JP6057330B2 - 複合材及び複合材の製造方法 - Google Patents
複合材及び複合材の製造方法 Download PDFInfo
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- JP6057330B2 JP6057330B2 JP2013006480A JP2013006480A JP6057330B2 JP 6057330 B2 JP6057330 B2 JP 6057330B2 JP 2013006480 A JP2013006480 A JP 2013006480A JP 2013006480 A JP2013006480 A JP 2013006480A JP 6057330 B2 JP6057330 B2 JP 6057330B2
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- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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Description
第1実施形態の複合材は、後述するSBサイドフレーム10として用いられている。
SCパネル114は、シート幅方向に延びて両端部が一対のSCサイドフレーム112のシート上方側の折り曲げ部分にそれぞれ固定されている。
アッパーパネル124は、シート幅方向に延びて両端部が一対のSBサイドフレーム10のシート後方側の折り曲げ部分にそれぞれ固定されている。
図1には、SBサイドフレーム10の断面(板厚方向と直交する方向の断面)が示されている。SBサイドフレーム10は、金属製のサイドフレーム基板20と、繊維強化樹脂(FRP)製のサイドフレーム補強板30と、サイドフレーム基板20とサイドフレーム補強板30とを貼り合せる接着層40と、を有している。なお、本実施形態のサイドフレーム基板20は金属板の一例であり、本実施形態のサイドフレーム補強板30は繊維強化樹脂板の一例であり、本実施形態の接着層40は接着層の一例である。
まず、図3に示すように、金属板(本実施形態では、高張力鋼板)を製品形状に曲げ加工してサイドフレーム基板20を形成する。次に、未硬化の接着剤を含浸させた不織布42(厚みがほぼ均一の不織布)によって構成されたフィルム状の接着層40をサイドフレーム基板20の外周面20A全体に配置する。
なお、接着層40を配置する前に、サイドフレーム基板20を脱脂処理してもよい。また、接着層40の外周面20A全体を粗面化処理(例えば、プラズマ処理など)してもよい。上記処理などを行うことで、サイドフレーム基板20と接着層40との接着力を高めることができる。
なお、サイドフレーム補強板30は、製品形状に曲げ加工済みのフィルム状のプリプレグ素材(マトリックス樹脂に炭素繊維を混在させたもの)を複数枚重ねて形成される。
ここで、サイドフレーム基板20とサイドフレーム補強板30の間に不織布42を挟んだ状態でプレス成形が行われることから、接着層40がプレスされてもサイドフレーム基板20とサイドフレーム補強板30を貼り合わせる接着層40の厚み(層厚)を十分に確保することができる。特に、不織布42は、サイドフレーム基板20の外周面20A全体に配置されるため、接着層40の厚みをほぼ均一に確保することができる。
また、プレス成形を行う前にサイドフレーム基板20とサイドフレーム補強板30を製品形状に曲げ加工していることから、例えば、サイドフレーム基板20またはサイドフレーム補強板30を曲げ加工しながらプレス成形する製造方法ものと比較して、接着層40(不織布42)の厚みが片寄るのを防止することができる。
なお、プレス成形時には、下型50の代わりに上型60をあらかじめ加熱(予熱)しておいてもよく、下型50及び上型60の両方をあらかじめ加熱しておいてもよい。
SBサイドフレーム10では、サイドフレーム基板20とサイドフレーム補強板30の間に不織布42を挟んでいることから、サイドフレーム基板20とサイドフレーム補強板30のプレス成形時に接着層40がプレスされても、接着層40の厚み(層厚)を十分に確保することができる。すなわち、サイドフレーム基板20とサイドフレーム補強板30の間に挟まれる不織布42の厚みに応じて接着層40の厚みを規定することができる。
ここで、接着層40の厚みを増すと、SBサイドフレーム10に例えば、シート後方側のモーメントが作用してサイドフレーム基板20とサイドフレーム補強板30とが板厚方向と直交する方向にずれて接着層40にせん断力F(図2参照)が作用した場合に、接着層40が許容できる最大許容せん断歪(図2では、せん断歪をLで示している。)を増やすことができる。
