JP6540085B2 - Propeller shaft - Google Patents

Description

  The present invention relates to a propeller shaft made of fiber reinforced plastic (FRP) used as a propeller shaft or a roll of an automobile or the like.

  Since relatively large pipes made of fiber reinforced plastic are light in weight and excellent in various mechanical properties, they have been widely used in recent years for propeller shafts of automobiles, various types of rotating rolls for industrial use, and the like. For example, weight reduction of automobiles for the purpose of improving fuel consumption is strongly desired from the viewpoint of energy saving. For example, in shaft parts such as propeller shafts, as one means, the main cylinder is made of metal to fiber reinforced plastic An alternative to making is being done. In the case of a propeller shaft, a main body cylinder of the propeller shaft is made of fiber reinforced plastic, and a metal part (this part is also called a yoke) functioning as a universal joint is joined to both ends thereof.

  As a method of efficiently producing a main tube made of fiber reinforced plastic, for example, there is a filament winding method. In the filament winding method, generally, after winding a resin-impregnated fiber or fiber bundle around a mandrel, the resin is cured and then the mandrel is pulled out to produce a product, ie, a main tube made of fiber reinforced plastic. Ru. The strength of the product produced by the filament winding method is largely influenced by the winding angle between the fibers and the axial direction of the mandrel and the state of arrangement of the fibers.

  Moreover, in the fiber reinforced plastic propeller shaft, although the main cylinder is made of fiber reinforced plastic, since the joint is made of metal, it can not be joined by welding like a propeller shaft made entirely of steel. It is. With regard to the joint strength between the main body cylinder and the metal joint, it is also necessary to achieve the above-mentioned torsional joint strength. In addition, it is known that it is effective to provide an outer reinforcing layer of fiber reinforced plastic around the end of the main body cylinder in order to secure the joint strength and the like by press-fitting.

  The main cylinder of the fiber reinforced plastic propeller shaft mainly has a winding angle of about ± 5 to ± 45 ° with respect to the axial direction of the main cylinder in order to give excellent torsional strength and bending rigidity to the fiber reinforced plastic propeller shaft. And a hoop winding layer in which the reinforcing fiber bundle is wound at a winding angle of about ± 90 ° with respect to the axial direction of the main cylinder in order to give the bonding strength mainly. It has often been formed in combination.

  Since various industrial shaft parts such as propeller shafts of automobiles are often used by inserting and joining metal members such as yokes to at least one end of a fiber reinforced plastic main body cylinder, insert and joint parts Needs to be improved. At the same time, the wound layer of the main cylinder generated in the step of curing the resin after winding the fiber or fiber bundle impregnated with the resin around the mandrel is cracked, so-called cracking of the wound layer between layers with different winding angles Various measures are also taken to prevent cracking.

  In Patent Document 1 (Japanese Patent Laid-Open No. 2000-318053), a propeller shaft includes a cylindrical shaft (a fiber reinforced plastic pipe) and metal parts joined on both sides thereof, and the cylindrical shaft and the metal parts are serrated. The cylindrical shaft and the metal part are joined together by joining the serrations to the inner peripheral surface of the cylindrical shaft. Specifically, the cylindrical axis is formed by winding reinforcing fibers impregnated with resin in layers, and the reinforcing fibers are wound at an angle (orientation angle) of about ± 10 degrees with respect to the axial direction of the cylindrical axis The helical winding layer and the hoop winding layer wound with an orientation angle of about 90 degrees are formed, and the hoop winding layer is formed only at the end of the cylindrical axis and is disposed between the helical winding layers. Configuration is described.

  In patent document 1, thermosetting resin, such as an epoxy resin, a thermoplastic resin with a high bending elastic modulus, etc. are illustrated as a matrix resin. However, cylindrical shafts such as propeller shafts are required to have higher durability, and although the properties of the matrix resin are important for the prevention of cracks in the hoop winding layer and the improvement of the durability, the configuration of the specific measures is disclosed. It has not been. In addition, the preferred relationship between the winding angle of the reinforcing fiber bundle between the hoop winding layer and the helical winding layer for improving the durability can be prevented, and the layer thickness relationship can not be disclosed.

  Moreover, in patent document 2 (Unexamined-Japanese-Patent No. 2003-1717), the helical winding layer in which the reinforced fiber was wound so that an orientation angle may be 5 to 15 degrees, and an orientation angle may be 80 to 90 degrees. A fiber-reinforced plastic cylinder having a reinforcing fiber wound hoop wound layer, a helical wound layer wound with six layers, and a hoop wound layer disposed between the fourth and fifth layers of the helical wound layer Body composition is described.

  In the configuration of Patent Document 2, since the junction of the helical winding layer and the hoop winding layer is separated from the junction of the metal part and the FRP pipe, the stress applied to the junction of the helical winding layer and the hoop winding layer is suppressed small. Although the strength characteristics of the FRP pipe can be improved, the bonding strength of the fiber reinforced plastic propeller shaft cylinder may be weakened by the separation of the hoop wound layer from the main cylinder to the outer peripheral side.

  Further, in Patent Document 3 (Japanese Patent Application Laid-Open No. 7-91430), the propeller shaft is a main body cylinder on the inner layer side with a helical winding layer of ± 5 ° to ± 30 ° with respect to the extension direction of the rotation shaft, on the outer layer side. A configuration in which a unidirectional winding layer of 75 ° to 90 ° is formed, or a helical winding layer made of twisted yarn of ± 10 ° to ± 45 ° with respect to the extension direction of the rotation axis on the inner layer side, ± on the outermost layer A configuration in which a reinforcing fiber layer composed of 45 ° to 90 ° non-twisted yarn is formed is disclosed, and the thickness ratio between the helical winding layer and the unidirectional winding layer is preferably in the range of 50: 1 to 10: 1. Is described.

