fiber layer 31 in the axial direction. The resin 32 stored in the resin reservoirs 113 and 123 is discharged from a discharge hole formed on the side opposite to the introduction gate 112 in the arrangement direction of the carbon fiber layer 31 (on the outer peripheral surface side of the other axial end of the carbon fiber layer 31). Vacuum suction from the gate 114 moves the mandrel body 10 in the axial direction and impregnates the carbon fiber layer 31. Heat is applied to the molding device 100A in a state in which the carbon fiber layer 31 is impregnated with the resin 32, and pressure is further applied within the molding device 100A, thereby forming the fiber-reinforced resin pipe body 30.

Following step S12, in step S13, the pressure inside the mandrel body 10 is reduced to approximately atmospheric pressure. Following step S13, in step S14, the molded assembly, ie, the intermediate body, is taken out from the molding apparatus 100A.

Following step S14, the pressure inside the mandrel body 10 is further reduced in step S15. In this embodiment, the mandrel main body 10 is reduced in diameter (deformed in a radial direction) by applying a negative pressure inside the mandrel main body 10 . Following step S15, the mandrel 1 is extracted from the fiber-reinforced resin pipe body 30 in step S16. Here, the first metal member 40 and the second metal member 50 remain on the fiber-reinforced resin tube 30 side. Following step S16, in step S17, the cutting tool 200 cuts and removes the large diameter portion 30Z corresponding to the resin pools 113 and 123 of the fiber reinforced resin tube 30 held by a device not shown. . Here, an annular groove 30Z1 corresponding to the first section 130A is formed on the outer circumferential surface of the large diameter portion 30Z, which has a larger radial dimension than the surrounding portion, so that the resin 32 is cooled. The internal distortion of the large diameter portion 30Z can be suppressed when the large diameter portion 30Z hardens and contracts, and the hardness of the resin 32 does not increase significantly in the large diameter portion 30Z, and the removal area R including the large diameter portion 30Z can be easily removed. (See Fig. 10 → Fig. 11). Note that the groove portion 31Z is preferably arranged in the resin reservoir portions 113, 123 having a large radial dimension, and may be arranged on the outside of the fixing member 60 in the radial direction within the resin reservoir portions 113, 123. It may be arranged closer to the end of the carbon fiber layer 31 than the member 60 (on the right side of the fixing member 60 in FIG. 10). Following step S17, a universal joint is attached to the intermediate body in step S18. In this embodiment, the first joint member (yoke assembly) 3 is attached to the first metal member 40 of the intermediate body, and the second joint member (plunge joint assembly) 4 is attached to the second metal member 50. Attach.

The forming apparatus 100A according to the first embodiment of the present invention includes a metal member (second metal member 50), carbon fibers (carbon fiber layer 31) wound around the outer peripheral surface of the metal member, and A fixing member (end fixing member 60) that fixes one end in the longitudinal direction to the metal member is accommodated in accommodating parts 111 and 121, and is connected to the accommodating parts 111 and 121, and a portion corresponding to the fixing member is connected to the accommodating parts 111 and 121. The resin reservoirs 113, 123 provided are separated into a first region closer to one longitudinal end of the carbon fiber and a first region closer to the other longitudinal end of the carbon fiber. A first section 130A that can be divided into a second section and a first section 130A.
Therefore, the molding apparatus 100A can manufacture a carbon fiber-reinforced resin pipe body in which the hardened resin 32 and the fixing member in the resin reservoirs 113 and 123 can be easily removed.

In the forming apparatus 100A, the first section 130A is divided into a plurality of parts in the circumferential direction, and is movable in the radial direction of the metal member.
Therefore, the molding apparatus 100A can facilitate the accommodation of metal members and carbon fibers in the molding apparatus 100A, and the removal of the manufactured carbon fiber reinforced resin tube from the molding apparatus 100A.

