JP6251070B2 - Manufacturing method of shaft-shaped composite member - Google Patents

Description

The present invention relates to a method of manufacturing a shaft-like composite member.

  In recent years, automobiles have been demanded to reduce the weight and strength of various members in order to improve fuel efficiency. For example, fiber reinforced resins such as carbon materials are used. For example, Patent Document 1 discloses a technical idea of using a rolling table and winding a carbon fiber reinforced layer (fiber reinforced layer) around the outer surface of a carbon fiber reinforced aluminum pipe (metal shaft-like member). Is disclosed.

Japanese Patent Laid-Open No. 3-166937

  By the way, when a fiber reinforced resin material is used for a shaft-shaped composite member having a shape with high curvature (bending portion), such as a shaft-shaped composite member used for a frame structure of an automobile, for example, It is difficult to secure the rigidity of the frame structure by wrapping the fiber reinforced resin material around the frame. For example, when the core metal is bent and deformed after the carbon fiber reinforced layer disclosed in Patent Document 1 is wound around a straight core metal, the core metal is wound around the outside of the bent section when the curvature of the bent section becomes high. There is a possibility that the carbon fiber reinforced layer may stretch and break.

The present invention has been made in view of the above points, a method for producing a desired capable of ensuring strength and rigidity shaft-like composite member inner periphery difference absorbs bent portion of the bent portion The purpose is to provide.

In order to achieve the above object, the present invention provides a method for producing a shaft-shaped composite member having a bent portion, wherein a fiber reinforced resin material made of a unidirectional reinforcing material is bonded to the outer surface of the bent portion. After a plurality of pieces are attached in parallel along the axial direction, a restraining material that restricts the movement of the fiber-reinforced resin material to the outside in the radial direction of the core metal is wound . Furthermore, after the fiber reinforced resin material is heated and solidified in a state where the fiber reinforced resin material is constrained by the constraining material, the constraining material is peeled off .

  According to the present invention, for example, a plurality of fiber reinforced resin materials made of a unidirectional reinforcing material such as a prepreg in which fibers are oriented only in one direction are juxtaposed along the axial direction of the core metal while applying a predetermined tension. Thus, a shaft-like composite member pasted can be obtained. Therefore, in the present invention, the difference between the inner and outer circumferences of the fiber reinforced resin material in the bent portion of the shaft-shaped composite member can be absorbed and formed without causing wrinkles or twists, for example. As a result, in the present invention, desired strength and rigidity can be ensured in the bent portion of the shaft-shaped composite member.

In the present invention, it is possible to obtain a manufacturing method of a desired capable of ensuring strength and rigidity shaft-like composite member inner periphery difference absorbs bent portion of the bent portion.

It is a perspective view of the shaft-shaped composite member manufactured using the manufacturing method of the shaft-shaped composite member which concerns on embodiment of this invention. It is a perspective view which shows the state which affixes several prepregs affixed with the metal core with the heat shrink tape with a manufacturing apparatus. (A)-(c) is explanatory drawing which showed the manufacturing process of the shaft-shaped composite member along the time series. (A) is a characteristic diagram showing the relationship between the fiber orientation angle of the prepreg and the Young's modulus at the bent portion of the shaft-shaped composite member, (b) is an explanatory diagram of the fiber orientation angle (± θ) with respect to the axis, (C) is explanatory drawing which shows the load input point provided to a shaft-shaped composite member. (A) is the partial top view at the time of setting the width dimension of the heat-shrink tape which spirally winds the linear part and bending part of an axial composite member, respectively, (b) is (a) It is the diagram which tied the center point of the wound heat shrink tape. In (a), the width dimension W2 of the heat-shrinkable tape that spirally winds the bent portion of the shaft-shaped composite member is set to be narrower than the width dimension W1 of the heat-shrinkable tape that spirally winds the linear portion. (B) is the diagram which tied the center point of the heat-shrink tape wound by (a).

  Next, embodiments of the present invention will be described in detail with reference to the drawings as appropriate. FIG. 1 is a perspective view of a shaft-shaped composite member manufactured using the method for manufacturing a shaft-shaped composite member according to an embodiment of the present invention.

  As shown in FIG. 1, the shaft-shaped composite member 10 has a substantially L-shape in a part thereof, and has a composite shape in which a straight portion 12 and a bent portion 14 are combined. The shaft-shaped composite member 10 covers a cored bar 16 formed of a metal (for example, aluminum) hollow pipe and substantially the entire outer surface of the cored bar 16, and the fiber orientation direction is only in one direction (one And a fiber reinforced resin material 18 made of a directional reinforcing material.

