JP6045432B2 - Method for bonding fiber reinforced resin laminate and fiber reinforced resin molded body - Google Patents

Description

  Conventionally, fiber reinforced materials are used in addition to aluminum and the like as lightweight and high-strength structural members. The fiber reinforced material is a composite material reinforced with fibers, and fiber reinforced rubber (FRR), fiber reinforced metal (FRM), fiber reinforced ceramics (FRC), fiber reinforced plastic (FRP), and the like are known. Of these, FRP most frequently used as a fiber reinforced material uses plastic as a matrix (base), and uses fibers such as carbon and glass as a reinforcing material. FRP is a lightweight, high-strength, high-modulus material and is indispensable in the automotive field, aviation field, space field, and the like.

An example of the manufacturing method of the fiber reinforced resin laminated body which is 1 type of FRP is demonstrated with reference to FIG.
First, a thin film of base resin 11 (matrix resin) made of nylon or the like is heated to give flexibility (FIG. 4A). Next, the reinforcing fibers 12 are spread on the thin film of the base resin 11 before the heated base resin 11 is lowered and cured (FIG. 4B). Subsequently, a thin film of the base resin 11 on which the reinforcing fibers 12 are dispersed is laminated to form a laminated body (FIG. 4C). Finally, the fiber reinforced resin laminate 1 is manufactured by pressing and cooling the laminate (FIG. 4D).

  By the way, when FRP is used as a member of a large structure such as an automobile or an aircraft, a large size FRP may be required. In such a case, the FRP having a desired size can be manufactured by joining a plurality of FRPs manufactured by the above method. As a method for joining FRPs, a technique for joining FRPs using resistance welding is known (for example, see Patent Document 1). When the FRPs are resistance-welded, they are joined by solidifying after the resin at the joint of the FRP is melted.

JP 2012-16867 A

  However, for example, when a fiber reinforced resin material is obtained by welding the ends of the fiber reinforced resin laminate 1 manufactured by the method shown in FIG. Has almost no reinforcing fiber 12. Of the fiber reinforced resin material, a portion where almost no reinforcing fiber is present may be destroyed when stress is applied to the joint portion.

  More specifically, as shown in FIG. 5, the joining portion 71 of the pair of joined fiber reinforced resin laminates (fiber reinforced resin material 7) is composed only of resin (FIG. 5A). In such a fiber reinforced resin material 7, as shown in FIG.5 (b), the part comprised only by resin containing the reinforced fiber 12, and the part comprised only by resin (joining part 71) Breakage at the interface (interfacial breakage) and breakage (cohesive breakage) at the portion (joint portion 71) composed only of the resin as shown in FIG.

  This invention is made | formed in view of said problem, and it aims at providing the joining method of the fiber reinforced resin laminated body which can obtain the fiber reinforced resin material with the high intensity | strength of a junction part.

  In order to achieve the above object, the present invention provides a fiber reinforced resin laminate (for example, a laminate of a thermoplastic resin (for example, a base resin 11 to be described later) with a reinforcing fiber (for example, a reinforcing fiber 12 to be described later) interposed therebetween. A fiber-reinforced resin laminate joining method that joins fiber-reinforced resin laminates 1 described later, and an end portion (for example, an end portion described later) in a direction orthogonal to the stacking direction of the plurality of fiber-reinforced resin laminates 13) by heating, at least a part of the layers are separated from each other at the end, and the ends of the plurality of fiber reinforced resin laminates heated by the heating step are brought into contact with each other. And a bonding step of bonding with the other end layer interposed between the layers of the one end portion, and a method for bonding the fiber reinforced resin laminate.

