JP6428577B2 - Manufacturing method of joined body - Google Patents

Description

  The present invention relates to a method for manufacturing a joined body obtained by joining two composite materials made of a fiber reinforced resin material.

  Conventionally, a technique has been proposed in which a foam material that is foamed by heating is inserted into a hollow portion formed in the tubular member, and the foam material is foamed in the hollow portion of the tubular member by heating the tubular member. (For example, refer to Patent Document 1). According to this technique, since the foamed foam material is filled in the hollow portion of the tubular member, a solid molded body with improved rigidity and sound insulation can be obtained.

JP-A-4-209691

  By the way, a hollow member having a hollow portion, such as the tubular member described above, may be manufactured by joining two members formed with recesses in a state where the recesses face each other. When manufacturing the solid molded body described above, after joining the two members to produce a joined body having a hollow portion, a foam material is inserted into the hollow portion of the joined body, and the joined body is placed in a heating furnace. It will heat up and it will take time. In particular, when the joined body is made of a thermoplastic resin, it takes time to transmit heat to the foamed material in the joined body in order to foam the foamed material.

  In view of such a point, the present invention aims at a solid body in which two members are joined so that a hollow portion is formed, and the hollow portion of the joined body is filled with a foam material. An object of the present invention is to provide a method for manufacturing a joined body, which can easily produce a joined body.

  In view of the above problems, a method for manufacturing a bonded body according to the present invention is a method for manufacturing a bonded body in which two composite materials made of a fiber reinforced resin material containing carbon fibers in a thermoplastic resin are bonded. A step of preparing two composite materials in which concave portions are formed as two composite materials, and a step of inserting a foam material that is foamed by heating into the concave portions of at least one of the two composite materials; Contacting the two composite materials in a state where the concave portions of the two composite materials face each other so that a hollow portion is formed between the two composite materials; and the two composite materials contact each other. While pressurizing the contact surfaces, sliding the contact surfaces or applying ultrasonic vibrations to the contact surfaces, the contact surfaces are heated, the contact surfaces are fused, Contact surface The heat generated by the Judges, the allowed within the hollow portion is foamed the foam, characterized in that it and a step of filling the foam material into the hollow portion.

  According to the present invention, when two composite materials are brought into contact so that the concave portions of the two composite materials face each other, a hollow portion is formed by the two concave portions, and the foam material is disposed in the hollow portion. In this state, heat is generated between the contact surfaces by sliding them while pressing the contact surfaces of the two composite materials or by applying ultrasonic vibration to them (the sliding surfaces generate heat). .

  Since the two composite materials contain carbon fibers in the thermoplastic resin, the thermoplastic resin between the contact surfaces is softened by the generated heat, and the contact surfaces are fused. Further, the heat generated between the contact surfaces is efficiently and uniformly transmitted to the hollow portion where the foam material is disposed via the carbon fiber. As a result, the foam material disposed in the hollow portion can be efficiently foamed by the transmitted heat without using another heat source such as a heating furnace.

  In this way, while joining the two composite materials, the foam material can be foamed in the hollow portion formed between them, and the foam material is filled in the hollow portion of the joined body composed of the two composite materials. A solid molded body can be easily manufactured.

(A)-(f) is the figure which showed the series of processes for demonstrating the manufacturing method of the conjugate | zygote of this invention. It is a typical conceptual diagram of the vibration welding machine used at the process of FIG.1 (b)-(e).

Embodiments of the present invention will be described below with reference to FIGS. 1 and 2.
Fig.1 (a)-FIG.1 (f) are the figures which showed the series of processes for demonstrating the manufacturing method of the conjugate | zygote 1 of this invention. FIG. 2 is a schematic conceptual diagram of the vibration welding machine 30 used in the steps of FIGS.