Further, the method for manufacturing a carbon fiber reinforced resin pipe (fiber reinforced resin pipe 30) according to the first embodiment of the present invention uses the resin injection mold device (molding device 100A) to (carbon fiber layer 31) is impregnated with resin 32 and cured. a step of fixing one longitudinal end of the fiber with the fixing member (end fixing member 60); a step of accommodating the metal member, the carbon fiber, and the fixing member in the accommodating portions 111 and 121; and a step of accommodating the resin reservoir. a step of injecting the resin 32 into the portions 113, 123 and impregnating the carbon fiber with the resin 32; and a step of dividing the resin 32 in the resin reservoir portions 113, 123 by the first dividing portion 130A. , a step of curing the resin 32 in a state where the resin 32 is divided by the first dividing section 130A, and the metal member, the carbon fiber, the fixing member, and the cured resin 32 are placed in the housing section 111. , 121, and removing portions of the cured resin 32 corresponding to the resin pools 113, 123.
Therefore, according to the method for manufacturing the fiber-reinforced resin tube 30, it is possible to manufacture a carbon fiber-reinforced resin tube in which the hardened resin 32 and the fixing member in the resin reservoirs 113 and 123 can be easily removed.

In the method for manufacturing the fiber-reinforced resin pipe body 30, the first section 130A is divided into a plurality of parts in the circumferential direction, is movable in the radial direction of the metal member, and is configured to inject the resin 32. In the step of separating the resin reservoirs 113 and 123, the first dividing portion 130A is retracted radially outward, and in the step of dividing the resin reservoirs 113 and 123, the first dividing portion 130A moves radially inward. The resin 32 is divided into sections.
Therefore, according to the method for manufacturing the fiber-reinforced resin tube 30, it is easy to accommodate the metal member and carbon fibers in the molding device 100A and to take out the manufactured carbon fiber-reinforced resin tube from the molding device 100A. be able to.

<Second embodiment>
Next, a molding apparatus according to a second embodiment of the present invention will be described, focusing on the differences from the molding apparatus 100A according to the first embodiment.

As shown in FIG. 12, a molding device 100B according to the second embodiment of the present invention includes an upper mold 110B, a lower mold 120B, and a first section 130A and a second section 140B.

A second division gate 117 is formed in the upper die 110B. The second division gate 117 is a hole that passes through the housing part 117a in which the second division part 140B is accommodated, and connects the housing part 117a and the surface of the upper mold 110B opposite to the housing part 116a. 116b.

The lower mold 120B has a second division gate 127 formed therein. The second division gate 127 is a hole that passes through the housing part 127a in which the second division part 140B is accommodated, and connects the housing part 127a and the surface of the lower mold 120B opposite to the housing part 117a. 117b.

<Second division>
The second section 140B extends the radially outer side of the carbon fiber 31 in the longitudinal direction at a portion closer to the other longitudinal end of the carbon fiber 31 than the resin reservoirs 113 and 123 (on the first metal member 40 side). It is structured so that it can be classified. The second section 140B forms an annular groove having an opening on the outer circumferential side of the resin 32, which is cured on the outer circumferential surface of the carbon fiber 31, so that the resin 32 is axially Separate by direction. The groove functions as a positioning section for a removal range when partially removing the resin 32.

The second division part 140B is configured to be divided in the circumferential direction, and in this embodiment includes a second division member 141 for the upper mold and a second division member 142 for the lower mold. The second division member 141 for the upper mold is a metal plate-like member that is accommodated in the housing portion 117a of the second division gate 117 so as to be movable in the radial direction. A semicircular recess is formed at the lower edge of the second upper mold division member 141. The recess has a V-shape in side view. The second dividing member 142 for the lower mold is a metal plate-like member that is accommodated in the accommodating portion 127a of the second dividing portion gate 127 so as to be movable in the radial direction. A semicircular recess is formed at the lower edge of the second section 142 for the lower mold. The recess has a V-shape in side view.

<Manufacturing method>
Next, we will explain the differences between the method for manufacturing the power transmission shaft 2 according to the first embodiment and the method for manufacturing the power transmission shaft 2 using the mandrel 1 and the forming apparatus 100B according to the second embodiment of the present invention. The explanation will be centered on the flowchart shown in FIG.