In the present invention, in a method of bonding fiber reinforced resin laminates formed by laminating thermoplastic resins with intervening reinforcing fibers, by heating an end portion in a direction orthogonal to the lamination direction of the fiber reinforced resin laminates. Then, at least some of the layers are separated from each other at the end portion. Moreover, the layer of the other edge part is interposed between the layers of one edge part by contact | abutting the edge parts which some layers separated.
According to the present invention, since the resin layers at least part of the end portions in the direction orthogonal to the lamination direction of the fiber reinforced resin laminate are separated from each other, the reinforcing fibers are exposed between the separated resin layers. . In the present invention, since the fiber reinforced resin laminates are joined so that the resin layer at the other end is interposed between the resin layers at one end, the fiber reinforced resin laminates are reinforced at the joining portion. The fibers come into contact. Thereby, a reinforced fiber will exist also in the junction part of a fiber reinforced resin laminated body, and the intensity | strength of the junction part of a fiber reinforced resin laminated body will improve.

  It is preferable to use a preformed fiber reinforced resin laminate as the fiber reinforced resin laminate.

In this invention, the fiber reinforced resin laminated bodies shape | molded previously are joined.
According to the present invention, the shape of the fiber reinforced resin laminate to be joined is not limited because only the end portion in the direction orthogonal to the lamination direction of the fiber reinforced resin laminate is heated and molded. Therefore, it is possible to join the preformed fiber reinforced resin laminates, and even if the preformed fiber reinforced resin laminates are joined together, the strength of the joint portion can be sufficiently improved.

  Further, a fiber reinforced resin laminate (for example, a fiber reinforced resin laminate 1 described later) formed by laminating a thermoplastic resin (for example, a base resin 11 described below) with a reinforcing fiber (for example, a reinforcing fiber 12 described later) interposed therebetween. ) A fiber reinforced resin molded body (for example, a fiber reinforced resin molded body 3 to be described later) formed into a tubular shape by welding each other, and formed by welding the fiber reinforced resin laminates. A part (for example, welding part 15) provides the fiber reinforced resin molding characterized by including the said reinforced fiber.

In the present invention, in a fiber reinforced resin molded body formed into a tubular shape by welding fiber reinforced resin laminates formed by laminating thermoplastic resins with reinforcing fibers interposed therebetween, the welded portion includes reinforcing fibers. Composed.
According to the present invention, there is provided a fiber-reinforced resin molded body that is formed into a tubular shape and that has sufficiently improved the strength of a bonded portion in which fiber-reinforced resin laminates are bonded together. it can.
Moreover, the fiber reinforced resin molded object which concerns on this invention can be easily obtained by joining the fiber reinforced resin laminated bodies shape | molded previously by the joining method of the above-mentioned fiber reinforced resin laminated body.

  ADVANTAGE OF THE INVENTION According to this invention, the joining method of the fiber reinforced resin laminated body which can obtain the fiber reinforced resin material with the high intensity | strength of a junction part can be provided.

It is the schematic shown about the joining method of the fiber reinforced resin laminated body which concerns on one Embodiment of this invention. It is the schematic shown about the manufacturing method of the fiber reinforced resin molding which concerns on one Embodiment of this invention. It is the schematic shown about the manufacturing method of the fiber reinforced resin molding which concerns on one Embodiment of this invention. It is a figure which shows an example of the manufacturing method of a fiber reinforced resin laminated body. It is an expanded sectional view of the joined part of the fiber reinforced resin laminated bodies joined by the joining method of the conventional fiber reinforced resin laminated body, (a) is a figure which shows the state by which the fiber reinforced resin laminated body was joined. (B) And (c) is a figure which shows an example of the state by which the junction part of fiber reinforced resin laminated bodies was destroyed.

  Embodiments of the present invention will be described in detail with reference to the drawings.

<Joint method of fiber reinforced resin laminate>
FIG. 1 is a view showing a method for joining fiber reinforced resin laminates according to an embodiment of the present invention.
The joining method of the fiber reinforced resin laminated body which concerns on this embodiment has a heating process and a joining process.

  In the heating step, as shown in FIGS. 1A and 1B, at least a part of the end portion 13 is heated by heating the end portion 13 in the direction orthogonal to the stacking direction of the plurality of fiber reinforced resin laminates 1. The base resin layers 11 are separated from each other.

