JP6682320B2 - Fiber-reinforced resin hollow body support structure - Google Patents

Description

  The present invention relates to a support structure (load transmission structure) for a fiber-reinforced resin hollow body.

  A fiber-reinforced resin hollow body containing a thermosetting resin is used in various fields such as a fluid transportation field, a construction field, and an automobile field. The fiber-reinforced resin hollow body is expected as a material to replace a metal material in the future, especially in the field of automobiles.

  As such a fiber-reinforced resin hollow body, Patent Document 1 discloses a reinforcement (rectangular pipe) for mounting automobile accessories. Conventionally, such a hollow body has an end portion support structure that is connected to the side frame of the vehicle body at both axial end portions thereof, and is directly supported by a support member between both axial end portions of the hollow body. It has an intermediate support structure.

Japanese Unexamined Patent Publication No. 8-282333

  The inventors of the present invention have found that when a load is applied to a fiber-reinforced resin hollow body having a rectangular vertical cross-section with respect to the axial direction at the time of a collision, the hollow body is relatively supported by a support member in an intermediate support structure. I found that it was destroyed early. Specifically, for example, as shown in a schematic cross-sectional view perpendicular to the axial direction in FIG. 16A, when a load F is applied to the hollow body 110 at the time of a collision, the hollow body is supported by the support member 111. It was crushed relatively early in the supporting part. Therefore, even if the hollow body 110 is supported via the steel flat plate 112 as shown in FIGS. 16 (A) and 16 (B) in order to relieve the pressure by the support member 111, the hollow structure 110 still has the hollow structure. The body could not exhibit sufficiently high strength under compressive load. FIG. 16 (A) is a schematic view showing a conventional supporting structure of the hollow body in a cross section perpendicular to the axial direction of the fiber-reinforced resin hollow body, and FIG. 16 (B) shows the supporting structure of (A) in the direction D ′. FIG.

  It is an object of the present invention to provide a support structure for a fiber-reinforced resin hollow body in which the fiber-reinforced resin hollow body exhibits sufficiently high strength.

The present invention
A fiber-reinforced resin hollow body having a rectangular cross-section perpendicular to the axial direction, an enveloping member surrounding three outer peripheral surfaces continuous in the circumferential direction of the hollow body, and a side of the enveloping member opposite to the fiber-reinforced resin hollow body side. The present invention relates to a support structure for a fiber-reinforced resin hollow body having a support member arranged in

  According to the support structure for a hollow fiber-reinforced resin body of the present invention, the hollow fiber-reinforced resin body can exhibit a sufficiently high strength particularly against a compressive load.

