JP5899026B2 - Monolithic molded part manufacturing method and monolithic molded part - Google Patents
Monolithic molded part manufacturing method and monolithic molded part Download PDFInfo
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- JP5899026B2 JP5899026B2 JP2012083021A JP2012083021A JP5899026B2 JP 5899026 B2 JP5899026 B2 JP 5899026B2 JP 2012083021 A JP2012083021 A JP 2012083021A JP 2012083021 A JP2012083021 A JP 2012083021A JP 5899026 B2 JP5899026 B2 JP 5899026B2
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- 238000004519 manufacturing process Methods 0.000 title claims description 38
- 229920005989 resin Polymers 0.000 claims description 90
- 239000011347 resin Substances 0.000 claims description 90
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 88
- 239000004917 carbon fiber Substances 0.000 claims description 88
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 88
- 229910052751 metal Inorganic materials 0.000 claims description 78
- 239000002184 metal Substances 0.000 claims description 78
- 238000000926 separation method Methods 0.000 claims description 20
- 238000003825 pressing Methods 0.000 claims description 19
- 238000000034 method Methods 0.000 claims description 13
- 239000012212 insulator Substances 0.000 claims description 5
- 229910000831 Steel Inorganic materials 0.000 description 7
- 229910052782 aluminium Inorganic materials 0.000 description 7
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 7
- 239000010959 steel Substances 0.000 description 7
- 238000010438 heat treatment Methods 0.000 description 5
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 5
- 230000003014 reinforcing effect Effects 0.000 description 4
- 238000010586 diagram Methods 0.000 description 3
- 238000006056 electrooxidation reaction Methods 0.000 description 3
- 229920001187 thermosetting polymer Polymers 0.000 description 3
- 239000004566 building material Substances 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 239000013585 weight reducing agent Substances 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000009477 glass transition Effects 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
Description
本発明は、金属板と炭素繊維強化樹脂シートとの一体成型部品製造方法および一体成型部品に関する。 The present invention relates to a method for producing an integrally molded part of a metal plate and a carbon fiber reinforced resin sheet, and an integral molded part.
従来、軽量化を目的として、自動車や飛行機などの骨格に、アルミニウム系金属が使用されている。アルミニウムを使用する場合、アルミニウムは通常使用されている鋼板に比べて剛性が弱く補強が必要である。このため、鋼板で補強することがある。しかし、アルミニウムを鋼板で補強した場合、アルミニウムと鋼板との接合面において、自然電位差が生じ、電気化学的腐蝕が発生する。 Conventionally, for the purpose of weight reduction, aluminum-based metals have been used in the skeletons of automobiles and airplanes. When aluminum is used, aluminum is less rigid than a normally used steel plate and needs to be reinforced. For this reason, it may reinforce with a steel plate. However, when aluminum is reinforced with a steel plate, a natural potential difference occurs at the joint surface between the aluminum and the steel plate, and electrochemical corrosion occurs.
このため、これを防止するために、特許文献１には、自然電位の低い材料からなるパッキンを介在させる技術が開示されている。 For this reason, in order to prevent this, Patent Document 1 discloses a technique in which a packing made of a material having a low natural potential is interposed.
近年、さらなる軽量化と剛性、強度の向上のため、炭素繊維強化樹脂などの強化樹脂の使用が検討されている。この強化樹脂は、車両や飛行機の骨格だけでなく、船、建材、橋などの補強部材としての使用も期待されている。 In recent years, the use of reinforced resins such as carbon fiber reinforced resins has been studied for further weight reduction, rigidity, and strength improvement. This reinforced resin is expected to be used not only as a frame for vehicles and airplanes but also as a reinforcing member for ships, building materials and bridges.
そこで、炭素繊維強化樹脂を金属板（鋼板やアルミニウム）で補強した一体成型部品を用いる場合、炭素繊維強化樹脂は、表面が樹脂であるため、アルミニウムのように、金属板との表面の接合面での電気化学的腐蝕は発生しないが、端部において、電気化学的腐蝕が発生する場合がある。これは、炭素繊維強化樹脂の端部が切断されたままであり、炭素繊維強化樹脂の端部から露出した炭素繊維に水分が付着することで、金属板との接触部位において自然電位に差が生じ、発生するためである。 Therefore, when using an integrally molded part in which carbon fiber reinforced resin is reinforced with a metal plate (steel plate or aluminum), the surface of the carbon fiber reinforced resin is a resin. In this case, electrochemical corrosion does not occur at the edge, but electrochemical corrosion may occur at the edge. This is because the end of the carbon fiber reinforced resin remains cut, and moisture adheres to the carbon fiber exposed from the end of the carbon fiber reinforced resin, resulting in a difference in natural potential at the contact point with the metal plate. This is because it occurs.