  The fiber reinforced resin material 18 is preferably, for example, a prepreg 18a described later. The fiber orientation direction of the prepreg 18a is only one direction coinciding with the axial direction (longitudinal direction) of the prepreg 18a. As will be described later, the fiber reinforced resin material 18 is coated on the outer surface of the cored bar 16 in parallel along the axial direction of the cored bar 16 so as to be coated on the outer surface of the cored bar 16. Yes. In other words, the fiber orientation angle of the fiber reinforced resin material 18 is 0 degree, and the axial direction of the core metal 16 and the fiber orientation direction of the fiber reinforced resin material 18 are parallel.

  “Pre-preg” means, for example, impregnating a fibrous reinforcing material such as carbon fiber with a thermosetting resin in which an additive such as a curing agent is mixed, and then heating or drying to make a semi-cured state. This is a reinforced plastic molding material that is completely cured later by heating or the like. As the prepreg 18a, for example, “tuprepreg” is preferably used.

  At both end portions along the axial direction of the shaft-shaped composite member 10, mounting portions 20 are provided. The mounting portion 20 is a portion that is mounted to a vehicle structure (for example, a body panel) (not shown) when the shaft-shaped composite member 10 is assembled to a vehicle. In the mounting portion 20, the outer surface of the cored bar 16 is not coated with the fiber reinforced resin material 18, and the outer surface of the cored bar 16 is exposed to the outside.

  The shaft-shaped composite member 10 manufactured by the method for manufacturing a shaft-shaped composite member according to the present embodiment is basically configured as described above. Next, the function and effect will be described.

First, the manufacturing apparatus of the shaft-shaped composite member 10 will be schematically described. FIG. 2 is a perspective view showing a state in which a plurality of prepregs are attached to a cored bar by a manufacturing apparatus and the attached prepregs are restrained by a heat shrink tape.
As shown in FIG. 2, the manufacturing apparatus includes a plurality of small-diameter bobbins 22, a single large-diameter bobbin 24, and a rubber member 28 having a through hole 28 a that surrounds the outer peripheral surface of the cored bar 16.

  Each of the plurality of small-diameter bobbins 22 is wound beforehand with a predetermined amount of prepreg 18a that is a precursor of the fiber reinforced resin material 18 (for example, a length corresponding to the length of the shaft-shaped composite member 10 that is a finished product). It has been turned. Each prepreg 18a is made of the same material, and has the same width dimension substantially perpendicular to the axis. Each of the plurality of small-diameter bobbins 22 is arranged in a substantially annular shape on the outer diameter side with the axial center of the metal core 16 as a center, and the whole of the metal core 16 is arranged in a generally annular shape via a displacement means (not shown). It is provided so as to be displaceable along the axial direction.

  A predetermined amount (a necessary amount for construction) is wound around a single large-diameter bobbin 24 in advance with a heat-shrink tape 26 that functions as a restraining material. The rubber member 28 is provided so as to be displaceable along the axial direction of the cored bar 16 through a displacement means (not shown). In this embodiment, the width dimension of the heat-shrinkable tape 26 that is substantially orthogonal to the axis is set to the same dimension in each of the straight portion 12 and the bent portion 14, but is set to a different size as described later. You may do it. Regardless of the size, the prepreg 18a is attached to the surface of the cored bar 16 without causing a gap between the prepregs 18a.

  Next, the manufacturing method of the shaft-shaped composite member 10 manufactured by this manufacturing apparatus will be described in detail below. Fig.3 (a)-FIG.3 (c) are explanatory drawings which showed the manufacturing process of the axial composite member along the time series.

  First, a metal core that is linearly formed from one end to the other end along the axial direction is subjected to a bending process, and a straight portion 12 and a bent portion 14 composed of an R portion having a desired radius of curvature, A substantially L-shaped cored bar 16 is formed. In addition, you may form the substantially L-shaped metal core 16 with which the linear part 12 and the bending part 14 were combined with another shaping | molding method, for example by casting molding or forge molding.

  Subsequently, in a state where a predetermined tension is applied to each prepreg 18 a via a tensioner (not shown), the prepreg 18 a is pulled out from each small-diameter bobbin 22, and a plurality of prepregs 18 a are arranged in parallel along the axial direction of the cored bar 16. Affix with no gap (see FIG. 2). A plurality of prepregs 18a are pasted from the boundary portion between one mounting portion 20 and the straight portion 12 of the substantially U-shaped cored bar 16 through the straight portion 12, the bent portion 14 and the straight portion 12, and the other mounting portion. It sticks continuously toward the boundary part of 20 and the linear part 12. FIG.

  In addition, it is preferable that the bonding of the plurality of prepregs 18a to the outer peripheral surface of the cored bar 16 is performed simultaneously or substantially simultaneously, but after pasting a part of the prepregs 18a along the axial direction of the cored bar 16, The remaining prepreg 18a may be attached along the axial direction of the cored bar 16.