(A) is a schematic cross-sectional view showing an example of the support structure of the fiber-reinforced resin hollow body of the present invention in a cross section perpendicular to the axial direction of the fiber-reinforced resin hollow body, and (B) shows the support structure of (A) in the direction D. It is an outline sketch when it sees at. (A) is a schematic cross-sectional view showing an example of the support structure of the fiber-reinforced resin hollow body of the present invention in a cross section perpendicular to the axial direction of the fiber-reinforced resin hollow body, and (B) shows the support structure of (A) in the direction D. It is an outline sketch when it sees at. (A) is a schematic cross-sectional view showing an example of the support structure of the fiber-reinforced resin hollow body of the present invention in a cross section perpendicular to the axial direction of the fiber-reinforced resin hollow body, and (B) shows the support structure of (A) in the direction D. It is an outline sketch when it sees at. (A) is a schematic cross-sectional view showing an example of the support structure of the fiber-reinforced resin hollow body of the present invention in a cross section perpendicular to the axial direction of the fiber-reinforced resin hollow body, and (B) shows the support structure of (A) in the direction D. It is an outline sketch when it sees at. FIG. 3 is a schematic cross-sectional schematic view perpendicular to the axial direction in an example of a hollow body that can be used in the support structure for a fiber-reinforced resin hollow body of the present invention. FIG. 3 is a schematic cross-sectional schematic view perpendicular to the axial direction in an example of a hollow body that can be used in the support structure for a fiber-reinforced resin hollow body of the present invention. FIG. 3 is a schematic cross-sectional schematic view perpendicular to the axial direction in an example of a hollow body that can be used in the support structure for a fiber-reinforced resin hollow body of the present invention. FIG. 3 is a schematic cross-sectional schematic view perpendicular to the axial direction in an example of a hollow body that can be used in the support structure for a fiber-reinforced resin hollow body of the present invention. The schematic block diagram of an example of the manufacturing apparatus by the pultrusion molding method for manufacturing the hollow body which can be used in the support structure of the fiber-reinforced resin hollow body of the present invention is shown. The schematic sketch when an example of the support structure of the fiber reinforced resin hollow body of this invention is applied to the support structure for supporting the cross car beam of an automobile by a peripheral member is shown. An enlarged schematic sketch when an example of the support structure of the fiber-reinforced resin hollow body of the present invention is applied to a support structure for supporting a cross car beam of an automobile by a cowl bracket is shown. An enlarged schematic sketch when an example of the support structure of the hollow fiber-reinforced resin body of the present invention is applied to a support structure for supporting a cross car beam of an automobile by a brake pedal backward movement preventing bracket is shown. (A) is a schematic configuration diagram for explaining a method for measuring the strength of the hollow body by applying a load to the fiber-reinforced resin hollow body through the surrounding member in the support structure of the present invention, (B) FIG. 4A is a schematic cross-sectional view taken along the line BB of FIG. 7A showing the relationship between the surrounding member (U-shaped jig) and the fiber-reinforced resin hollow body, and (C) is a U-shaped cradle and fiber-reinforced resin hollow. It is a CC sectional schematic diagram of (A) showing a relation with a body. It is a schematic block diagram for demonstrating the method of measuring the intensity | strength of the said hollow body by applying a load to a fiber reinforced resin hollow body via a flat plate in the support structure of a prior art, and corresponds to FIG. 13 (B). It is a figure. It is a deflection amount-load graph showing the results of a three-point bending test in Examples and Comparative Examples. (A) is a schematic cross-sectional view showing an example of a conventional support structure of a fiber-reinforced resin hollow body in a cross section perpendicular to the axial direction of the fiber-reinforced resin hollow body, and (B) is a support structure of (A) in a direction D ′. It is an outline sketch when it sees at.

  The supporting structure of the fiber-reinforced resin hollow body of the present invention (hereinafter sometimes simply referred to as "hollow body") will be described in detail with reference to FIGS. It should be noted that the various elements shown in the drawings are merely schematic for understanding of the present invention, and dimensional ratios, appearances, and the like may be different from actual ones. The left-right direction and the up-down direction used directly or indirectly in the present specification correspond to the left-right direction and the up-down direction in the drawing, respectively. Further, unless otherwise specified, in these drawings, common reference numerals indicate the same members, parts, dimensions or regions.

[Support structure for hollow fiber-reinforced resin]
The hollow body support structure of the present invention surrounds, for example, as shown in FIG. 1A, a rectangular hollow body 10 which will be described in detail later, and three outer peripheral surfaces continuous in the circumferential direction of the hollow body 10. It has the surrounding member 11 and the supporting member 12 arranged on the opposite side of the surrounding member 11 from the fiber-reinforced resin hollow body side. In such a support structure, since the load is transmitted through the surrounding member 11, the hollow body 10 can exhibit sufficiently high strength. Without the enclosure, the hollow body is relatively easy to break. Such intervening effect of the surrounding member is an effect peculiar to the fiber-reinforced resin hollow body. That is, when the hollow body is simply made of polymer or metal, the strength of the hollow body does not change much between when the surrounding member is used and when it is not used. However, when the hollow body is made of fiber reinforced resin, the effect of significantly increasing the strength of the hollow body when the surrounding member is used (for example, an effect of about 1.5 times increase) is obtained as compared with the case where the surrounding member is not used. Indicates. FIG. 1 (A) is a schematic cross-sectional view showing an example of the hollow body support structure of the present invention in a vertical cross section (hereinafter, may be simply referred to as “vertical cross section”) with respect to the axial direction of the hollow body, 8A is a schematic sketch of the support structure of FIG. In the present specification, the longitudinal direction of the hollow body is simply referred to as "axial direction". The circumferential direction of the hollow body means the circumferential direction in a cross section perpendicular to the axial direction of the hollow body.