この端部での自然電位の差が金属板においてサビを発生させ、補強部材としての強度や剛性の特性を劣化させてしまう可能性がある。 This difference in natural potential at the end portion may cause rust in the metal plate and may deteriorate the strength and rigidity characteristics of the reinforcing member.
本発明は、上記課題に鑑みてなされたものであり、その目的の一例は、金属板と炭素繊維強化樹脂との一体成型部品において、金属板でのサビを防止できる一体成型部品製造方法および一体成型部品を提供することである。 The present invention has been made in view of the above problems, and an example of the object thereof is an integrally molded part manufacturing method and an integrated part capable of preventing rust on a metal plate in an integrally molded part of a metal plate and a carbon fiber reinforced resin. It is to provide molded parts.
このような課題を解決するために、本発明に係る一体成型部品製造方法は、金属板と炭素繊維強化樹脂シートとの一体成型部品を製造する一体成型部品製造方法であって、凸状部を備える金属板と、炭素繊維強化樹脂シートを、炭素繊維強化樹脂シートの端部近傍が凸状部を覆うように重ねる工程と、凸状部に対応した型で、炭素繊維強化樹脂シートの端部と金属板の表面とが離間するようにプレスするプレス工程とを備える。 In order to solve such a problem, an integrally molded part manufacturing method according to the present invention is an integrally molded part manufacturing method for manufacturing an integrally molded part of a metal plate and a carbon fiber reinforced resin sheet, wherein a convex portion is formed. The end of the carbon fiber reinforced resin sheet is a mold corresponding to the convex part and a step of stacking the metal plate and the carbon fiber reinforced resin sheet so that the vicinity of the end of the carbon fiber reinforced resin sheet covers the convex part. And a pressing step of pressing so that the surface of the metal plate is separated .
好適には、上記解決手段に加えて、本発明に係る一体成型部品製造方法は、炭素繊維強化樹脂シートの端部と金属板の表面との間に離間部材を設ける。 Preferably, in addition to the above solution, the integrally molded component manufacturing method according to the present invention provides a separation member between the end of the carbon fiber reinforced resin sheet and the surface of the metal plate .
好適には、上記解決手段に加えて、本発明に係る一体成型部品製造方法は、離間部材を金属板側に設ける。 Preferably, in addition to the above solution, the integrally molded component manufacturing method according to the present invention provides the separating member on the metal plate side.
好適には、上記解決手段に加えて、本発明に係る一体成型部品製造方法は、離間部材を炭素繊維強化樹脂シート側に設ける。 Preferably, in addition to the above solution, in the integrally molded component manufacturing method according to the present invention, the spacing member is provided on the carbon fiber reinforced resin sheet side.
好適には、上記解決手段に加えて、本発明に係る一体成型部品製造方法は、離間部材が絶縁体である。 Preferably, in addition to the above solution, in the integrally molded component manufacturing method according to the present invention, the separating member is an insulator.
好適には、上記解決手段に加えて、本発明に係る一体成型部品製造方法は、離間部材をプレス工程後に取り除く離間部材除去工程を備える。 Preferably, in addition to the above solution, the method for manufacturing an integrally molded part according to the present invention includes a separation member removing step of removing the separation member after the pressing step.
さらに、上記解決手段に加えて、本発明に係る一体成型部品は、金属板と炭素繊維強化樹脂シートとの一体成型部品であって、炭素繊維強化樹脂シートの端部と金属板の表面とを離間して一体的に成形する。 Further, in addition to the above solution, the integrally molded component according to the present invention is an integrally molded component of a metal plate and a carbon fiber reinforced resin sheet, and includes an end portion of the carbon fiber reinforced resin sheet and a surface of the metal plate. Separated and molded integrally.
好適には、上記解決手段に加えて、本発明に係る一体成型部品は、金属板が、炭素繊維強化樹脂シートが重ねられる位置における炭素繊維強化樹脂シートの端部より内側の部位であって、かつ炭素繊維強化樹脂シート側へ向かって凸状部を備えている。 Preferably, in addition to the above solution, in the integrally molded part according to the present invention, the metal plate is a portion inside the end portion of the carbon fiber reinforced resin sheet at a position where the carbon fiber reinforced resin sheet is superimposed, And the convex part is provided toward the carbon fiber reinforced resin sheet side.