  However, the configuration of Patent Document 3 is insufficient for achieving higher durability with respect to a cylindrical axis such as a propeller shaft because the configuration simply provides a helical winding layer and a unidirectional winding layer. In addition, the preferred relationship between the winding angle of the reinforcing fiber bundle between the hoop winding layer and the helical winding layer for improving the durability, which can prevent the delamination and cracking, and the specific characteristics of the matrix resin are not disclosed. .

  Further, according to Patent Document 4 (Japanese Patent Laid-Open No. 2004-293708), in a fiber reinforced plastic propeller shaft in which a fiber reinforced plastic cylindrical body and a metal part are integrally joined, the fiber reinforced plastic cylindrical body is The helical winding layer is formed in the innermost layer on the circumferential surface side, and the helical winding layer is provided on the outer side of the axial direction reinforcing winding layer at both ends.

JP 2000-318053 A Japanese Patent Application Publication No. 2003-1717 Japanese Patent Application Laid-Open No. 7-91430 JP 2004-293708 A

  In view of the problems of the prior art, the present invention relates to a hoop winding layer generated in the process of winding and curing a fiber bundle impregnated with a matrix resin around a mandrel, in a propeller shaft having a main tube made of fiber reinforced plastic. Generation of cracks can be suppressed, and torsional strength and joint strength can be secured, and when other members are press-bonded to the end of the main body cylinder, interlayer breakage of the end is less likely to occur, and long-term use It aims to provide a highly reliable propeller shaft.

(1) A propeller shaft having a fiber reinforced plastic main body cylinder, wherein the main body cylinder is in order from at least the outermost layer with respect to the helical winding A layer on which reinforcing fibers are wound, the extending direction of the rotation axis of the main body cylinder And a reinforcing portion in which the hoop winding layer is thickened is formed at at least one end of the main body cylinder. In the innermost layer of the above, there is provided a crack preventing layer which is a helical wound B layer in which reinforcing fibers are wound at a winding angle HB (.degree.) Of 5 to 30.degree. Propeller shaft.
(2) The propeller shaft according to (1), wherein the thickness ratio of the crack prevention layer to the hoop winding layer in the reinforcing portion is in the range of 1: 2 to 1:20.
( 3 ) The propeller shaft according to (1) or (2) , wherein an angle difference between the winding angle HB (°) of the helical winding B layer and the winding angle HP (°) of the hoop winding layer is 40 to 85 °. .
( 4 ) The propeller shaft according to any one of (1) to ( 3 ), wherein a winding angle HA (°) of the helical winding A layer is 5 to 45 °.
( 5 ) The propeller shaft according to ( 1 ) to ( 4 ), in which the winding angle HA (°) of the helical winding A layer and the winding angle HB (°) of the helical winding B layer have the following relationship.
HB (°) <HA (°)
( 6 ) When the helical winding A layer is composed of the helical winding A1 layer and A2 in order from the outermost layer, and the helical winding A1 layer and A2 have respective winding angles of HA1 (°) and HA2 (°), the helical The propeller shaft according to any one of ( 1 ) to ( 4 ), which has the relationship of the winding angle HB (°) of the winding B layer and the following equation.
HA1 (°) ≦ HB (°) <HA2 (°)
( 7 ) The propeller shaft according to any one of (1) to ( 6 ), which contains an epoxy-based thermosetting resin having a glass transition point of at least 185 to 230 ° C. as a matrix resin used for the hoop winding layer.
( 8 ) The propeller shaft according to ( 7 ), wherein in the matrix resin, an alicyclic epoxy resin is contained in an amount of 25 parts by weight or more and 100 parts by weight or less based on 100 parts by weight of the epoxy main agent.
( 9 ) The propeller shaft as described in ( 7 ) or ( 8 ) whose matrix resin used for the layer which wound the reinforcement fiber is the same resin.

  According to the propeller shaft of the present invention, the occurrence of cracks in the hoop wound layer can be suppressed, and the torsional strength and the joint strength can be secured. Another object of the present invention is to provide a propeller shaft having high reliability in long-term use, in which interlayer breakage of the end portion layer is less likely to occur when other members are press-bonded to the end portion of the main body cylinder of the propeller shaft. .

It is an expanded sectional view of the one-side end of fiber reinforced plastic main part pipe 1 which constitutes the propeller shaft concerning one embodiment of the present invention. FIG. 6 is a view showing a reinforcing fiber 12 wound at a fixed winding angle in the crack preventing layer 4 with respect to the extending direction of the rotary shaft 11 of the main body cylinder 1; It is a figure which shows the winding angle HB with respect to the extension direction of the rotating shaft 11 of the reinforcement fiber 12 wound by the crack prevention layer 4 shown to FIG. 2 a. It is a form figure with which the reinforcement fiber 13 of the hoop winding layer 3 was wound by a fixed winding angle on the reinforcement fiber 12 of a crack prevention layer. It is a figure which shows the winding angles HB and HP with respect to the extension direction of the rotating shaft 11 of the reinforcement fiber 12 and the reinforcement fiber 13 of the hoop winding layer 3 which were wound by the crack prevention layer 4 shown to FIG. 3 a. FIG. 3 is a view showing the reinforcing fiber 12 wound in a direction opposite to that in FIG. 2a. The direction in which the reinforcing fibers 12 are wound is the reverse of the relative relationship with FIG. 2 b. The direction in which the reinforcing fibers 13 of the hoop winding layer 3 are wound is a mode diagram wound in a direction opposite to that in FIG. 3a. The direction in which the reinforcing fibers 13 of the hoop winding layer 3 are wound is a direction opposite to that in FIG. 3b. It is sectional drawing of the propeller shaft by which the metal joint 8 which concerns on one Embodiment of this invention was press-fit joined. FIG. 6 is an enlarged cross-sectional view of one end portion of a fiber-reinforced plastic main body cylinder 1 constituting a propeller shaft in which a helical winding A layer according to an embodiment of the present invention comprises a helical winding A1 layer and A2 in order from the outermost layer. FIG. 2 is a schematic view of a torsion evaluation tester 20.