  The surrounding member 11 usually includes a flat plate-shaped central portion 11a and side end portions 11b and 11c which are erected from both ends of the central portion, and has a so-called U shape (U shape) in a vertical cross section. . The central portion 11a and the side end portions 11b and 11c are usually integrally formed as the same member, but may be formed by connecting those formed as separate members.

  The surrounding member 11 surrounds three continuous outer peripheral surfaces of the hollow body 10 in a part of the hollow body 10 in the axial direction, and more specifically, on the inner side surfaces of the flat plate-shaped central portion 11a and the side end portions 11b and 11c of the surrounding member 11. It is in contact with the three outer peripheral surfaces of the hollow body. Of the four outer peripheral surfaces of the hollow body 10 in the circumferential direction, the surface in contact with the central portion 11a of the surrounding member 11 is called a load transmitting surface 10p, and the surface in contact with the side end portions 11b, 11c of the surrounding member 11. Are referred to as outer peripheral side surfaces 10q and 10r, and a surface not surrounded by the surrounding member 11 is referred to as a non-enclosed surface 10s. The load transmitting surface 10p is a surface having the function of transmitting the load most out of the four outer peripheral surfaces of the hollow body 10 in the circumferential direction, and the hollow body 10 is directly attached to the supporting member as in the conventional case. This is a surface to which the supporting member is attached when the above is performed.

  The surrounding member 11 does not surround all the three outer peripheral surfaces 10p, 10q, and 10r of the hollow body 10, but may surround the three outer peripheral surfaces at a part in the axial direction of the hollow body. That is, the central portion 11a surrounds the entire length of the load transmitting surface 10p of the hollow body 10 in the circumferential direction d1 in a vertical cross section in a part of the hollow body axial direction. The side ends 11b and 11c surround at least a part of the circumferential length d2 of the outer peripheral side surfaces 10q and 10r of the hollow body 10 in a vertical cross section in a part of the hollow body axial direction. The surrounding member 11 may surround, for example, the portion of the hollow body 10 where the support member 12 is to be arranged.

  Specifically, for example, the axial length w (mm) (see FIG. 1B) of the region surrounded by the surrounding member 11 on the load transmitting surface 10p is such that the hollow body has sufficiently high strength due to the support structure. It is not particularly limited as long as it can exhibit a value of 0.5 × d1 to 2 × d1, and preferably 0.8 × d1 to 1.5 × d1. d1 is the circumferential length (mm) of the surface 10p. The circumferential length of the surrounding area of the load transmitting surface 10p by the surrounding member 11 is usually the total length of d1.

  Further, for example, the axial length of the area surrounded by the surrounding member 11 on the outer peripheral side surfaces 10q, 10r is usually the same value as the axial length w (mm) of the surrounded area on the load transmitting surface 10p. The circumferential lengths (enveloping depths) h1 and h2 of the enclosing area of the enclosing member 11 on the outer peripheral side surfaces 10q and 10r are not particularly limited as long as the hollow structure can exhibit sufficiently high strength due to the supporting structure, and are usually respectively Independently, it is 0.2 × d2-1 × d2, preferably 0.4 × d2-1 × d2. d2 is the circumferential length (mm) of the surfaces 10q and 10r (see FIG. 1A).

  The thickness of the surrounding member 11 is not particularly limited as long as the hollow structure can exhibit sufficiently high strength due to the support structure. In the surrounding member 11, the thickness t1 of the central portion 11a and the thicknesses t2 and t3 of the side end portions 11b and 11c are usually independently 1 × t or more, particularly 1 × t-10 × t, preferably 1.2. It is xt-5xt. t is the thickness (mm) of the hollow body 10.