本発明の一体成型部品製造方法および一体成型部品によれば、自然電位の差により発生する金属板におけるサビを防止することで、補強部材としての強度や剛性の特性の劣化を防止できる。 According to the integrally molded component manufacturing method and the integrally molded component of the present invention, it is possible to prevent deterioration of strength and rigidity characteristics as a reinforcing member by preventing rust on the metal plate generated due to a difference in natural potential.
図１は、本発明の実施形態を示している。図１に基づいて本発明の一体成型部品について説明する。 FIG. 1 shows an embodiment of the present invention. The integrally molded part of the present invention will be described with reference to FIG.
図１は、本発明の第１実施形態に係る一体成型部品１の斜視図である。一体成型部品１は、鋼板やアルミニウム系金属などからなる金属板１０と炭素繊維強化樹脂シート２０とが重ね合されて一体となっている。炭素繊維強化樹脂シート２０の端部２０Ｔは、一体成型部品１において、金属板１０の表面１０Ｓから離間している。 FIG. 1 is a perspective view of an integrally molded component 1 according to the first embodiment of the present invention. The integrally molded component 1 is formed by superimposing a metal plate 10 made of a steel plate or an aluminum-based metal and a carbon fiber reinforced resin sheet 20. The end 20T of the carbon fiber reinforced resin sheet 20 is separated from the surface 10S of the metal plate 10 in the integrally molded component 1.
金属板１０は、炭素繊維強化樹脂シート２０の端部２０Ｔよりも内側の部位であって、かつ炭素繊維強化樹脂シート２０へ向かって凸状部１０Ａを備えている。したがって、金属板１０は、炭素繊維強化樹脂シート２０の端部２０Ｔの部位で、炭素繊維強化樹脂シート２０と接しないようになっている。 The metal plate 10 is a portion inside the end portion 20T of the carbon fiber reinforced resin sheet 20 and includes a convex portion 10A toward the carbon fiber reinforced resin sheet 20. Therefore, the metal plate 10 does not come into contact with the carbon fiber reinforced resin sheet 20 at the end portion 20T of the carbon fiber reinforced resin sheet 20.
さらに、本発明の第１実施形態に係る一体成型部品１では、金属板１０が、炭素繊維強化樹脂シート２０の端部２０Ｔよりも内側の部位であって、かつ炭素繊維強化樹脂シート２０へ向かって凸状となり、その延長が金属板１０の平面と同一平面に戻っている。図２において、わかりやすく図示する。 Furthermore, in the integrally molded component 1 according to the first embodiment of the present invention, the metal plate 10 is a portion inside the end portion 20T of the carbon fiber reinforced resin sheet 20 and faces the carbon fiber reinforced resin sheet 20. It is convex and its extension returns to the same plane as the plane of the metal plate 10. In FIG. 2, it is illustrated in an easy-to-understand manner.
図２は、本発明の第１実施形態にかかる一体成型部品１の断面図である。金属板１０と炭素繊維強化樹脂シート２０が張り合わされており、炭素繊維強化樹脂シート２０の端部２０Ｔは金属板１０の表面１０Ｓから離間している。 FIG. 2 is a cross-sectional view of the integrally molded component 1 according to the first embodiment of the present invention. The metal plate 10 and the carbon fiber reinforced resin sheet 20 are bonded together, and the end 20T of the carbon fiber reinforced resin sheet 20 is separated from the surface 10S of the metal plate 10.
金属板１０が、炭素繊維強化樹脂シート２０の端部２０Ｔよりも内側の部位であって、かつ炭素繊維強化樹脂シート２０へ向かって凸状となり、その延長が金属板１０の平面と同一平面に戻っている。 The metal plate 10 is a portion inside the end portion 20T of the carbon fiber reinforced resin sheet 20 and is convex toward the carbon fiber reinforced resin sheet 20, and its extension is flush with the plane of the metal plate 10 I'm back.
なお、図１および図２の右側は図示を省略しているが、左側と同様に炭素繊維強化樹脂シート２０の端部２０Ｔが金属板１０の表面１０Ｓから離間している。 Although not shown on the right side of FIGS. 1 and 2, the end 20T of the carbon fiber reinforced resin sheet 20 is separated from the surface 10S of the metal plate 10 as in the left side.