  Hereinafter, the present invention will be described using the drawings. The present invention is not limited at all by the drawings.

  FIG. 1 is an enlarged cross-sectional view of one end of a main tube 1 made of fiber reinforced plastic for propeller shafts, and the main tube 1 is a helical winding A layer 2 wound with reinforcing fibers in order from at least the outermost layer, A hoop winding layer 3 in which reinforcing fibers are wound at a winding angle of 70 to 90 ° with respect to the extending direction of the rotating shaft 11 of the main body cylinder 1, a glass non-woven fabric, a cloth made of reinforcing fibers, or at least a heat resistant resin film It is a structure which has the crack prevention layer 4 containing one.

  In the present invention, it is important to dispose the helically wound A layer wound with the reinforcing fiber as the outermost layer and then dispose the hoop wound layer 3. Thereby, the improvement of the torsional strength of the main body cylinder 1 and the bending rigidity can be secured.

  Among the configurations of the present invention, the helically wound layer A 2 is a layer in which reinforcing fibers are wound at an angle close to parallel to the rotation axis 11 of the main body cylinder 1 as described later in detail. The hoop winding layer 3 has a winding angle close to a radial direction (direction orthogonal to the rotation shaft 11) in order to secure the bonding strength with the metal joint 8. Therefore, after winding on a mandrel, as the matrix resin is cured, the shrinkage of the resin first occurs in the fiber winding direction (direction close to perpendicular to the rotation axis 11), and a crack starting point is generated, which spreads to form cracks. Become. On the other hand, by arranging a crack preventing layer 4 described later on the inner side of the hoop wound layer 3 which is the starting point of the crack generation, that is, on the innermost layer of the main cylinder 1, the heat of the hoop wound layer 3 is cured. Cracking that occurs along the fiber orientation can be suppressed by the influence of expansion.

  The winding angle of the reinforcing fibers 13 of the hoop winding layer 3 is preferably 72 to 88 °, more preferably 75 to 87 °, and still more preferably 78 to 86 ° with respect to the rotation axis 11 of the main body cylinder 1. If the winding angle is less than 70 °, it will be difficult to secure the bonding strength of the metal joint 8.

  It is important to use at least one of a glass non-woven fabric, a cloth made of reinforcing fibers, or a heat-resistant resin film as the anti-cracking layer 4.

  The presence of the fibers oriented in the direction intersecting the hoop winding layer 3 can suppress the occurrence of cracks in the hoop winding layer 3 in the glass nonwoven fabric. As a glass non-woven fabric that functions as the crack prevention layer 4, a unidirectional material, a mat, and a cloth are preferably usable. When installing a glass nonwoven fabric in a main body cylinder, it is preferable to perform filament winding molding after installing a glass nonwoven fabric on a mandrel beforehand. At this time, resin impregnation into the glass non-woven fabric may be carried out in a separate step before molding, or surplus resin of reinforcing fibers to be wound during molding can be utilized.

  In addition, by using a woven fabric having a fiber orientation in the vicinity of the rotary shaft 11 such as twill weave or plain weave, a fabric made of reinforcing fibers exerts a function of suppressing a crack generated in the hoop wound layer 3 it can. The cloth made of reinforced fibers used as the crack prevention layer 4 is preferably a cloth or fabric having not only cotton, hemp, silk but also carbon fibers, aramid fibers, boron fibers, ceramic fibers, cellulose fibers etc. as raw yarns It is possible. When the fabric is placed on the main cylinder, it is preferable to perform the filament winding after placing the fabric on a mandrel in advance. At this time, the resin may be impregnated into the fabric in a separate step before molding, or excess resin of fibers to be wound during molding may be used.

  Moreover, as a heat resistant resin film which functions as the crack prevention layer 4, polyvinyl acetate resin, polycarbonate resin, polyacetal resin, polyphenylene oxide resin, polyphenylene sulfide resin, polyarylate resin, polyester resin, polyamide resin, polyamide imide resin, Polyimide resin, polyetherimide resin, polysulfone resin, polyethersulfone resin, polyetheretherketone resin, polyaramid resin, polybenzimidazole resin, polyethylene resin, polypropylene resin, cellulose acetate resin, polyethylene terephthalate resin, etc. are preferably usable. . When the resin film is placed in the main cylinder, the resin film is attached to the mandrel in advance with a tape and then filament winding molding is performed. At this time, the resin impregnation into the resin film can utilize an excess resin of fibers to be wound during molding.

  Further, in the present invention, it is important to dispose the reinforcing portion 5 composed of the crack preventing layer 4, the hoop winding layer 3 and the helical winding A layer 2 in a region of a fixed length from at least one end of the main body cylinder 1 is there. It is preferable to install the reinforcing portion 5 at a length equal to or longer than the total length of the joint portion 9 of the metal joint 8. Thereby, it becomes possible to press-fit and join other members such as the metal joint 8 and the like. Here, the press-fit bonding is a method of bonding the main body cylinder 1 and the metal joint 8 and applies pressure to the metal joint 8 whose outer diameter is slightly larger than the inner diameter of the main body cylinder 1 and pushes it inside the main body cylinder 1 It is to join.