  The surrounding member 11 may be made of any kind of material as long as the hollow structure can exhibit sufficiently high strength due to the supporting structure. Examples of the material forming the surrounding member 11 include metals such as steel, aluminum and magnesium, and polymers such as polycarbonate, polyimide, polyacrylate, polyester, polyolefin, polyamide, polyphenylene sulfide, FRP and FRTP.

  The enclosing member 11 and the hollow body 10 are usually fixed, but may be detachable without being fixed as long as the load can be transmitted. The fixing means for the surrounding member 11 and the hollow body 10 is not particularly limited, and any fixing means conventionally used for fixing the hollow body and the supporting member can be used. For example, fixing means using bolts or screws and fixing means using an adhesive can be mentioned.

  The support member 12 may or may not be fixed to the enveloping member 11 at one end and to another member at the other end. For example, when the support member 12 is fixed to another member at the other end, the hollow body 10 is supported by the support member 12 via the surrounding member 11. Further, for example, when the support member 12 is not fixed at the other end, the hollow body 10 supports the support member 12 via the surrounding member 11. In addition, as long as the load can be transmitted, the support member 12 does not necessarily have to be fixed to the enclosing member 11, and may be detachable from the enclosing member 11.

  The fixing means for fixing the surrounding member 11 at one end of the supporting member 12 and the fixing means for fixing another member at the other end of the supporting member 12 are not particularly limited as long as the load can be transmitted. A fixing means to the hollow body 10 can be used.

  The support member 12 may be made of any kind of material capable of transmitting a load. Examples of the material forming the supporting member 12 include the same materials as those forming the surrounding member 11.

  In the support structure of the present invention, the load is transmitted through the surrounding member 11. Specifically, the load is bidirectionally transmitted between the hollow body 10 and the support member 12 via the surrounding member 11.

  For example, in one embodiment, in FIG. 1A, when the load F1 is applied to the left side of the surrounding member 11 (that is, the hollow body 10 side) (for example, the non-surrounding surface 10s of the hollow body 10), from the left side, It is transmitted to the right side (support member 12 side) via the surrounding member 11. In this embodiment, the support member 12 and / or another member to which the support member 12 is fixed receives the load applied to the hollow body 10 side.

  Further, for example, in another embodiment, in FIG. 1 (A), when the load F2 is applied to the right side of the surrounding member 11 (the side of the supporting member 12), from the right side through the surrounding member 11 to the left side (hollow) It is transmitted to the body 10 side). In the present embodiment, the hollow body 10 receives the load applied to the support member 12 side.

  In any of the above embodiments, the support structure of the present invention sufficiently prevents breakage of the hollow body 10, and the hollow body 10 exhibits sufficiently high strength.

  In FIGS. 1A and 1B (hereinafter, these are collectively referred to as FIG. 1; the same applies to FIGS. 2 to 4), the surrounding member 11 and the support member 12 are formed as separate members. However, as shown in FIG. 2, they may be integrally formed as the same member made of the same material.

The support structure of FIG. 2 is the same as the support structure of FIG. 1 except the following matters.
(1.1) In FIG. 2, the surrounding member 11 and the supporting member 12 are integrally formed as the same member made of the same material;
(1.2) The shape of the support member 12 in FIG. 2 is different from that in FIG. 1; and (1.3) In FIG. 2, the support member 12 fixed to the surrounding member 11 at one end is It is not fixed to another member.

  In FIG. 2, the surrounding member 11 (the central portion 11a and the side end portions 11b and 11c) and the support member 12 may be integrally formed by members made of different materials.

  In FIG. 1 (A), the support member 12 forms a right angle with respect to the central portion 11a of the surrounding member 11, but as shown in FIG. 3 (A), an inclination angle θ may be formed.

The support structure of FIG. 3 is the same as the support structure of FIG. 1 except the following matters.
(2.1) In FIG. 3, the support member 12 forms an inclination angle θ with respect to the central portion 11a.

  In FIG. 3, the inclination angle θ may be an angle at which the load in the horizontal direction (direction perpendicular to the load transmission surface 10p of the hollow body 10) can be transmitted by the support member 12. The inclination angle θ is usually more than 0 ° and less than 180 °, and may be in particular 10 to 170 °.