このように、炭素繊維強化樹脂シート２０の端部２０Ｔを金属板１０の表面１０Ｓから離間させているので、炭素繊維強化樹脂シート２０の端部２０Ｔから露出する炭素繊維に水分が付着したとしても、金属板１０との間に自然電位の差は生じず、金属板１０をサビから防ぐことができる。 As described above, since the end 20T of the carbon fiber reinforced resin sheet 20 is separated from the surface 10S of the metal plate 10, even if moisture adheres to the carbon fiber exposed from the end 20T of the carbon fiber reinforced resin sheet 20. The difference in natural potential does not occur between the metal plate 10 and the metal plate 10 can be prevented from rust.
また、一体成型部品１を使用する場所によっては、金属板１０の表面１０Ｓに塗装が行われていてもよいが、塗装がない場合、炭素繊維強化樹脂シート２０の表面が溶解し金属板１０に接着しやすいので、金属板１０の表面１０Ｓに塗装を行っていない本実施形態は接着においてより効果がある。 Further, depending on the location where the integrally molded component 1 is used, the surface 10S of the metal plate 10 may be painted. However, when there is no coating, the surface of the carbon fiber reinforced resin sheet 20 is dissolved and the metal plate 10 is melted. Since it adheres easily, this embodiment which is not coating the surface 10S of the metal plate 10 is more effective in adhesion | attachment.
続いて、本実施形態に係る一体成型部品の製造方法を図３および図４に基いて説明する。図３は、本発明の第１実施形態に係る一体成型部品製造方法を示すフローブロック図である。図４は、本発明の第１実施形態に係る一体成型部品製造方法を示すフロー図である。 Then, the manufacturing method of the integrally molded component which concerns on this embodiment is demonstrated based on FIG. 3 and FIG. FIG. 3 is a flow block diagram showing the integrally molded component manufacturing method according to the first embodiment of the present invention. FIG. 4 is a flowchart showing the integrally molded component manufacturing method according to the first embodiment of the present invention.
一体成型部品製造方法を実現する装置は、L字形状の下側型２００と下側型２００と金属板１０の凸状部１０Ａに対応した下部が短い台形の上側型２０１から構成される。上側型２０１は、スプリングなどのプレスをするための部材が接続されている。 An apparatus for realizing the integrally molded component manufacturing method includes an L-shaped lower mold 200, a lower mold 200, and a trapezoidal upper mold 201 having a short lower portion corresponding to the convex portion 10 </ b> A of the metal plate 10. The upper die 201 is connected to a member such as a spring for pressing.
図３における重ね合わせ載置工程（ステップＳＴ１）は、図４のＡに、図３におけるプレス工程（ステップＳＴ２）は、図４のＢに、図３における離間部材除去工程（ステップＳＴ３）は、図４のＤにそれぞれ対応する。 The overlay placement process (step ST1) in FIG. 3 is performed in A of FIG. 4, the press process (step ST2) in FIG. 3 is performed in FIG. 4B, and the separation member removing process (step ST3) in FIG. Each corresponds to D in FIG.
まず、絶縁体からなる離間部材３０を凸状部１０Ａの外側に備えるシート状の金属板１０と炭素繊維強化樹脂シート２０とを装置の下側型２００に載置する。このとき、炭素繊維強化樹脂シート２０を、炭素繊維強化樹脂シート２０の端部２０Ｔが金属板１０の凸状部１０Ａよりも外側になるように重ね、載置する（ステップＳＴ１：図４のＡ）。 First, the sheet-like metal plate 10 and the carbon fiber reinforced resin sheet 20 provided with the separating member 30 made of an insulator on the outside of the convex portion 10A are placed on the lower mold 200 of the apparatus. At this time, the carbon fiber reinforced resin sheet 20 is stacked and placed so that the end 20T of the carbon fiber reinforced resin sheet 20 is outside the convex portion 10A of the metal plate 10 (step ST1: A in FIG. 4). ).
炭素繊維強化樹脂シート２０は金属板１０よりも内側の位置で重ね合わされる。このため、炭素繊維強化樹脂シート２０の面積は金属板１０の面積よりも小さいことが好ましい。 The carbon fiber reinforced resin sheet 20 is overlaid at a position inside the metal plate 10. For this reason, the area of the carbon fiber reinforced resin sheet 20 is preferably smaller than the area of the metal plate 10.