  In the reinforcing portion 6 of the main body cylinder 1, the thickness ratio of the crack preventing layer 4 to the hoop winding layer 3 is preferably in the range of 1: 2 to 1:20. The crack preventing layer 4 plays a role of a lid for suppressing a crack generated in the hoop wound layer 3 and can sufficiently exhibit the role even with a thin wall. However, if the thickness ratio of the crack prevention layer 4 to the hoop wound layer 3 is smaller than 1: 2 the thickness of the hoop wound layer 3 becomes smaller, the amount of the hoop layer decreases, so the metal joint 8 by the hoop wound layer 3 is tightened. As a result, the fastening force (joining strength) may be weakened and the joining strength of the main cylinder 1 and the metal joint 8 may be weakened. In addition, when the thickness of the hoop winding layer 3 is larger than 1:20, the weight reduction is violated. The thickness ratio is preferably 1: 3 to 1:18, more preferably 1: 5 to 1:15, and still more preferably 1: 8 to 1:10.

  In the present invention, it is also preferable to use, as one of the crack preventing layers 4, a fabric in which reinforcing fibers are oriented in a direction different from the fiber winding angle of the hoop wound layer 3. Specifically, it is preferable to use a helical winding layer (hereinafter, helical winding B layer) having a winding angle similar to that of the helical winding A layer. That is, by arranging the reinforcing fiber 12 at a winding angle close to parallel to the rotation shaft 11 of the main body cylinder 1, it serves as a protective wall against the occurrence of a crack.

  It is preferable that the helical winding B layer winds reinforcing fibers at a winding angle of 5 to 30 ° with respect to the rotation axis 11 of the main body cylinder 1. If the winding angle of the helical winding B layer to the rotary shaft 11 of the main body cylinder 1 is less than 5 °, it becomes difficult to ensure the torsional strength, and tension is applied to the fiber in the radial direction of the mandrel due to the nature of filament winding molding. And the strength of the main cylinder 1 may be reduced. Also, if the winding angle of the helical winding B layer with respect to the rotation axis 11 of the main body cylinder 1 exceeds 30 °, the effect of the role of a protective wall against cracking of the hoop winding layer 3 may be weakened and securing of bending rigidity may be difficult. . The winding angle of the helical winding layer is preferably 6 to 28 °, more preferably 8 to 26 °, and still more preferably 10 to 25 ° with respect to the rotation axis 11 of the main body cylinder 1.

  Furthermore, assuming that the winding angle of the helical winding B layer relative to the rotation axis 11 is HB (°) and the winding angle of the hoop winding layer 3 relative to the rotation axis 11 is HP (°), the angle between HP (°) and HB (°) Preferably the difference is between 40 and 85 degrees.

  By arranging the helical winding B layer at an angle difference of 40 ° or more opened from the winding angle of the fibers of the hoop winding layer 3, the occurrence of cracks can be suppressed. The angle HP (°) of the hoop winding layer 3 is preferably in the range of 70 to 90 ° in order to secure the bonding strength with the metal joint 8. On the other hand, as described above, the angle HB (°) of the helically wound B layer is preferably in the range of 5 to 30 °. Therefore, it is good for the angle difference of HP (°) and HB (°) to be in the range of 40 ° to 85 °.

  Here, the difference in winding angle will be described. FIG. 2a shows a part of the form in which the reinforcing fiber 12 is wound at a constant winding angle in the case where the crack prevention layer 4 is a helical wound layer (helical wound B layer described above) with respect to the rotary shaft 11 of the main cylinder 1 It is a schematic diagram when the main body cylinder 1 is seen from a side. Here, the angle HB (°) at which the reinforcing fiber 12 of the helical winding B layer shown in FIG. 2a is wound is measured counterclockwise with respect to the rotation axis 11 (horizontal axis) as shown in FIG. 2b. It is shown as an angle.

  FIG. 3a is a schematic view of the main tube 1 as viewed from the side, showing a part of the configuration in which the reinforcing fibers 13 of the hoop winding layer 3 are wound at a constant winding angle on the helical winding B layer. Similar to FIG. 2b described above, as shown in FIG. 3b, the angle HP (°) at which the reinforcing fiber 13 of the hoop wound layer 3 is wound can be defined, and the angle HB (°) of the helical wound B layer and the hoop The difference in angle (angle 14 in FIG. 3 b) with the angle HP (°) of the winding layer 3 is taken as the angle difference of the winding angles.

  As shown in FIG. 4a, when reinforcing fiber 12 in the helically wound B layer is wound in the opposite direction relative to FIG. 2a, the angle HB (°) at which the reinforcing fiber 12 is wound is shown in FIG. 4b. As shown, it is shown as an angle measured clockwise with respect to the rotation axis 11. That is, the winding angle of the reinforcing fiber is defined so that the angle at which the reinforcing fiber intersects the rotation axis is 90 ° or less.

  Even when the reinforcing fiber 12 of the helical winding B layer and the reinforcing fiber 13 of the hoop winding layer 3 are wound as shown in FIG. 5a, the angle HB (°) of the reinforcing fiber 12 of the helical winding B layer and the hoop winding As the angle difference between the reinforcing fibers 13 of the layer 3 and the angle HP (°), as shown in FIG. 5b, the crossing angle 15 which is 90 ° or less is taken as the angle difference.

  In the present invention, the winding angle HA (°) at which the reinforcing fiber is wound with respect to the rotation axis 11 of the helical wound layer A 2 is preferably 5 to 45 °. By arranging the helical winding A layer 2 and setting the winding angle to 45 ° or less, high torsional strength and flexural rigidity can be secured when the torsional torque is applied to the main cylinder 1. If it is less than 5 °, tension may not be applied to the reinforcing fiber in the radial direction of the mandrel, and the strength of the main cylinder 1 may be reduced. If it exceeds 45 °, securing of torsional strength may be difficult. Preferably it is 6-45 degrees, More preferably, it is 8-45 degrees More preferably, it is 10-45 degrees.