すなわち、本実施形態では、接着層40の厚みを規定することで、最大許容せん断歪を調整することができるため、最大せん断強度を適切なものに設定することができる。このように最大せん断強度を適切なものに設定することで、サイドフレーム基板20とサイドフレーム補強板30の分離を防ぐことができ、後方モーメントが作用した際の破壊靭性を高めることができる。
なお、プレス成形機に減圧機能を持たせてプレス成形と同時に減圧を行ってもよい、
次に、本発明の複合材の効果を確かめるために、本発明の複合材を用いたSBサイドフレームを有するシートバックフレームを2種、本発明の複合材を用いていないSBサイドフレームを有するシートバックフレームを4種用意し、各シートバックフレームにシート後方のモーメントを作用させたときのSBサイドフレームの最大荷重(破壊(剥離)荷重)及び最大変位(破断までの許容変形量(最大許容せん断歪量))を測定し、表1に示した。また、SBサイドフレームの設計上の最大荷重をSPEC、設計上の最大変位をSPEC変位として表1に示した。なお、SBサイドフレームの最大変位は、左右一対のSBサイドフレームのそれぞれの最大変位(RH変位、LH変位)の平均値である。また、図10では、実施例1、比較例1、2の各SBサイドフレームの荷重と変位量の関係をグラフとして示した。
比較例2〜4、実施例1、2の各SBサイドフレームは、サイドフレーム基板とサイドフレーム補強板を未硬化の接着層で貼り合せ、真空引きを行った後、プレス成形を行いつつ接着層を硬化させてサイドフレーム基板にサイドフレーム補強板を貼り合せる「改良工程」で成形されている。
また、実施例1では、サイドフレーム基板にプラズマ処理を施していることから、実施例2よりも接着層とサイドフレーム基板の接着力が向上しているため、最大荷重及び最大変位が向上している。
20 サイドフレーム基板(金属板)
20A 外周面(貼り合せ面)
30 サイドフレーム補強板(繊維強化樹脂板)
30A 内周面(貼り合せ面)
40 接着層
42 不織布(層厚規制部材)
Claims (6)
- 車両用シートのフレームに用いられ、高張力鋼板である金属板と繊維強化樹脂板を接着層で貼り合せた複合材であって、
前記金属板と前記繊維強化樹脂板に挟まれ、前記接着層の層厚を規定する層厚規定部材を有し、
前記接着層が前記金属板と前記繊維強化樹脂板との間に全体に亘って配置されており、
前記金属板は、板部と、該板部の幅方向両端部を折り曲げて形成された一対の対向部とを備え、
前記繊維強化樹脂板は、板部と、該板部の幅方向両端部を折り曲げて形成された一対の対向部とを備え、
前記繊維強化樹脂板の一対の対向部間に、前記金属板の一対の対向部が配置され、
前記層厚規定部材は、前記金属板の板部と前記繊維強化樹脂板の板部との間、及び、前記金属板の一対の対向部と前記繊維強化樹脂板の一対の対向部との間の前記接着層の層厚をそれぞれ規定する、複合材。 - 前記層厚規定部材は絶縁性を有する請求項1に記載の複合材。
- 前記層厚規定部材は不織布または織物である請求項1または請求項2に記載の複合材。
- 車両用シートのフレームに用いられ、高張力鋼板である金属板と繊維強化樹脂板を接着層で貼り合せて形成される複合材の製造方法であって、
金属板と繊維強化樹脂板の貼り合せ面に接着層を構成する接着剤と前記接着層の層厚を規定する層厚規定部材とを配置する工程と、
前記金属板と前記繊維強化樹脂板をプレス成形して、前記金属板と前記繊維強化樹脂板を貼り合せる工程と、
を有し、
前記接着層が前記金属板と前記繊維強化樹脂板との間に全体に亘って配置され、
前記金属板は、板部と、該板部の幅方向両端部を折り曲げて形成された一対の対向部とを備え、
前記繊維強化樹脂板は、板部と、該板部の幅方向両端部を折り曲げて形成された一対の対向部とを備え、
前記繊維強化樹脂板の一対の対向部間に、前記金属板の一対の対向部が配置され、
前記層厚規定部材は、前記金属板の板部と前記繊維強化樹脂板の板部との間、及び、前記金属板の一対の対向部と前記繊維強化樹脂板の一対の対向部との間の前記接着層の層厚をそれぞれ規定する、複合材の製造方法。 - プレス成形する前に前記接着層を真空引きする工程を有する請求項4に記載の複合材の製造方法。
- 前記金属板と前記繊維強化樹脂板を製品形状に曲げ加工した後で、前記金属板と前記繊維強化樹脂板の貼り合せ面に前記接着剤と前記層厚規定部材を配置する請求項4または請求項5に記載の複合材の製造方法。
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