次に、プレス工程によって、下側型２００と金属板１０の凸状部１０Ａに対応した下部が短い台形の上側型２０１が、下側型２００に対して、金属板１０と炭素繊維強化樹脂シート２０とをプレスする（ステップＳＴ２：図４のＢ）。 Next, the lower die 200 and the trapezoidal upper die 201 having a short lower portion corresponding to the convex portion 10A of the metal plate 10 are formed by pressing the metal plate 10 and the carbon fiber reinforced resin sheet with respect to the lower die 200. 20 (step ST2: B in FIG. 4).
このとき、炭素繊維強化樹脂シート２０の端部２０Ｔは離間部材３０に押し付けられる状態となる。また、凸上部１０Aよりも内側の部位は、上側型２０１の形状に沿って、下側型２００に押し付けられるため、金属板１０と炭素繊維強化樹脂シート２０が密着する。 At this time, the end 20T of the carbon fiber reinforced resin sheet 20 is pressed against the separation member 30. Moreover, since the site | part inside 10 A of convex parts is pressed against the lower mold | type 200 along the shape of the upper mold | type 201, the metal plate 10 and the carbon fiber reinforced resin sheet 20 contact | adhere.
このプレスにより、炭素繊維強化樹脂シート２０の端部２０Ｔが金属板１０の表面から離間して一体的に形成される（図４のＣ）。 By this pressing, the end 20T of the carbon fiber reinforced resin sheet 20 is formed integrally with being separated from the surface of the metal plate 10 (C in FIG. 4).
さらに、金属板１０に備えられた離間部材３０を除去する（ステップＳＴ３：図４のＤ）。 Further, the separation member 30 provided on the metal plate 10 is removed (step ST3: D in FIG. 4).
なお、プレス時には、必要に応じて、適宜パッドやベースを加熱することで、加工しやすくすることも可能である。 In addition, at the time of pressing, it is possible to facilitate processing by appropriately heating the pad and base as necessary.
例えば、加熱により重合を起こして高分子の網目構造を形成し、硬化する熱硬化性樹脂を使用した場合、金属板１０と炭素繊維強化樹脂シート２０の重ね合わせを行い、プレス後の一体成型部品１を加熱する。この加熱は、プレス時の上側型２０１を加熱することで行うことも可能である。 For example, when a thermosetting resin that polymerizes by heating to form a polymer network structure and is cured is used, the metal plate 10 and the carbon fiber reinforced resin sheet 20 are overlapped, and the integrally molded part after pressing 1 is heated. This heating can also be performed by heating the upper die 201 during pressing.
また、ガラス転移温度または融点まで加熱することによって軟らかくなる熱可塑性樹脂を使用した場合、金属板１０と炭素繊維強化樹脂シート２０の重ね合わせを行った後のプレス時に、加熱された上側型２０１によって炭素繊維強化樹脂シート２０側からプレスをするようにする。若しくは、下側型２００を加熱しておき、金属板１０を介して炭素繊維強化樹脂シート２０を加熱するようにしてもよい。 Further, when a thermoplastic resin that becomes soft by heating to the glass transition temperature or the melting point is used, the heated upper die 201 is used during the pressing after the metal plate 10 and the carbon fiber reinforced resin sheet 20 are superposed. The pressing is performed from the carbon fiber reinforced resin sheet 20 side. Alternatively, the lower mold 200 may be heated and the carbon fiber reinforced resin sheet 20 may be heated via the metal plate 10.
以上のような工程によって、本実施形態の一体成型部品１が製造される。 The integrally molded component 1 of the present embodiment is manufactured through the above-described steps.
一体成型部品１は、プレス後、不要な金属板１０の一部を切断したり、またさらなる形状加工を経て使用することも可能である。 The integrally molded component 1 can be used after being pressed, by cutting a part of an unnecessary metal plate 10 or through further shape processing.
例えば、車両のボディーや骨格、飛行機や船のボディーや骨格、建材、橋などの補強部材として使用できる。 For example, it can be used as a reinforcing member for vehicle bodies and skeletons, airplane and ship bodies and skeletons, building materials, bridges, and the like.