  In the present invention, assuming that the winding angle of the reinforcing fiber 12 of the helical winding B layer is HB (°) and the winding angle of the reinforcing fiber of the helical winding A layer 2 is HA (°), then HB (°) <HA (° It is more preferred that

  When a torsional torque is applied to the main body cylinder 1, a compressive force is applied to the main body cylinder 1, and a buckling failure may occur to cause the main cylinder 1 to be broken with a torsional strength lower than expected. Here, it is possible to suppress the buckling failure by giving a compressive resistance to the helical winding B layer to which the compressive force most acts. For example, making the angle as small as possible with respect to the rotation axis 11 of the helical winding B layer, such as setting the HB (°) to 5 °, is advantageous because the compression resistance can be exhibited. On the other hand, in order to improve the torsional strength, it is advantageous to dispose an angle close to 45 ° with respect to the rotating shaft 11. However, since it is difficult to achieve both compression resistance and torsional strength with one helical winding layer, the helical winding layer is divided, and helical winding having a winding angle larger than that of the reinforcing fiber of the helical winding B layer. By providing the A layer 2 on the outer peripheral side, it is possible to achieve both the compression resistance and the torsional strength of the main body cylinder 1.

  Further, in the present invention, the helically wound layer A 2 may have a single angle or may have fibers having two winding angles. In particular, when the helical winding A layer 2 is formed of two layers of helical winding A 1 layer and helical winding A 2 layer from the outermost layer side and the angles are HA 1 (°) and HA 2 (°), the winding angle of helical winding B layer It is preferable that the relationship with HB (°) be HA1 (°) ≦ HB (°) <HA2 (°). As described above, the smaller the helical angle, the higher the compressive resistance, and the larger the angle, the higher the torsional strength. When the above-mentioned relational expression HA1 (°) ≦ HB (°) <HA2 (°), the helical winding A2 layer having a two-layer configuration and the helical winding A2 layer bearing the compressive strength Since the laminated structure is sandwiched between the layer and the helical winding B layer, the deformation of the helical winding A2 layer applied when torsional torque is applied can be strongly suppressed from above and below, and higher torsional strength is developed.

  Here, it is preferable that the winding angle HA1 (.degree.) Of the helical winding A1 layer be equal to or smaller than the angle HB (.degree.) Of the helical winding B layer in order to expect compression resistance.

  As in the case of HB (°), it is preferable to wind reinforcing fibers at a winding angle of 5 to 30 ° with respect to the rotation axis 11 of the main body cylinder 1 similarly to HB (°). HA1 (°) is similar to HB (°) By setting the angle of (2), it is possible to suppress compressive deformation when torsional torque is applied to the helical winding A2 layer. The winding angle HA 1 (°) of the helical winding A 1 layer is preferably 6 to 28 °, more preferably 8 to 26 °, and still more preferably 10 to 25 ° with respect to the rotation axis 11 of the main cylinder 1.

  As a matrix resin which comprises the main body cylinder 1 of this invention, a thermosetting epoxy resin can be used. As an epoxy resin, for example, bisphenol A type epoxy resin, phenol novolac type epoxy resin, cresol novolac type epoxy resin, glycidyl amine type epoxy resin, alicyclic epoxy resin, urethane modified epoxy resin, brominated bisphenol A type epoxy resin, etc. Can be used. These epoxy resins can be used alone or in combination of two or more, and can be used from liquid to solid.

  Further, in the present invention, it is preferable to use an epoxy-based thermosetting resin having a glass transition temperature of 185 to 230 ° C. as a matrix resin for forming the hoop winding layer 3.

  The heat resistance of the main cylinder 1 can be secured by using the matrix resin of the epoxy thermosetting resin having the glass transition point. Further, although the matrix resin having high heat resistance tends to be brittle, the inner peripheral surface side of the main body cylinder 1 which is a free end is expanded to the rotary shaft 11 by thermal expansion during curing by arranging the crack preventing layer 4 inside. The expansion of the hoop winding layer 3 in the rotational axis direction 11 can be suppressed and the cracks of the hoop winding layer 3 can be suppressed by playing a role of a protective wall against a crack at the time of cracking.

  If the glass transition point is less than 185 ° C., a problem may occur in the heat resistance of the main cylinder 1. If the glass transition temperature exceeds 230 ° C., the main cylinder 1 may become brittle and the torsional strength may decrease, and it may be difficult to suppress the occurrence of cracks due to thermal expansion during hardening. The glass transition point is preferably 188 to 225 ° C, more preferably 190 to 220 ° C, and still more preferably 195 to 215 ° C.

  In the present invention, the matrix resin is preferably such that the alicyclic epoxy resin is contained in an amount of 25 parts by weight or more and 100 parts by weight or less with respect to 100 parts by weight of the epoxy main agent. The use of a brittle epoxy as a matrix resin, which is relatively inexpensive as a cycloaliphatic epoxy, ensures constant heat resistance, and improves heat resistance while suppressing cracks without lowering product cost competitiveness. Can be obtained, and the torsional strength and bending rigidity can be improved.

  In the present invention, the matrix resin used for the layer in which the reinforcing fiber is wound may be changed for each winding layer or may be the same.

  In the present invention, the main body cylinder 1 may adopt other fibers generally called high elasticity and high strength such as carbon fiber, aramid fiber, glass fiber, etc. as reinforcing fibers, and these fibers may be used in combination. Good. Among these, carbon fibers are preferable in consideration of the rigidity required for the propeller shaft. The fibers used for the hoop winding layer and the helical winding layer may be the same or may be changed for each layer.