  In FIG. 1A, the support member 12 has a symmetric shape, but as shown in FIG. 4A, the support member 12 may not have a symmetric shape.

The support structure of FIG. 4 is the same as the support structure of FIG. 1 except the following matters.
(3.1) In FIG. 4 (A), the supporting member 12 does not have a symmetrical shape; and (3.2) In FIG. 4, the surrounding member 11 (11a, 11b and 11c) and the supporting member 12 are separated from each other. They are integrally formed as the same member made of the same material.

[Fiber reinforced resin hollow body]
In the present invention, the hollow body 10 is an impregnated body of a curable resin having a long shape. The hollow body 10 is not particularly limited as long as it is a long shaped body having a hollow shape, which includes a fiber layer containing reinforcing fibers and a curable resin impregnated in the fiber layer and cured.

  The hollow body 10 has a square shape in the vertical cross section shown in FIG. 5 and the like, but is not limited to this as long as it has a rectangular shape. The rectangular shape is used as a concept including all square shapes such as a square shape and a rectangular shape. In automobile applications of hollow bodies, a rectangular shape, particularly a square shape is preferable from the viewpoint of easy attachment of various members.

(Fiber layer)
The fiber layer containing reinforcing fibers in the hollow body of the present invention preferably contains at least an axial fiber layer, and further comprises a non-axial fiber layer laminated on at least one of the inner side and the outer side of the axial fiber layer. It is more preferable to include. For example, the hollow body 10 of the present invention shown in FIG. 5 has an axial fiber layer 1 and non-axial fiber layers 2 and 3 on both inner and outer sides of the axial fiber layer 1, It is preferable to have a non-axial fiber layer on at least one of the inside and the outside of the fiber layer 1. From the viewpoint of the strength of the hollow body, the hollow body 10 preferably has a non-axial fiber layer on at least the inside of the axial fiber layer 1, and more preferably on both the inner and outer sides. In the present specification, the non-axial fiber layer laminated inside the axial fiber layer 1 may be referred to as “inner non-axial fiber layer” and is indicated by reference numeral “2” in FIG. The non-axial fiber layer laminated on the outer side of the axial fiber layer 1 may be referred to as an “outer non-axial fiber layer” and is indicated by reference numeral “3” in FIG.

  The axial fiber layer 1 is a fiber layer mainly containing reinforcing fibers oriented parallel to the axial direction (longitudinal direction) of the hollow body, and in the present invention, it is parallel to the axial direction of the hollow body. A fiber layer consisting only of oriented reinforcing fibers is preferred. Such a preferred axial fiber layer does not have to consist strictly of reinforcing fibers oriented parallel to the axial direction of the hollow body, but not less than 95% by weight of the reinforcing fibers included, preferably It is sufficient that 98% by weight or more is oriented substantially parallel to the axial direction of the hollow body. Here, “substantially parallel” means that a direction within a range of ± 10 ° with respect to the axial direction of the hollow body is also allowed.

  As the reinforcing fiber forming the axial fiber layer 1, any fiber conventionally used in the field of fiber reinforced plastic can be used, and examples thereof include glass fiber and carbon fiber. The preferred reinforcing fibers that make up the axial fiber layer 1 are glass fibers. The roving of the reinforcing fibers (a bundle of glass fibers) constituting the axial fiber layer may be in the range that usually achieves 500 to 5000 tex (g / 1 km). The axial fiber layer 1 does not prevent the inclusion of fibers other than the reinforcing fibers, but it is preferable that 95% by weight or more, and preferably 98% by weight or more of the fibers contained are the reinforcing fibers.

  Specifically, the axial fiber layer 1 may be, for example, a layer of roving (a bundle of glass fibers), and the number of glass fibers forming the axial fiber layer is uniform in the circumferential direction of the hollow body. Is preferred.

  The fiber amount of the axial fiber layer 1 may be determined according to the strength and dimensions required for the hollow body. For example, when the hollow body is used as a member for supporting and fixing an automobile instrument panel (square tubular member having a size of 3 to 10 cm x 3 to 10 cm), the axial fiber layer 1 per 1 m of the hollow body is The amount of fiber is usually 50 to 1000 g / m.