次に図５により、本発明の第２実施形態に係る一体成型部品製造方法を説明する。図５は、本発明の第２実施形態に係る一体成型部品製造方法を示すフロー図である。フローブロック図は、図３を流用して説明する。図３における重ね合わせ載置工程（ステップＳＴ１）は、図５のＢに、図３におけるプレス工程（ステップＳＴ２）は、図５のＤに、図３における離間部材除去工程（ステップＳＴ３）は、図５のＦにそれぞれ対応する。 Next, referring to FIG. 5, a method for manufacturing an integrally molded part according to the second embodiment of the present invention will be described. FIG. 5 is a flowchart showing an integrally molded part manufacturing method according to the second embodiment of the present invention. The flow block diagram will be described with reference to FIG. The overlay placement process (step ST1) in FIG. 3 is shown in FIG. 5B, the press process (step ST2) in FIG. 3 is in D in FIG. 5, and the spacing member removal process (step ST3) in FIG. Each corresponds to F in FIG.
まず、絶縁体からなる離間部材３１を備える炭素繊維強化樹脂シート２１を用意する（図５のＡ）。離間部材３１は、炭素繊維強化樹脂シート２１の端部２１Ｔに設けられる。 First, a carbon fiber reinforced resin sheet 21 having a separation member 31 made of an insulator is prepared (A in FIG. 5). The spacing member 31 is provided at the end 21 </ b> T of the carbon fiber reinforced resin sheet 21.
シート状の金属板１１と炭素繊維強化樹脂シート２１とを装置の下側型２０２に載置する。このとき、端部２１Ｔに離間部材３１を備えた炭素繊維強化樹脂シート２１を、端部２１Ｔが金属板１１の凸状部１１Ａよりも外側になるように重ね、載置する（ステップＳＴ１：図５のＢ）。 The sheet-like metal plate 11 and the carbon fiber reinforced resin sheet 21 are placed on the lower mold 202 of the apparatus. At this time, the carbon fiber reinforced resin sheet 21 provided with the separation member 31 at the end 21T is stacked and placed so that the end 21T is outside the convex portion 11A of the metal plate 11 (step ST1: FIG. 5 B).
炭素繊維強化樹脂シート２１は金属板１１よりも内側の位置で重ね合わされる。このため、炭素繊維強化樹脂シート２１の面積は金属板１１の面積よりも小さいことが好ましい。 The carbon fiber reinforced resin sheet 21 is overlapped at a position inside the metal plate 11. For this reason, it is preferable that the area of the carbon fiber reinforced resin sheet 21 is smaller than the area of the metal plate 11.
炭素繊維強化樹脂シート２１が熱硬化性である場合、自重によって図５のＣのように、炭素繊維強化樹脂シート２１が撓み、金属板１１の表面と炭素繊維強化樹脂シート２１の表面が密着する。 When the carbon fiber reinforced resin sheet 21 is thermosetting, the carbon fiber reinforced resin sheet 21 bends by its own weight as shown in FIG. 5C, and the surface of the metal plate 11 and the surface of the carbon fiber reinforced resin sheet 21 are in close contact with each other. .
次に、プレス工程によって、下側型２０２と、金属板１１の凸状部１１Ａと離間部材３１の形状に対応した上側型２０３が、下側型２０２に対して、金属板１１と炭素繊維強化樹脂シート２１とをプレスする（ステップＳＴ２：図５のＤ）。 Next, the lower die 202 and the upper die 203 corresponding to the shape of the convex portion 11A of the metal plate 11 and the separation member 31 are reinforced with the metal plate 11 and the carbon fiber by the pressing process. The resin sheet 21 is pressed (step ST2: D in FIG. 5).
このとき、炭素繊維強化樹脂シート２１の端部２１Ｔは離間部材３１に押し付けられる状態となる。このプレスにより、炭素繊維強化樹脂シート２１の端部２１Ｔが金属板１１の表面から離間して一体的に形成される（図５のＥ）。 At this time, the end portion 21 </ b> T of the carbon fiber reinforced resin sheet 21 is pressed against the separation member 31. By this pressing, the end 21T of the carbon fiber reinforced resin sheet 21 is formed integrally with being separated from the surface of the metal plate 11 (E in FIG. 5).
さらに、金属板１１に備えられた離間部材３１を除去する（ステップＳＴ３：図５のＦ）。これにより、本発明の第２実施形態に係る一体成型部品製造方法によって一体成型部品２が形成される。 Further, the separation member 31 provided on the metal plate 11 is removed (step ST3: F in FIG. 5). Thereby, the integrally molded component 2 is formed by the integrally molded component manufacturing method according to the second embodiment of the present invention.