The fiber reinforced resin laminate 1 used in the present embodiment is manufactured by the above-described method shown in FIG. The fiber reinforced resin laminate 1 is a laminate obtained by laminating a base resin 11 with reinforcing fibers 12 interposed. The base resin 11 is made of a thermoplastic resin such as nylon. Examples of the reinforcing fiber 12 include a curved short fiber of glass fiber or carbon fiber. The reinforcing fibers 12 are mainly present between the base resins 11, but a part of the reinforcing fibers 12 are present inside the base resin 11 because the base resin 11 is heated and softened when the fiber reinforced resin laminate 1 is manufactured.
In addition, the base resin 11 in the fiber reinforced resin laminate 1 may be referred to as a base resin layer 11.

  In the heating step, the base resin 11 is made flexible by heating the end 13 in the direction orthogonal to the stacking direction of the fiber reinforced resin laminate 1, and the end 13 of the fiber reinforced resin laminate 1 is expanded in the stacking direction. The base resin layer 11 is softened by heating the fiber reinforced resin laminate 1, and the base resin layers 11 are separated from each other at the end portion 13 by a force that releases the internal stress of the reinforcing fiber 12 that is a curved short fiber. (FIG. 1 (b)). When the base resin layers 11 are separated from each other at the end portion 13, the reinforcing fibers 12 are exposed on the surface of the base resin layer 11 in the stacking direction.

  The method for heating the end portion 13 of the fiber reinforced resin laminate 1 is not particularly limited. As a method of heating the fiber reinforced resin laminate 1, a method using a far infrared heater, a method of heating by a laser, a method of energizing the end 13 to generate heat, a method of bringing a high temperature substance into contact with the end 13, etc. Is mentioned.

  In the joining step, the end portions 13 of the plurality of fiber reinforced resin laminates 1 heated in the heating step are brought into contact with each other, so that the base resin of the other end portion 13 is interposed between the base resin layers 11 of the one end portion 13. Bonding is performed with the layer 11 interposed.

  As described above, since the base resin layers 11 at the end portions 13 are separated from each other in the heating step, the base resin at one end portion 13 is brought into contact with the end portions 13 of the pair of fiber reinforced resin laminates 1. The base resin layer 11 at the other end 13 can be interposed between the layers 11 (FIG. 1C). If the base resin layer 11 of the other end 13 is interposed between the base resin layers 11 of one end 13 of the pair of fiber reinforced resin laminates 1, the base resin layer 11 is exposed on the surface in the stacking direction. The reinforced fibers 12 can be brought into contact with each other. When the reinforcing fibers 12 exposed on the surface of the base resin layer 11 in the stacking direction are in contact with each other and entangled with each other, the strength of the joint portion 14 where the end portions 13 of the fiber reinforced resin laminate 1 are joined is improved.

In the joining step, the fiber-reinforced resin material is formed by welding the end portions 13 of the fiber-reinforced resin laminate 1 to each other.
In the joining process, the joining portions 14 of the fiber reinforced resin laminates 1 are pressed from above and below in the laminating direction using rollers and molds while the temperature is high, so that the end portions 13 of the fiber reinforced resin laminate 1 are joined together. Weld.

  After the fiber reinforced resin laminates 1 are welded together to form a fiber reinforced resin material, the fiber reinforced resin material may be subjected to press molding or the like to be molded into a desired shape.

<Method for producing fiber-reinforced resin molded article>
2 and 3 are diagrams showing a method for manufacturing a fiber-reinforced resin molded body according to an embodiment of the present invention, and a bonding apparatus for performing the method for bonding fiber-reinforced resin laminates according to the embodiment. It is a figure shown about operation | movement. 2 and 3 are schematic cross-sectional views of the fiber reinforced resin laminate 1 and the joining device 100 thereof.

The manufacturing method of a fiber reinforced resin molding is demonstrated.
The fiber reinforced resin molded body is manufactured using the bonding apparatus 100. The joining apparatus 100 includes a robot 21, a heater 22, and a roller 23 (FIGS. 2 and 3).