  The plurality of prepregs 18a attached in parallel along the axial direction of the cored bar 16 are formed with stepped portions that partially overlap with the adjacent prepregs 18a. A plurality of prepregs 18a may be arranged in parallel to the axis of the cored bar 16 so that the clearance between adjacent prepregs 18a becomes zero without forming a stepped portion. In either case, no gap is generated between the prepregs 18a.

  As shown in FIG. 2, each prepreg 18 a that is tensioned and pulled out from each small-diameter bobbin 22 is placed on the outer peripheral surface of the core metal 16 by a disk-shaped rubber member 28 that surrounds the outer peripheral surface of the core metal 16. It is held in an aligned state. The plurality of prepregs 18 a held on the outer peripheral surface of the cored bar 16 are arranged in parallel with the axis of the cored bar 16 at the straight line part 12 and the bent part 14.

  After the plurality of prepregs 18a are held on the outer peripheral surface of the cored bar 16 by the rubber member 28, the heat shrink tape 26 drawn out from the large-diameter bobbin 24 is spirally wound around the cored bar 16 (see FIG. 2). ).

  That is, after a plurality of prepregs 18a are attached to the outer peripheral surface of the cored bar 16 along the axial direction of the cored bar 16, a heat shrink tape 26 wound around the large-bore bobbin 24 is further attached to another tensioner (not shown). The prepreg 18a is pulled out in a state where a predetermined tension is applied, and is wound spirally from above the prepreg 18a to restrain the plurality of prepregs 18a.

  The heat-shrink tape 26 is laminated (superimposed) on the prepreg 18 a attached to the core metal 16. The plurality of prepregs 18 a attached to the outer peripheral surface of the core metal 16 are held by the inner peripheral surface of the through hole 28 a of the rubber member 28 until being restrained by the heat shrink tape 26. In addition, you may make it interpose an adhesive etc. between the some prepreg 18a and the outer peripheral surface of the metal core 16, for example.

  The heat shrinkable tape 26 functions as a restraining material, and the prepreg 18a moves outward in the radial direction of the cored bar 16 or the prepreg 18a moves in the circumferential direction of the cored bar 16 to cause displacement. regulate. As a result, it is avoided that the arrangement of the plurality of prepregs 18a attached in parallel along the axial direction on the outer peripheral surface of the core metal 16 is disturbed.

  The intermediate molded body 30 (see FIG. 3A) in which the prepreg 18a is constrained by the heat shrink tape 26 is accommodated in a curing furnace such as a heating furnace (not shown) and heated at a predetermined temperature. And thermosetting (see FIG. 3B). By heat-curing, the plurality of prepregs 18 a (semi-cured state) affixed to the outer peripheral surface of the cored bar 16 are completely cured and integrally coupled to the outer peripheral surface of the cored bar 16.

  Finally, the heat-shrinkable tape 26 is peeled from the prepreg 18a and the cored bar 16 to complete the shaft-shaped composite member 10 as a finished product (see FIG. 3C). In addition, after peeling the heat-shrink tape 26, you may make it improve the design aesthetics by grind | polishing the level | step-difference part in which the several prepreg 18a was arranged in parallel, and removing an unevenness | corrugation.

  FIG. 4A is a characteristic diagram showing the relationship between the fiber orientation angle of the prepreg and the Young's modulus at the bending portion of the shaft-shaped composite member, and FIG. 4B is the fiber orientation angle (± θ) based on the axis. FIG. 4C is an explanatory diagram showing load input points given to the shaft-shaped composite member. As shown in FIG. 4A, the angle (fiber orientation angle θ) when each prepreg 18a is attached along the axial direction of the cored bar 16 is set to about 10 degrees or less (including 0 degrees). Good. This is because when the fiber orientation angle exceeds about 10 degrees, the Young's modulus decreases rapidly and the bending rigidity decreases. As shown in FIG. 4B, the fiber orientation angle (θ) is set to an angle of ± θ with respect to the axis of the cored bar. Also, as shown in FIG. 4C, the load input point when calculating the Young's modulus (stress / strain) in the bent portion 14 is the mounting portion 20 at one end of the shaft-shaped composite member 10, and the mounting A load is applied in a vertically downward direction substantially orthogonal to the axis of the portion 20.

  As a result, the fiber orientation angle (± θ) of the prepreg 18 a (fiber reinforced resin material 18) is set within a range of about ± 10 degrees (including 0 degree) with respect to the axis of the shaft-shaped composite member 10. It is preferable. When the fiber orientation angle is 0 degree, the axis of the cored bar 16 and the axis of each prepreg 18a are parallel, and the highest bending rigidity is obtained.