＜実施形態の構成及び効果＞
本実施形態における一体成型部品製造方法は、金属板１０，１１と炭素繊維強化樹脂シート２０，２１との一体成型部品１，２を製造する一体成型部品製造方法であって、凸状部１０Ａ，１１Ａを備える金属板１０，１１と炭素繊維強化樹脂シート２０，２１を、炭素繊維強化樹脂シート２０，２１の端部２０Ｔ，２１Ｔが凸状部１０Ａ，１１Ａよりも外側になるように重ねる工程（ステップＳＴ１：図４のＡ、図５のＢ）と、凸状部１０Ａに対応した型でプレスするプレス工程（ステップＳＴ２：図４のＢ、図５のＤ）とを備える。
<Configuration and Effect of Embodiment>
The integrally molded component manufacturing method in this embodiment is an integrally molded component manufacturing method for manufacturing the integrally molded components 1 and 2 of the metal plates 10 and 11 and the carbon fiber reinforced resin sheets 20 and 21, A step of stacking the metal plates 10 and 11 having 11A and the carbon fiber reinforced resin sheets 20 and 21 so that the end portions 20T and 21T of the carbon fiber reinforced resin sheets 20 and 21 are outside the convex portions 10A and 11A ( Step ST1: A of FIG. 4 and B of FIG. 5) and the press process (step ST2: B of FIG. 4, B of FIG. 5) which presses with the type | mold corresponding to the convex-shaped part 10A.
上記のように構成したことで、プレスと同時に、炭素繊維強化樹脂シート２０，２１の端部２０Ｔ，２１Ｔと金属板１０，１１の表面とを離間させることができる。 By having comprised as mentioned above, the edge parts 20T and 21T of the carbon fiber reinforced resin sheets 20 and 21 and the surface of the metal plates 10 and 11 can be spaced apart simultaneously with pressing.
本実施形態における一体成型部品製造方法は、凸状部１０Ａ，１１Ａの外側に離間部材３０，３１を設ける工程を備える。 The integrally molded component manufacturing method according to the present embodiment includes a step of providing the separation members 30 and 31 outside the convex portions 10A and 11A.
本実施形態における一体成型部品製造方法は、離間部材３０を金属板１０側に設ける。 In the integrally molded component manufacturing method in the present embodiment, the separation member 30 is provided on the metal plate 10 side.
本実施形態における一体成型部品製造方法は、離間部材３１を炭素繊維強化樹脂シート２１側に設ける。 In the integrally molded component manufacturing method in the present embodiment, the separation member 31 is provided on the carbon fiber reinforced resin sheet 21 side.
本実施形態における一体成型部品製造方法は、離間部材３０，３１が絶縁体である。 In the integrally molded component manufacturing method in this embodiment, the separation members 30 and 31 are insulators.
上記のように構成したことで、プレスと同時に、炭素繊維強化樹脂シート２０，２１の端部２０Ｔ，２１Ｔと金属板１０，１１の表面とを完全に離間させることができる。 By comprising as mentioned above, the edge parts 20T and 21T of the carbon fiber reinforced resin sheets 20 and 21 and the surface of the metal plates 10 and 11 can be completely separated simultaneously with pressing.
本実施形態における一体成型部品製造方法は、離間部材３０，３１をプレス工程後に取り除く離間部材除去工程（ステップＳＴ３：図４のＤ、図５のＦ）を備える。 The integrally molded component manufacturing method according to the present embodiment includes a separation member removing step (step ST3: D in FIG. 4 and F in FIG. 5) for removing the separation members 30 and 31 after the pressing step.
本実施形態における一体成型部品１，２は、金属板１０，１１と炭素繊維強化樹脂シート２０，２１との一体成型部品であって、炭素繊維強化樹脂シート２０，２１の端部２０Ｔ，２１Ｔと金属板１０，１１の表面とを離間して一体的に成形する。 The integrally molded parts 1 and 2 in the present embodiment are integrally molded parts of the metal plates 10 and 11 and the carbon fiber reinforced resin sheets 20 and 21, and the end portions 20 T and 21 T of the carbon fiber reinforced resin sheets 20 and 21. The surfaces of the metal plates 10 and 11 are separated and integrally formed.
本実施形態における一体成型部品１，２は、金属板１０，１１が、炭素繊維強化樹脂シート２０，２１が重ねられる位置における炭素繊維強化樹脂シート２０，２１の端部２０Ｔ，２１Ｔより内側の部位であって、かつ炭素繊維強化樹脂シート２０，２１側へ向かって凸状部１０Ａ，１１Ａを備えている。 In the integrally molded parts 1 and 2 in the present embodiment, the metal plates 10 and 11 are located inside the end portions 20T and 21T of the carbon fiber reinforced resin sheets 20 and 21 at the position where the carbon fiber reinforced resin sheets 20 and 21 are stacked. Moreover, convex portions 10A and 11A are provided toward the carbon fiber reinforced resin sheets 20 and 21 side.