The robot 21 has a drive mechanism (not shown), and holds the preformed fiber reinforced resin laminate 1 and moves the fiber reinforced resin laminate 1.
The heater 22 is disposed in the vicinity of the end portion 13 of the fiber reinforced resin laminate 1 held by the robot 21.
The rollers 23 are arranged above and below a joint portion 14 formed by bringing the end portions 13 of the fiber reinforced resin laminate 1 into contact with each other. The roller 23 has a drive mechanism (not shown) and is movable in a direction orthogonal to the stacking direction while pressing the fiber reinforced resin laminate 1 from above and below in the stacking direction.

  In the method for manufacturing a fiber-reinforced resin molded body, first, the fiber-reinforced resin laminate 1 molded in advance is gripped by the robot 21 (FIG. 2A). Here, the pair of fiber reinforced resin laminates 1 formed in advance are respectively held by the two robots 21. Since one end part in the direction orthogonal to the lamination direction of the pair of fiber reinforced resin laminates 1 and the other end part are finally joined, they are arranged in the vicinity of each other.

The method for previously molding the fiber reinforced resin laminate 1 is not particularly limited. Examples of the method for previously molding the fiber reinforced resin laminate 1 include pressure molding and bending molding.
The pre-molded fiber reinforced resin laminate 1 may be held by a jig instead of a robot.

  Then, the edge part 13 of the direction orthogonal to the lamination direction of the fiber reinforced resin laminated body 1 is heated with the heater 22 (FIG.2 (b)). By heating the end 13, the base resin layers 11 are separated from each other as described above.

  Subsequently, the robot 21 is driven to bring the end portions 13 of the pair of heated fiber reinforced resin laminates 1 into contact with each other, whereby the other end portion 13 is interposed between the base resin layers 11 of the one end portion 13. The joining portion 14 is formed with the base resin layer 11 interposed (FIG. 2C). As described above, by interposing the base resin layer 11 of the other end portion 13 between the base resin layers 11 of the one end portion 13, the reinforcing fibers 12 exposed on the surface in the stacking direction of the base resin layer 11 are bonded together. Can be contacted.

  Subsequently, the pair of rollers 23 is arranged above and below the joint 14 formed by bringing the end portions 13 of the fiber reinforced resin laminate 1 into contact with each other, and pressurizes the joint 14 (FIG. 3A). The roller 23 is moved in the direction orthogonal to the stacking direction of the fiber reinforced resin laminate 1 while pressing the joint 14 from above and below, so that the thickness of the joint 14 is made uniform, and the base in the joint 14 is obtained. The welded portion 15 is formed by welding the resin 11 (FIGS. 3A and 3B).

  The method of pressurizing the joining portion 14 from above and below in the stacking direction is not limited to a roller, and for example, a method of pressing the joining portion 14 with a mold can also be used.

  By the manufacturing method as described above, a fiber-reinforced resin molded body 3 formed into a tubular shape is obtained (FIG. 3B).

<Fiber-reinforced resin molding>
The fiber-reinforced resin molded body 3 according to the embodiment of the present invention is manufactured using the above-described method for manufacturing a fiber-reinforced resin laminated molded body (FIG. 3B).
The fiber-reinforced resin molded body 3 according to the embodiment of the present invention is formed into a tubular shape by welding the fiber-reinforced resin laminates 1 formed by laminating the base resin 11 with the reinforcing fibers 12 interposed therebetween. The welded portion 15 formed by welding the reinforced resin laminates 1 to each other includes the reinforcing fibers 12.