  In the present embodiment, a shaft shape in which a plurality of fiber reinforced resin materials 18 composed of prepregs 18a in which fibers are oriented only in one direction are affixed in parallel along the axial direction of the core metal 16 while applying a predetermined tension. The composite member 16 can be obtained. Therefore, in this embodiment, compared with the case where the outer peripheral surface of the bending part 14 is spirally wound, the inner and outer peripheral difference of the prepreg 18a in the bending part 14 can be absorbed. can do. As a result, in the present embodiment, desired strength and rigidity in the bending portion 14 of the shaft-shaped composite member 10 can be ensured.

  In the present embodiment, the fiber orientation angle of the prepreg 18a is set within a range of about ± 10 degrees (including 0 degrees) from the characteristic diagram shown in FIG. The shaft-shaped composite member 10 can be obtained.

  FIG. 5 (a) is a partial plan view when the width dimensions of the heat-shrinkable tape for spirally winding the linear portion and the bent portion of the shaft-shaped composite member are set to be the same, and FIG. 5 (b) FIG. 6A is a diagram connecting the center points of the heat-shrinkable tape wound in FIG. 5A, and FIG. 6A shows that the width dimension W2 of the heat-shrinkable tape spirally wound around the bent portion of the shaft-shaped composite member is as follows. FIG. 6B is a partial plan view when the width of the heat-shrinkable tape wound in a spiral shape is set narrower than the width dimension W1, FIG. 6B shows the center of the heat-shrinkable tape wound in FIG. It is the diagram which connected the point.

  In this embodiment, as shown in FIG. 5 (a), the width dimension W of the heat shrink tape 26 in the linear portion 12 and the bent portion 14 of the shaft-shaped composite member 10 is set to be the same. As shown in FIG. 6A, the width dimension W2 of the heat-shrinkable tape 26 that spirally winds the bent portion 14 is set smaller than the width dimension W1 of the heat-shrinkable tape 26 that winds the linear portion 12. Then it is good (W1> W2).

  By setting the width dimension W2 of the heat-shrinkable tape 26 that winds the bent portion 14 to be narrower than the width dimension W1 of the heat-shrinkable tape 26 that winds the straight portion 12, the inner dimension of the bent portion 14 is aligned. The heat shrinkable tape 26 can be made to follow (see FIG. 5B and FIG. 6B for comparison). For this reason, in this embodiment, while increasing the binding force of the prepreg 18a on the inner peripheral side of the bent portion 14, the design aesthetics of the prepreg 18a attached along the inner shape of the cored bar 16 is improved. Can do.

  It should be noted that the heat shrinkable tapes 26 having different width dimensions between the linear portion 12 and the bent portion 14 may be configured continuously and integrally, or separate heat shrinkable tapes 26 may be used. Good. When a separate heat shrink tape 26 is used, the discontinuous portion between the straight portion 12 and the curved portion 14 may be temporarily fixed by a temporary fixing means (not shown).

  In the present embodiment, the shaft-shaped composite member 10 having the bent portion 14 is described. However, the present invention is not limited to this. For example, the present invention is applied to an automobile suspension member, a stabilizer, a bicycle frame, and the like. Is possible. In addition, in the present embodiment, an example in which the prepreg 18a is thermally cured is shown, but it may be cured with light.

  Furthermore, in this embodiment, the fiber orientation angle (± θ) of the prepreg 18a (fiber reinforced resin material 18) is within a range of about ± 10 degrees (including 0 degrees) with respect to the axis of the shaft-shaped composite member 10. However, in order to further improve the torsional rigidity, different fiber orientation angles (for example, the inner layer of the prepreg 18a disposed within the range of about ± 10 degrees or the outer layer (for example, , About ± 45 degrees) may be laminated.

  Furthermore, in the present embodiment, the shaft-shaped composite member 10 having a substantially L shape is described as an example. For example, a shape having a L shape in a part thereof (for example, a substantially U shape) You may apply to the shaft-shaped composite member which consists of.

DESCRIPTION OF SYMBOLS 10 Shaft-shaped composite member 12 Linear part 14 Bending part 16 Core metal 18 Fiber reinforced resin material 18a Pre-preg 26 Heat shrink tape (restraint material, tape)

Claims (1)

A method for producing a shaft-shaped composite member having a bent portion,
Affixing step in which a plurality of fiber-reinforced resin materials made of unidirectional reinforcing material are attached in parallel along the axial direction of the core metal to the outer surface of the bent portion;
A constraining step of winding a constraining material that restricts the fiber reinforced resin material from moving outward in the radial direction of the core after the pasting step;
A heating step of heating in a state where the fiber reinforced resin material is restrained by the restraining material;
After the fiber-reinforced resin material is heated and solidified, a peeling step of peeling the restraint material;
A method for producing a shaft-shaped composite member, comprising:

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