上記のように構成したことで、炭素繊維強化樹脂シート２０，２１の端部２０Ｔ，２１Ｔが金属板１０，１１の表面に密着することを防止でき、金属板１０，１１のサビを防止することができる。 By having comprised as mentioned above, it can prevent that edge part 20T, 21T of the carbon fiber reinforced resin sheets 20 and 21 adheres to the surface of the metal plates 10 and 11, and prevents rust of the metal plates 10 and 11. Can do.
＜定義等＞
本発明の金属板とは、鋼板やアルミニウム系金属などの板をいう。
<Definition etc.>
The metal plate of this invention means plates, such as a steel plate and an aluminum-type metal.
また、本発明で、炭素繊維強化樹脂は、熱可塑性または熱硬化性の炭素繊維強化樹脂をいう。 Further, in the present invention, the carbon fiber reinforced resin refers to a thermoplastic or thermosetting carbon fiber reinforced resin.
１ 一体成型部品
１０，１１ 金属板
２０，２１ 炭素繊維強化樹脂シート
３０，３１ 離間部材
２０Ｔ 炭素繊維強化樹脂シートの端部
２００，２０２ 下側型
２０１，２０３ 上側型
DESCRIPTION OF SYMBOLS 1 Integrally molded parts 10, 11 Metal plates 20, 21 Carbon fiber reinforced resin sheet 30, 31 Separation member 20T End portions 200, 202 of carbon fiber reinforced resin sheet Lower mold 201, 203 Upper mold
Claims (8)
凸状部を備える前記金属板と、前記炭素繊維強化樹脂シートを、前記炭素繊維強化樹脂シートの端部近傍が前記凸状部を覆うように重ねる工程と、
前記凸状部に対応した型で、前記炭素繊維強化樹脂シートの端部と前記金属板の表面とが離間するようにプレスするプレス工程と、を備える
一体成型部品製造方法。 An integrally molded part manufacturing method for manufacturing an integrally molded part of a metal plate and a carbon fiber reinforced resin sheet,
The step of stacking the metal plate provided with a convex part and the carbon fiber reinforced resin sheet so that the vicinity of the end of the carbon fiber reinforced resin sheet covers the convex part,
A method of manufacturing an integrally molded part, comprising: a pressing step of pressing an end portion of the carbon fiber reinforced resin sheet and a surface of the metal plate with a mold corresponding to the convex portion.
請求項１に記載の一体成型部品製造方法。 The method for manufacturing an integrally molded part according to claim 1, further comprising a step of providing a spacing member between an end portion of the carbon fiber reinforced resin sheet and a surface of the metal plate .
請求項２に記載の一体成型部品製造方法。 The integrally molded component manufacturing method according to claim 2, wherein the spacing member is provided on the metal plate side.
請求項２に記載の一体成型部品製造方法。 The integrally molded component manufacturing method according to claim 2, wherein the spacing member is provided on the carbon fiber reinforced resin sheet side.
請求項２〜４のいずれか１項に記載の一体成型部品製造方法。 The integrally molded component manufacturing method according to claim 2, wherein the spacing member is an insulator.
請求項２〜５のいずれか１項に記載の一体成型部品製造方法。 The method for manufacturing an integrally molded part according to any one of claims 2 to 5, further comprising a separation member removing step of removing the separation member after the pressing step.
前記炭素繊維強化樹脂シートの端部と金属板の表面とを離間して一体的に成形する
一体成型部品。 An integrally molded part of a metal plate and a carbon fiber reinforced resin sheet,
An integrally molded component that integrally molds the end portion of the carbon fiber reinforced resin sheet and the surface of the metal plate separately from each other.
前記炭素繊維強化樹脂シートが重ねられる位置における前記炭素繊維強化樹脂シートの端部より内側の部位であって、
かつ前記炭素繊維強化樹脂シート側へ向かって凸状部を備えている
請求項７記載の一体成型部品。 The metal plate is
It is a site inside the end of the carbon fiber reinforced resin sheet at the position where the carbon fiber reinforced resin sheet is overlaid,
The integrally molded component according to claim 7, further comprising a convex portion toward the carbon fiber reinforced resin sheet.
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