According to the above embodiment, the following effects are produced.
In the method for bonding fiber reinforced resin laminates according to the present embodiment, in the method of bonding fiber reinforced resin laminates 1 formed by laminating base resin 11 with reinforcing fibers 12 interposed therebetween, By heating the end portion 13 in the direction orthogonal to the stacking direction, at least some of the base resin layers 11 were separated from each other at the end portion 13. Moreover, the base resin layer 11 of the other end part was interposed between the base resin layers 11 of the one end part 13 by bringing the end parts 13 apart of some base resin layers 11 into contact with each other.
According to this embodiment, since at least a part of the base resin layers 11 of the end portion 13 in the direction orthogonal to the stacking direction of the fiber reinforced resin laminate 1 are separated from each other, In the meantime, the reinforcing fiber 12 is exposed. Moreover, in this embodiment, since the fiber reinforced resin laminated bodies 1 are joined so that the base resin layer 11 of the other end 13 is interposed between the base resin layers 11 of the one end 13, the fiber reinforced resin The reinforcing fibers 12 are in contact with each other at the portion where the laminates 1 are joined. Thereby, the reinforced fiber 12 exists also in the junction part of the fiber reinforced resin laminated body 1, and the intensity | strength of the junction part of the fiber reinforced resin laminated body 1 improves.

Moreover, in this embodiment, the fiber reinforced resin laminated bodies 1 shape | molded previously were joined.
According to this embodiment, since the end part 13 in the direction orthogonal to the lamination direction of the fiber reinforced resin laminate 1 is only heated and molded, the shape of the fiber reinforced resin laminate to be joined is not limited. Therefore, it is possible to join the preformed fiber reinforced resin laminates 1 to each other, and even if the preformed fiber reinforced resin laminates 1 are joined together, the strength of the joint portion can be sufficiently improved.

Moreover, in the fiber reinforced resin molding which concerns on this embodiment, the fiber reinforced resin molding shape | molded by the tubular shape by welding the fiber reinforced resin laminated bodies 1 formed by laminating the base resin 11 with the reinforcing fibers 12 interposed therebetween. In the body 3, the welded portion 15 includes the reinforcing fiber 12.
According to this embodiment, the fiber-reinforced resin molded body 3 is formed into a tubular shape, and the fiber-reinforced resin molded body 3 in which the strength of the joint portion where the fiber-reinforced resin laminates 1 are joined to each other is sufficiently improved. Can be provided.
Moreover, the fiber reinforced resin molding 3 which concerns on this embodiment is easy by joining the fiber reinforced resin laminated bodies 1 shape | molded previously by the joining method of the fiber reinforced resin laminated body which concerns on this embodiment mentioned above. Can get to.

  The present invention is not limited to the above-described embodiment, and modifications, improvements, and the like within the scope that can achieve the object of the present invention are included in the present invention.

DESCRIPTION OF SYMBOLS 1 ... Fiber reinforced resin laminated body 3 ... Fiber reinforced resin molding 11 ... Base resin (layer)
12 ... Reinforcing fiber 13 ... End 15 ... Welded part

Claims (3)

A fiber reinforced resin laminate joining method for joining fiber reinforced resin laminates formed by laminating thermoplastic resins with reinforcing fibers interposed therebetween,
A heating step of separating at least some of the layers at the end by heating the end in the direction orthogonal to the stacking direction of the plurality of fiber reinforced resin laminates;
A joining step of joining the end portions of the plurality of fiber reinforced resin laminates heated by the heating step together by interposing the layer of the other end portion between the layers of the one end portion; and A method for joining fiber reinforced resin laminates, comprising:   The fiber-reinforced resin laminate according to claim 1, wherein a preformed fiber-reinforced resin laminate is used as the fiber-reinforced resin laminate. A fiber-reinforced resin molded body formed into a tubular shape by welding ends of one fiber-reinforced resin laminate formed by laminating a thermoplastic resin with reinforcing fibers interposed therebetween and the other fiber-reinforced resin laminate. Because
The welded portion formed by welding the ends of one of the fiber reinforced resin laminates and the other of the fiber reinforced resin laminates is an interlayer between the ends of each other from the stacked tips. A fiber-reinforced resin molded article having a shape in which the reinforcing fibers are interlaced and fitted, and the reinforcing fibers are included in a form in which a layer of the other end is interposed between layers of one end of the reinforcing fibers.

Images