  As the crack prevention layer 4, as described above, a glass non-woven fabric, a cloth made of reinforcing fibers, or a heat-resistant resin film is preferable. Alternatively, it is also preferable to use a helical wound B layer in which the reinforcing fiber is wound at a winding angle of 5 to 30 ° with respect to the rotation axis direction. It is desirable to wind a glass non-woven fabric, a cloth made of reinforcing fibers or a heat-resistant resin film around a mandrel before molding. A method of winding on a mandrel is a method of affixing a non-woven fabric cut to a required length with a tape to a mandrel or impregnating a non-woven fabric with a resin used for molding using a roller and then attaching a non-woven fabric etc. to a mandrel There is. When the crack prevention layer 4 is a reinforcing fiber, it may be wound around the mandrel by the filament winding method described later as with the hoop winding layer 3 and the helical winding A layer 2. The hoop winding layer 3 and the helical winding A layer 2 are preferably formed by a filament winding method. That is, a carbon fiber bundle impregnated with a matrix resin such as an epoxy resin is supplied through a yarn feeding nozzle, crushed by a roller or the like to form a predetermined opening width, the resin on the outer periphery of the crack preventing layer 4 described above. The impregnated carbon fiber bundles are wound in layers. At this time, it is preferable that the both side ends of the hoop winding layer 3 be thickly wound in order to form a thick portion. When the helical winding A layer is formed after the hoop winding layer 3 is finished, the resin-impregnated carbon fiber bundle is wound around the entire length of the mandrel, and the main body cylinder 1 is heated and cured. It is formed.

  EXAMPLES The integrated molded article of the present invention and the method for producing the same will be specifically described below by examples, but the following examples do not limit the present invention in any way.

(1) Checking Method for Occurrence of Cracks Both ends of the obtained main cylinder 1 are cut in the axial direction, and the cut surfaces are polished with abrasive paper # 400, # 800, # 1200 (made by Refinetec), and then a microscope It observed by (VHX-1000 made from Keyence Co., Ltd.).

(2) Measurement Method of Glass Transition Point After about 20 mg of a test piece is cut out from the main cylinder 1 manufactured in (1) using a diamond cutter, using Diamond DSC (manufactured by Perkin Elmer Japan)), The glass transition point was measured based on the differential scanning calorimetry of JIS K 7121 (2012 version). The temperature was maintained at 20 ° C. for 5 minutes, and then the temperature was raised to 300 ° C. at a rate of 40 ° C./minute.

(3) Evaluation Test Method of Torsional Strength The obtained propeller shaft torsion evaluation test was measured by a torsion evaluation tester 20 shown in FIG. 8 provided with a torque detector 21 and a torque load device 22.

  The propeller shaft 24 with the joints 23 joined at both ends was fixed to the fixing portion flange portion 25 of the torsion evaluation tester 20. At this time, a torque load is applied to the propeller shaft 24 by a hydraulic rotary drive provided on one movable portion flange 26. An angle meter was provided on the rotating part, and the displacement amount was also measured. The other fixed part flange 25 was fixed to the tester base, and the torque at the time of breakage was detected from the load cell connected to the movable part flange 26, and the torque vs. angle diagram was displayed to read the torque at the time of destruction. The torsion evaluation test was performed after heating the propeller shaft at 170 ° C. for 1 hour in a thermostat.

Example 1
A main cylinder precursor of a three-layer structure as shown in FIG. 1 was produced by the following procedure. As a crack prevention layer 4, a glass non-woven fabric (Olivest Co., Ltd., AUO-90) was wound once around both ends of the mandrel, and then the resin was impregnated by hand lay-up. The area | region which wound the glass nonwoven fabric was 150 mm in length from the edge part of the main body cylinder 1, and the layer thickness was 0.5 mm.

  Three glass fiber non-woven carbon fiber bundles (Toray Industries, Inc. “TORAYCA” (registered trademark) T700SC-50C, 24000 filaments), which are reinforcing fibers, are aligned to obtain a total of three carbon fiber bundles immediately before the mandrel. After adjusting the tension to 15 kg, the carbon fiber bundle was impregnated with the matrix resin. The matrix resin includes a curing agent (MHAC-P, manufactured by Hitachi Chemical Co., Ltd.), a curing accelerator ("Cuazole" (registered trademark) 2E4MZ, manufactured by Shikoku Kasei Kogyo Co., Ltd.), and an epoxy main agent (bisphenol A type epoxy) 106.7: 2: 100 of resin (Mitsubishi Chemical Corporation, jER 827) and alicyclic epoxy resin (Huntsman Japan Co., Ltd., CY 179) mixed at a weight ratio of 50: 50) What was prepared by weight ratio was used. The carbon fiber bundle impregnated with the matrix resin was wound over the entire length of the mandrel at a winding angle of 85 ° with respect to the axial direction of the mandrel to obtain a hoop wound layer 3. The layer thickness of the hoop winding layer 3 was 0.2 mm. Furthermore, the hoop winding layer 3 was laminated at a winding angle of 85 ° with respect to the axial direction of the mandrel in a region 150 mm from the end of the main body cylinder 1. The layer thickness of the entire hoop wound layer 3 was 2.5 mm.

  Furthermore, on the hoop winding layer 3, a carbon fiber bundle impregnated with the above-mentioned matrix resin is laminated with the helical winding A layer 2 over the entire length of the main cylinder 1 at an angle of 45 ° to the axial direction of the mandrel. did. The layer thickness of the helical winding A layer 2 was 3.5 mm.