In this operation example, in step S10, the first dividing member 131 for the upper mold, the first dividing member 132 for the lower mold, the second dividing member 141 for the upper mold, and the second dividing member 142 for the lower mold advances inward in the radial direction, and in step S12, the first dividing member 131 for the upper mold, the first dividing member 132 for the lower mold, the second dividing member 141 for the upper mold, and the second dividing member 141 for the lower mold. The partitioning member 142 is retracted radially outwardly. Since the operation of the second division member 141 for the upper mold and the second division member 142 for the lower mold is the same as that of the first division member 131 for the upper mold and the first division member 132 for the lower mold, Illustrations are omitted.

Here, since the annular groove portion 30Y1 corresponding to the second section 140B indicates the end of the removal region R, the removal region R including the large diameter portion 30Z can be easily removed in step S17. (See Figure 13 → Figure 14).

The molding apparatus 100B according to the second embodiment of the present invention longitudinally divides the outside of the carbon fiber in the radial direction at a portion closer to the other longitudinal end of the carbon fiber than the resin reservoirs 113 and 123. A possible second section 140B is provided.
Therefore, the molding apparatus 100B can manufacture a carbon fiber reinforced resin pipe body in which the removal range of the resin 32 is set appropriately.

In the forming apparatus 100B, the second section 140B is divided into a plurality of parts in the circumferential direction, and is movable in the radial direction of the metal member.
Therefore, it is possible to easily accommodate the metal member and carbon fibers in the molding device 100B and to take out the manufactured carbon fiber reinforced resin tube from the molding device 100A.

In the method for manufacturing a fiber-reinforced resin pipe body 30 according to the second embodiment of the present invention, the resin injection molding device may be arranged so that the other end of the carbon fiber in the longitudinal direction is The resin 32 covering the carbon fibers is provided with a second dividing section that can longitudinally divide the resin 32 at a portion close to the carbon fiber, and in the step of dividing the resin 32, the second dividing section 140B 32 in the longitudinal direction and curing the resin 32, the resin 32 is divided by the second division portion 140B.
Therefore, according to the method for manufacturing the fiber-reinforced resin tube 30, it is possible to manufacture a carbon fiber-reinforced resin tube in which the removal range of the resin 32 is suitably set.

In the method for manufacturing the fiber-reinforced resin pipe body 30, the second section 140B is configured to be divided into a plurality of parts in the circumferential direction, is movable in the radial direction of the metal member, and is configured to inject the resin 32. In the step of dividing the resin 32, the second dividing section 140B is retracted radially outward, and in the step of dividing the resin 32, the second dividing section 140B moves radially inward to separate the resin 32. Separate.
Therefore, according to the method for manufacturing the fiber-reinforced resin tube 30, it is easy to accommodate the metal member and carbon fibers in the molding device 100B and to take out the manufactured carbon fiber-reinforced resin tube from the molding device 100A. be able to.

Further, the fiber reinforced resin tube 30 according to the second embodiment of the present invention includes a metal member (second metal member 50) and carbon fibers (carbon fiber layer 31) wound around the outer peripheral surface of the metal member. ), and a resin 32 impregnated into the carbon fibers and hardened, and one longitudinal end of the carbon fibers is further disposed on the outer peripheral surface of the metal member than the recess (groove 30Y1) formed on the outer peripheral surface of the resin. The carbon fibers and the resin 32 on the side have been removed.
Therefore, in the fiber-reinforced resin tube 30, the removal range of unnecessary resin 32 is stable, and productivity is improved.

<Third embodiment>
Next, a molding apparatus according to a third embodiment of the present invention will be described, focusing on the differences from the molding apparatus 100B according to the second embodiment.

As shown in FIGS. 15 to 17, a molding apparatus 100C according to the third embodiment of the present invention includes an upper mold 110C, a lower mold 120C, and a first section 130C and a second section 140C. Be prepared.

The upper die 110C is provided with a first divided part gate 116C and a second divided part gate 117C instead of the first divided part gate 116 and the second divided part gate 117.

The first dividing portion gate 116C is a hole that penetrates to connect the accommodating portion 111 and the surface of the upper mold 110C opposite to the accommodating portion 111.