  In this embodiment, the joined body 1 shown in FIG. The joined body 1 is a solid joined body in which the foamed material 3 is filled in the hollow joined body 2 (the hollow portion 28) in which the two composite materials 21 and 22 are joined. The hollow joined body 2 is made of a fiber reinforced resin material in which carbon fibers are contained in a thermoplastic resin, and the foamed material 3 is made of a foamed thermoplastic resin. The thermoplastic resin of the hollow joined body 2 and the foamed material 3 need not be the same thermoplastic resin.

  Below, the manufacturing method of the conjugate | zygote 1 is demonstrated. First, as shown in FIG. 1A, two composite materials 21 and 22 are prepared. Each of the composite materials 21 and 22 is made of a reinforced fiber resin material (CFRP) containing carbon fibers in a thermoplastic resin.

  Although the softening point (melting | fusing point) of the thermoplastic resin contained in the composite materials 21 and 22 changes with the materials, it is about 180-280 degreeC. Examples of the thermoplastic resin material include polypropylene (PP), polyamide (PA), polystyrene (PS), and the like, and the material is particularly limited as long as it can be softened at the time of joining described later. It is not something.

  Each composite material 21 (22) has a recess 23 (24), and a pair of flanges 25, 25 (26, 26) for joining them are formed on both sides of the recess 23. Yes. The composite materials 21 and 22 can be obtained by molding by injection molding or by hot-press molding a plate-like fiber reinforced resin material.

  Next, as shown in FIG. 1B, one of the two composite materials 21 and 22 is set on the lower jig 31. The lower jig 31 is a lower jig of a vibration welding machine 30 shown in FIG. 2 described later. Next, the foamed material 3 ′ which is foamed by heating is inserted into the concave portion 23 of the set composite material 21. The foam material 3 'is a material made of an unfoamed or pre-foamed (not completely foamed) thermoplastic resin.

  Examples of the material of the foamed material 3 ′ include polyurethane foam, polyolefin foam, and silicone foam in an unfoamed state or a pre-foamed state. The material of the foam material 3 ′ is not particularly limited as long as it can be foamed by the heat generated during the joining of the composite materials 21 and 22 (the apparent volume expands). Those which foam at a temperature lower than the softening point of the thermoplastic resin constituting 22 are preferred.

  Next, as shown in FIG. 1 (c), the concave portions 23 and 24 of the two composite materials 21 and 22 face each other so that a hollow portion 28 is formed between the two composite materials 21 and 22. The two composite materials 21 and 22 are brought into contact with each other. In this embodiment, the collar part 25 of the composite material 21 and the collar part 26 of the composite material 22 are in contact with each other at the contact surfaces 25a and 26a.

  In this contact state, the composite material 22 is placed on the upper jig 32. Specifically, by moving the pressurizing cylinder 33 shown in FIG. 2 along the guide shaft 34 and raising the composite materials 21 and 22 together with the lower jig 31, the composite material 22 can be disposed on the upper jig 32. it can.

  Next, as shown in FIG. 1 (d) and FIG. 2, using the vibration welding machine 30, the two composite materials 21 and 22 are joined and the foam material 3 disposed (inserted) in the hollow portion 28. 'Foam.

  Specifically, first, the contact surfaces 25a and 26a with which the two composite materials 21 and 22 are in contact with each other are pressed from the lower jig 31 toward the upper jig 32 by the pressurizing cylinder 33 through the lower jig 31. Next, a current is periodically supplied from the power source 35 to the electromagnetic coil 36 to vibrate the spring 37 via the driver box 39 and vibrate the upper jig 32 in the horizontal direction. The vibration of the upper jig 32 is feedback controlled by the detection signal of the pickup sensor 38.

  Thereby, as shown in FIG.1 (e), the contact surfaces 25a and 26a of the composite materials 21 and 22 can be slid. By this sliding, the contact surfaces 25a and 26a generate heat, and the contact surfaces 25a and 26a are fused. Further, the foamed material 3 ′ is foamed (expanded) in the hollow portion 28 by the heat generated by the contact surfaces 25 a and 26 a, and the hollow portion 28 is filled with the foamed material 3.