  Subsequently, the obtained main cylinder precursor is charged into a heating furnace, and the matrix resin is cured under temperature conditions of 100 ° C., 2 hours and 180 ° C., 4.5 hours, and after curing is completed, the mandrel is removed. (Cored). After core removal, both ends were cut off to obtain a main tube 1 having a length of 1000 mm. In addition, as shown in FIG. 6, a metal joint 8 in which serrations were provided in advance in the joint portion 9 was press-fitted to both ends of the main cylinder 1 to obtain the propeller shaft 24. The glass transition temperature of the obtained main cylinder was 200 ° C.

  Table 1 shows the constitution and material of each layer of the lamination, and the characteristics of each layer.

  In Example 1, generation of cracks was not observed in the hoop winding layer 3 of the main body cylinder 1 before press-fitting the metal joint 8. Further, in the torsion evaluation test, the cylinder was broken at the center of the main cylinder 1, and the breaking torque at this time was 6000 Nm, which was a level that causes no problem in practical use.

(Example 2)
A carbon fiber bundle impregnated with a matrix resin while impregnating the same carbon fiber bundle as in Example 1 on the mandrel as the anti-crack layer 2 with respect to the axial direction of the mandrel is prepared. The helical winding B layer was formed by winding over a length corresponding to the entire length of the main body cylinder 1 at a winding angle of °. The layer thickness of the helical winding B layer was 0.6 mm.

  The hoop winding layer 3 was wound on the helical winding B layer in the same manner as in Example 1 except that the winding angle was 88 ° with respect to the axial direction of the mandrel.

  Furthermore, helical wound A layer 2 was laminated on hoop wound layer 3 in the same manner as in Example 1 except that the impregnated carbon fiber bundle was formed at an angle of 10 ° with respect to the axial direction of the mandrel.

  Subsequently, in the same manner as in Example 1, a propeller shaft in which the metal joint 8 was press-fit into the main body cylinder 1 was obtained.

  In Example 2, occurrence of cracks was not observed in the hoop wound layer 3 of the main body cylinder 1 before the press-fitting of the metal joint 8. Further, in the torsion evaluation test, the cylinder was broken at the center of the main cylinder 1, and the breaking torque at this time was 5000 Nm, which was a level that causes no problem in practical use.

(Example 3)
As the crack prevention layer 2, a helical wound B layer was formed by laminating reinforcing fibers at a winding angle of 10 °. The helical winding B layer is formed over the entire length of the main body cylinder 1 under the same conditions as in Example 2 except that the layer thickness is 1.2 mm. Thereafter, under the same conditions as in Example 1, the hoop winding layer 3 and the helical winding A layer 2 were formed.

  Thereafter, in the same manner as in Example 2, a propeller shaft in which the metal joint 8 was press-fitted into the main body cylinder 1 was obtained.

  In Example 3, the occurrence of cracks was not observed in the hoop winding layer 3 of the main body cylinder 1 before the press fitting of the metal joint 8. Further, in the torsion evaluation test, the cylinder was broken at the center of the main cylinder 1, and the breaking torque at this time was 7800 Nm, which was a level that causes no problem in practical use.

(Example 4)
As a crack prevention layer 2, a helical winding B layer was wound at an angle of 10 °, and a layer thickness of 0.6 mm was laminated over the entire length of the main cylinder 1. Thereafter, the hoop winding layer 3 was formed in the same manner as in Example 2.

  Then, after forming a helical winding A2 layer having a winding angle of 45 ° and a layer thickness of 3.5 mm, the winding angle of the reinforcing fiber is 10 ° and a layer thickness is 0.6 mm outside the layer. The helical winding A1 layer was formed to be a two-layer helical winding A layer. Then, in the same manner as in Example 2, a propeller shaft in which the metal joint 8 was press-fit into the main body cylinder 1 was obtained.

  In Example 4, generation of cracks was not observed in the hoop wound layer 3 of the main body cylinder 1 before the press-fitting of the metal joint 8. Further, in the torsion evaluation test, the cylinder was broken at the center of the main cylinder 1, and the breaking torque at this time was 8400 Nm, which was a level that causes no problem in practical use.

(Example 5)
A helical winding B layer was formed as the crack preventing layer 2, and the laminate structure of the hoop winding layer 3 was manufactured in the same manner as in Example 2 except for the following. As the crack preventing layer 2, the winding angle of the reinforcing fiber of the helical winding B layer was 26 °, and the helical winding B layer was laminated over the entire length of the main cylinder 1. At this time, the layer thickness of the helical winding B layer was 1.2 mm.

  The hoop winding layer 3 was obtained in the same manner as in Example 2 except that the winding angle of the reinforcing fiber was set to 74 °, to obtain a propeller shaft in which the metal joint 8 was press-fit into the main body cylinder 1.

  In Example 5, the occurrence of cracks was not observed in the hoop winding layer 3 of the main body cylinder 1 before the press fitting of the metal joint 8. Further, in the torsion evaluation test, the cylinder was broken at the center of the main cylinder 1, and the breaking torque at this time was 8500 Nm, which was a level that causes no problem in practical use.

(Example 6)
A propeller shaft was obtained in the same manner as Example 1, except that a plain woven fabric (AS400S) made of reinforced fibers impregnated with a matrix resin was used as the crack prevention layer 2 and the thickness was 1 mm.

  In Example 6, generation of cracks was not observed in the hoop winding layer 3 of the main body cylinder 1 before press-fitting the metal joint 8. Further, in the torsion evaluation test, the cylinder was broken at the center of the main cylinder 1, and the breaking torque at this time was 6200 Nm, which was a level that causes no problem in practical use.