The second division gate 117C is a hole that penetrates to connect the accommodating part 111 and the surface of the upper mold 110C opposite to the accommodating part 111.

In the lower mold 120C, instead of the first section gate 126 and the second section gate 127, a first section gate 126C and a second section gate 127C are formed.

The first dividing portion gate 126C is a hole that penetrates so as to connect the accommodating portion 121 and the surface of the lower mold 120C on the opposite side from the accommodating portion 121.

The second division gate 127C is a hole that passes through the housing part 121 and the surface of the lower mold 120C opposite to the housing part 121.

<First division>
The first section 130C is formed by forming a plurality of holes having openings on the outer peripheral surface of the resin 32 in the resin 32 cured in the resin reservoir 113 so as to be arranged at equal intervals in the circumferential direction. The resin 32 is divided into a first part and a second part. Such a plurality of holes are effective in equalizing hardening and shrinkage due to cooling in the resin 32 and suppressing internal distortion in the large diameter portion 30Z, and can improve machinability during the cutting process in step S17. can.

The first section 130C includes a plurality of first section members 133 for upper molds and a plurality of first section members 134 for lower molds. The first section 133 for the upper mold is a metal bar-shaped member that is accommodated in the first section gate 116C so as to be movable in the radial direction. The first dividing member 134 for the lower mold is a metal bar-shaped member that is accommodated in the first dividing portion gate 126C so as to be movable in the radial direction.

<Second division>
The second section 140C is formed by forming a plurality of holes having openings on the outer circumferential surface side of the resin 32 in the resin 32 cured on the outer circumferential surface of the carbon fiber 31 so as to be lined up in the circumferential direction. The resin 32 is divided in the axial direction. The plurality of holes function as a positioning section for a removal range when partially removing the resin 32.

The second division section 140C includes a plurality of second division members 143 for upper molds and a plurality of second division members 144 for lower molds. The second division member 143 for the upper mold is a metal bar-shaped member that is accommodated in the second division gate 117C so as to be movable in the radial direction. The second dividing member 144 for the lower mold is a metal bar-shaped member that is accommodated in the second dividing portion gate 127C so as to be movable in the radial direction.

<Manufacturing method>
Next, we will explain the differences between the method for manufacturing the power transmission shaft 2 according to the second embodiment and the method for manufacturing the power transmission shaft 2 using the mandrel 1 and the forming apparatus 100C according to the third embodiment of the present invention. The explanation will be centered on the flowchart shown in FIG.

In this operation example, in step S10, a plurality of first division members 133 for upper molds, a plurality of first division members 134 for upper molds, a plurality of second division members 143 for upper molds, and a plurality of second division members 143 for upper molds, and The second mold division member 144 advances inward in the radial direction (FIG. 14→FIG. 15), and in step S12, the plurality of upper mold first division members 133 and the plurality of upper mold first division members 134 , and the plurality of second division members 143 for upper molds and the plurality of second division members 144 for lower molds retreat radially outward (FIG. 15→FIG. 14).

Here, on the outer circumferential surface of the large diameter portion 30Z, a plurality of holes 30Z2 corresponding to the plurality of first division members 133 for the upper die and the plurality of first division members 134 for the lower die are lined up in the circumferential direction. As a result, the internal distortion of the large diameter portion 30Z is suppressed to a small level, and the removal region R including the large diameter portion 30Z can be easily removed (see FIGS. 18 to 19). Furthermore, since the hole 30Y2 corresponding to the second section 140C indicates the end of the removal region R, the removal region R including the part 30Z can be easily removed in step S17 (FIG. 18→ (See Figure 19).

A molding apparatus 100C according to the third embodiment of the present invention includes a plurality of first division members 133 for upper molds, a plurality of first division members 134 for upper molds, and a plurality of second division members for upper molds. Since the member 143 and the plurality of second division members 144 for lower molds are each rod-shaped, the resin 32 does not flow into the first division gates 116, 126 and the second division gates 117, 127. On the other hand, it is possible to arrange a sealing member (for example, an O-ring) by a simple method, and the maintainability of the molding apparatus 100C can be improved.