  At this time, the contact surfaces 25 a and 26 a are caused to generate heat at a temperature equal to or higher than the softening point of the thermoplastic resin included in the composite materials 21 and 22. Thereby, the thermoplastic resin between the contact surfaces 25a and 26a is softened by the generated heat, and a fused portion 29 in which the contact surfaces are fused is formed.

  Moreover, since carbon fibers are dispersed and contained in the composite materials 21 and 22, the heat generated by the contact surfaces 25a and 26a is generated in the hollow portion 28 where the foam material 3 'is disposed via the carbon fibers. Efficient and uniform transmission. Thereby, the foamed material 3 ′ disposed in the hollow portion 28 can be efficiently foamed by the transmitted heat without using another heat source such as a heating furnace.

  Note that the sliding between the contact surfaces 25a and 26a is such that the distance at which the composite materials 21 and 22 are relatively close to each other (that is, the amount by which the composite material 21 sinks with respect to the composite material 22) ) When the amount is reached.

  Thereafter, the joined body 1 is removed from the vibration welding machine 30, and the joined body 1 shown in FIG. 1 (f) can be obtained. As described above, in this embodiment, it is possible to perform the fusion of the composite materials 21 and 22 and the foaming of the foam material 3 ′ at the same time by using heat for fusing the composite materials 21 and 22. Thereby, the joined body 1 in which the foaming material 3 is filled in the hollow portion 28 formed by the recesses 23 and 24 can be easily manufactured.

  Since the manufactured joined body 1 is filled with the foam material 3 in the hollow portion 28 of the hollow joined body 2, its rigidity is higher than that of the hollow joined body 2 alone, and its sound insulation is also high. . Furthermore, the joined body 1 is lighter than a solid body made of only a fiber-reinforced resin material having the same shape, and can be manufactured at a low cost.

  Although the embodiment of the present invention has been described in detail above, the specific configuration is not limited to this embodiment, and even if there is a design change within a scope not departing from the gist of the present invention, they are not limited to this embodiment. It is included in the invention.

  In the present embodiment, the contact surfaces of the composite material are slid using a vibration welding machine so that the contact surfaces generate heat and are welded. In addition to this, in a state where the contact surface of the composite material is pressurized, an ultrasonic horn is disposed on the flange portion of the composite material on one side, and ultrasonic vibration is applied between the contact surfaces, thereby bringing the contact surfaces together. Heat may be generated, the contact surfaces may be fused together, and the foam material may be foamed.

  1: joined body, 2: hollow joined body, 3 ′, 3: foamed material, 21, 22: composite material, 23, 24: recessed portion, 25, 26: collar portion, 25a, 26a: contact surface, 28: hollow portion , 29: fusion part, 30: vibration welding machine, 31: lower jig, 32: upper jig, 33: pressure cylinder, 34: guide shaft, 35: power supply, 36: electromagnetic coil, 37: spring, 38: pickup Sensor 39: Driver box.

Claims (1)

A method for producing a joined body obtained by joining two composite materials made of a fiber reinforced resin material containing carbon fibers in a thermoplastic resin,
Preparing two composite materials having recesses as the two composite materials;
Inserting a foamed material that foams by heating into a recess of at least one of the two composite materials; and
Contacting the two composite materials in a state in which the concave portions of the two composite materials face each other so that a hollow portion is formed between the two composite materials;
While pressing the contact surfaces with which the two composite materials are in contact with each other, sliding the contact surfaces or applying ultrasonic vibration to the contact surfaces, the contact surfaces are heated, and the contact surfaces with fusing with each other, the heat generated between the contact surface, the allowed within the hollow portion is foamed the foam material, seen including and a step of filling the foam material into the hollow portion,
The method of manufacturing a joined body, wherein the foam material is foamed at a temperature lower than a softening point of a thermoplastic resin constituting the two composite materials .

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