(Example 7)
A heat resistant resin film made of polyethylene terephthalate resin ("Lumirror" (registered trademark) product number S10 made of Toray Industries, Inc.) is used as the crack prevention layer 2, and the thickness is set to 0.25 mm except for Example 1 and The propeller shaft was obtained in the same manner.

  In Example 7, occurrence of cracks was not observed in the hoop winding layer 3 of the main body cylinder 1 before the press-fitting of the metal joint 8. Further, in the torsion evaluation test, the cylinder was broken at the center of the main cylinder 1, and the breaking torque at this time was 7400 Nm, which was a level that causes no problem in practical use.

(Example 8)
As a matrix resin, a curing agent (manufactured by Hitachi Chemical Co., Ltd., MHAC-P), a hardening accelerator (manufactured by Shikoku Kasei Kogyo Co., Ltd., "Cuazole" (registered trademark) 2E4MZ), and an epoxy main agent (alicyclic epoxy) A main cylinder 1 was obtained in the same manner as in Example 1 except that a mixture of a resin (Huntsman Japan KK, CY179 only) and a weight ratio of 106.7: 2: 100 was used.

  In Example 8, the glass transition temperature of the obtained main body cylinder of the main body cylinder 1 before press-fitting of the metal joint 8 was 230 ° C. Further, in the torsion evaluation test, the cylinder was broken at the center of the main cylinder 1, and the breaking torque at this time was 7600 Nm, which was a level that causes no problem in practical use.

(Example 9)
As a matrix resin, a curing agent (MHAC-P, manufactured by Hitachi Chemical Co., Ltd.), a curing accelerator ("Cuazole" (registered trademark) 2E4MZ, manufactured by Shikoku Kasei Kogyo Co., Ltd.), and an epoxy main agent (bisphenol A type epoxy) 106.7: 2: 100 of resin (Mitsubishi Chemical Corporation, jER 827) and alicyclic epoxy resin (Huntsman Japan Co., Ltd., CY 179) mixed at a weight ratio of 75:25) A main cylinder 1 was obtained in the same manner as in Example 1 except that one prepared at a weight ratio was used.

  In Example 9, the glass transition temperature of the obtained main body cylinder of the main body cylinder 1 before press-fitting of the metal joint 8 was 185 ° C. Further, in the torsion evaluation test, the cylinder was broken at the center of the main cylinder 1, and the breaking torque at this time was 6500 Nm, which was a level that causes no problem in practical use.

(Comparative example 1)
A main cylinder 1 was obtained in the same manner as in Example 1 except that the anti-crack layer 2 which was a glass non-woven fabric was not used. In Comparative Example 1, generation of cracks was observed in the hoop winding layer of the main body cylinder 1 before the press-fitting of the metal joint 8, which was at a level at which problems in practical use.

  The propeller shaft of the present invention can be effectively used not only as a propeller shaft for a motor vehicle, but also as a torque transmission shaft for manufacturing machines for other power transmission and transport machines.

DESCRIPTION OF SYMBOLS 1 main body cylinder 2 helical winding A layer 2a helical winding A1 layer 2b helical winding A2 layer 3 hoop winding layer 4 crack prevention layer 5 reinforcement part 8 metal joint 9 joint part 11 rotating shaft 12, 13 reinforcing fiber 14, 15 angular difference 20 twist Evaluation tester 21 Torque detector 22 Torque load device 23 Joint 24 Propeller shaft 25 Fixed part flange part 26 Movable part flange

Claims (9)

A propeller shaft having a fiber reinforced plastic main body cylinder, wherein the main body cylinder has a helical winding A layer on which reinforcing fibers are wound in order from at least the outermost layer, 70 to 70 in the extending direction of the rotation axis of the main body cylinder. A hoop winding layer is formed by winding reinforcing fibers at a winding angle of 90 °, and a reinforced portion obtained by thickening the hoop winding layer is formed on at least one end of the main body cylinder, and the innermost layer of the reinforcing portion Is provided with a crack preventing layer which is a helical wound B layer in which reinforcing fibers are wound at a winding angle HB (°) of 5 to 30 ° with respect to the extending direction of the rotation shaft. . The propeller shaft according to claim 1, wherein a thickness ratio of the anti-crack layer to the hoop wound layer in the reinforcing portion is in the range of 1: 2 to 1:20. The propeller shaft according to claim 1 or 2 , wherein an angle difference between a winding angle HB (°) of the helical winding B layer and a winding angle HP (°) of the hoop winding layer is 40 to 85 °. The propeller shaft according to any one of claims 1 to 3 , wherein a winding angle HA (°) of the helical winding A layer is 5 to 45 °. The propeller shaft according to any one of claims 1 to 4 , wherein a winding angle HA (°) of the helical winding A layer and a winding angle HB (°) of the helical winding B layer have the following relationship.
HB (°) <HA (°) When the helical winding A layer is composed of helical winding layers A1 and A2 in order from the outermost layer, and the helical winding layers A1 and A2 have respective winding angles of HA1 (°) and HA2 (°) The propeller shaft according to any one of claims 1 to 5, having a relationship of a winding angle HB (°) of the helical winding B layer and the following equation.
HA1 (°) ≦ HB (°) <HA2 (°) The propeller shaft according to any one of claims 1 to 6 , wherein an epoxy-based thermosetting resin having a glass transition point of at least 185 ° C to 230 ° C is contained as a matrix resin used for the hoop wound layer. 8. The propeller shaft according to claim 7 , wherein the matrix resin comprises 25 to 100 parts by weight of an alicyclic epoxy resin with respect to 100 parts by weight of an epoxy main agent. Propeller shaft according to claim 7 or 8 matrix resin used for the layer wound around the reinforcing fibers are of the same resin.

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