Although the embodiments of the present invention have been described above, the present invention is not limited to the embodiments described above, and can be modified as appropriate without departing from the gist of the present invention. For example, the shapes of the grooves 30Z1 and 30Y1 formed by the first section 130A and/or the second section 130B are not limited to those illustrated.

Further, the carbon fiber layers 41 may have a so-called crimp structure in which they are woven together. Further, as a reference example, the fibrous body is not limited to carbon fibers, and may be any fibrous member (for example, glass fiber, cellulose fiber, etc.) that can strengthen the resin layer.

30 Fiber reinforced resin tube (carbon fiber reinforced resin tube)
31 Carbon fiber layer (carbon fiber)
50 Second metal member (metal member)
60 End fixing member (fixing member)
100A, 100B, 100C Molding equipment (resin injection mold equipment)
111, 121 Storage part 130A, 130C First division part 140B, 140C Second division part

Claims (9)

a housing portion that accommodates a metal member, carbon fibers wound around the outer peripheral surface of the metal member, and a fixing member that fixes one longitudinal end of the carbon fibers to the metal member;
a resin reservoir connected to the accommodating portion and provided at a portion corresponding to the fixing member;
A first part that can divide the resin reservoir into a first part that is closer to one end in the longitudinal direction of the carbon fibers and a second part that is closer to the other end in the longitudinal direction of the carbon fibers. A dividing section;
A resin injection molding mold device. The first section is divided into a plurality of parts in the circumferential direction, and is movable in the radial direction of the metal member.
The resin injection mold device according to claim 1. a second dividing portion capable of dividing the radially outer side of the carbon fiber in the longitudinal direction at a portion closer to the other longitudinal end of the carbon fiber than the resin reservoir;
The resin injection mold device according to claim 1. The second division part is configured to be divided into a plurality of parts in the circumferential direction, and is movable in the radial direction of the metal member.
The resin injection mold device according to claim 3. A method for manufacturing a carbon fiber-reinforced resin pipe body in which the carbon fibers are impregnated with a resin and cured using the resin injection mold device according to claim 1,
Wrapping carbon fiber around the outer peripheral surface of a metal member and fixing one longitudinal end of the carbon fiber with the fixing member;
accommodating the metal member, the carbon fiber, and the fixing member in the accommodating part;
Injecting the resin into the resin reservoir and impregnating the carbon fiber with the resin;
dividing the resin in the resin reservoir using the first dividing section;
curing the resin in a state where the resin is divided by the first division part;
a step of taking out the metal member, the carbon fiber, the fixing member, and the cured resin from the storage section;
removing a portion of the cured resin that corresponds to the resin pool;
A method for manufacturing a carbon fiber reinforced resin pipe body comprising: The first division part is configured to be divided into a plurality of parts in the circumferential direction, and is movable in the radial direction of the metal member,
In the step of injecting the resin, the first section is retracted radially outward;
In the step of dividing the resin pool, the first dividing part moves radially inward to divide the resin.
The method for manufacturing a carbon fiber reinforced resin pipe according to claim 5. The resin injection mold device includes a second dividing section capable of dividing the resin covering the carbon fibers in the longitudinal direction at a portion closer to the other longitudinal end of the carbon fibers than the resin reservoir section. and
In the step of dividing the resin, dividing the resin in the longitudinal direction by the second dividing section,
In the step of curing the resin, the resin is divided by the second division part,
The method for manufacturing a carbon fiber reinforced resin pipe according to claim 5. The second section is divided into a plurality of parts in the circumferential direction, and is movable in the radial direction of the metal member,
In the step of injecting the resin, the second section is retracted radially outward;
In the step of dividing the resin, the second dividing section moves radially inward to divide the resin.
The method for manufacturing a carbon fiber reinforced resin pipe according to claim 7. comprising a metal member, carbon fibers wound around the outer peripheral surface of the metal member, and a resin impregnated with the carbon fibers and cured,
On the outer circumferential surface of the metal member, the carbon fibers and the resin on the one longitudinal end side of the carbon fibers are removed from the recess formed on the outer circumferential surface of the resin.
Carbon fiber reinforced resin tube body.

Images