  The non-axial fiber layers 2 and 3 may be any fiber layer including reinforcing fibers having different orientations from the axial fiber layer 1. A different orientation direction from the axial fiber layer 1 means that the orientation direction of the reinforcing fibers contained in the non-axial fiber layer is not parallel to the orientation direction of the reinforcing fibers of the axial fiber layer 1. (For example, in the circumferential direction of the hollow body) or not limited to any particular direction (for example, random orientation). Note that the random orientation includes irregularly random orientation and regularly random orientation.

  As the reinforcing fibers forming the non-axial fiber layers 2 and 3, independently of each other, all fibers conventionally used in the field of fiber-reinforced plastic are used, like the reinforcing fibers forming the axial fiber layer 1. It is possible, and for example, glass fiber or carbon fiber is used. A preferred reinforcing fiber forming the non-axial fiber layers 2 and 3 is glass fiber. The diameter of the reinforcing fibers forming the non-axial fiber layers 2 and 3 is within the same range as the diameter of the reinforcing fibers of the axial fiber layers. Although the non-axial fiber layers 2 and 3 do not prevent the inclusion of fibers other than the reinforcing fibers, it is preferable that 95% by weight or more, and preferably 98% by weight or more of the contained fibers are reinforcing fibers.

The basis weights of the non-axial fiber layers 2 and 3 may be independently determined according to the strength and size required for the hollow body. For example, when the hollow body is used as a member for supporting and fixing an automobile instrument panel (square tubular member having a size of 3 to 10 cm x 3 to 10 cm), the non-axial fiber layers 2 and 3 of the hollow body are used. The areal weight is, independently of each other, usually 10 to 1000 g / m ² , and preferably 100 to 500 g / m ² .

  The weight ratio of the total reinforcing fibers of the axial fiber layer to the total reinforcing fibers of the non-axial fiber layer is usually 100: 20 to 100: 200, and preferably 100: 30 to 100: from the viewpoint of the strength of the hollow body. It is 150, and more preferably 100: 50 to 100: 120. The total reinforcing fibers of the non-axial fiber layer are all the reinforcing fibers of the inner non-axial fiber layer 2 and the outer non-axial fiber layer 3.

  The non-axial fiber layers 2, 3 are each independently selected from the group consisting of, for example, a circumferential fiber layer, a non-oriented fiber layer, a woven fiber layer, a braided fiber layer, and a knitted fiber layer. You may

  The circumferential fiber layer is a fiber layer containing reinforcing fibers oriented parallel to the circumferential direction of the hollow body, and in the present invention only the reinforcing fibers oriented parallel to the circumferential direction of the hollow body. The following fiber layers are preferred. Such a preferred circumferential fiber layer does not have to consist strictly of reinforcing fibers oriented parallel to the circumferential direction of the hollow body, but not less than 95% by weight of the reinforcing fibers included, preferably It is sufficient that 98% by weight or more is oriented substantially parallel to the circumferential direction of the hollow body. Here, “substantially parallel” means that a direction within a range of ± 10 ° with respect to the circumferential direction of the hollow body is also allowed.

  As a specific example of the circumferential fiber layer, for example, a so-called fold-like reinforcing fiber sheet is preferably used. The swelling reinforcing fiber sheet is a connecting yarn formed by arranging a plurality of reinforcing fiber bundles (for example, 8 to 120 reinforcing fibers / bundle of bundles) parallel to one direction (for example, the circumferential direction of the hollow body) at substantially equal intervals. Is a fiber sheet formed by binding all bundles in a direction perpendicular to the one direction while binding each bundle. The connecting yarn may be a yarn made of a thermoplastic polymer or a yarn made of reinforcing fibers. The roving of the reinforcing fibers constituting the circumferential fiber layer (a bundle of glass fibers) is usually in the range that achieves 100 to 1000 tex (g / 1 km).

  An unoriented fiber layer is a fiber layer containing reinforcing fibers that are not oriented in any particular direction (eg, reinforcing fibers that are randomly oriented randomly). Examples of the non-oriented fiber layer include a nonwoven fabric layer of reinforcing fibers and a nonwoven fabric layer containing circumferential fibers of reinforcing fibers.

  As the non-woven fabric layer, for example, a so-called chopped strand mat of reinforcing fibers is preferably used. The chopped strand mat of reinforcing fibers may be a non-woven fabric layer in which reinforcing fibers cut into fiber lengths of 6 to 66 mm are bonded with a binder resin. The chopped strand mat as the non-woven fabric layer of the non-woven fabric layer containing the circumferential fibers of the reinforcing fibers may be formed by randomly sewing cut reinforcing fibers to the above-mentioned fold-like reinforcing fiber sheet. The binder typically comprises a thermoplastic polymer.

  The circumferential fiber-containing nonwoven fabric layer is composed of a plurality of reinforcing fiber bundles (circumferential fiber bundles) (for example, 8 to 120 reinforcing fibers / bundle, which are oriented parallel to the circumferential direction of the hollow body with respect to the above-mentioned reinforcing fiber nonwoven fabric layer. It may be a composite fiber layer in which bundles are bonded at substantially equal intervals. The circumferential fiber-containing non-woven fabric layer may also be a composite fiber layer in which reinforcing fibers cut into fiber lengths of 6 to 66 mm are randomly sewn to the fold-like reinforcing fiber sheet to fix the same. As the circumferential fiber-containing non-woven fabric layer, for example, chopped strand mat sudare is preferably used. The chopped strand mat sudare is a composite mat in which reinforcing fibers cut into fiber lengths of 6 to 66 mm are randomly sewn to the above-mentioned swelling reinforcing fiber sheet. The sewing thread may be a thread made of a thermoplastic polymer or a thread made of reinforcing fibers. The weight ratio of the total reinforcing fibers of the nonwoven fabric layer to the total reinforcing fibers as the circumferential fibers is usually 100: 20 to 100: 200, and preferably 100: 30 to 100: 150 from the viewpoint of the strength of the hollow body. , And more preferably 100: 50 to 100: 120.

  The woven fiber layer may be any fiber layer containing reinforcing fibers constituting a woven structure, and examples of the woven structure include plain weave, twill weave, satin weave and double weave. The reinforcing fibers of the textile fiber layer are regularly and randomly oriented.

  The braided fiber layer may be any fiber layer including the reinforcing fibers that make up the braided structure. The reinforcing fibers of the braided fiber layer are regularly and randomly oriented.

  The knitted fiber layer may be any fiber layer containing reinforcing fibers constituting a knitted structure, and examples of the knitted structure include knitted knitting and the like. The reinforcing fibers of the knitted fiber layer are regularly and randomly oriented.

  In the present invention, it is preferable that the non-axial fiber layers overlap each other at their ends in the circumferential direction. That is, as shown in FIG. 5, in the vertical cross section of the hollow body, at the seam of the end portions of the non-axial fiber layers (2, 3), the other end portion rides on one end portion, It is preferable that the overlapping portions 4a and 4b be formed. The overlapping portion is continuously formed in the axial direction of the hollow body. As a result, the designability is improved and the hollow body can obtain much higher strength.

  Unlike the inner non-axial fiber layer 2 in FIG. 5, the non-axial fiber layer is not divided in the circumferential direction of the hollow body and overlaps each other at the end portions of the fiber layer itself so that the overlapping portion 4a is formed. It may be formed. In FIG. 5, the inner non-axial fiber layer 2 overlaps with each other at the ends of the fiber layer 2 itself to form one overlapping portion 4a in the circumferential direction.

  The non-axial fiber layer is also divided into two or more fiber layers in the circumferential direction of the hollow body like the outer non-axial fiber layer 3 in FIG. Alternatively, the overlapping portions 4b may be formed by overlapping the end portions with each other in the circumferential direction. In FIG. 5, the outer non-axial fiber layer 3 is divided into four fiber layers in the circumferential direction of the hollow body, and adjacent fiber layers of the four fiber layers overlap each other at their ends in the circumferential direction, A total of four overlapping portions 4b are formed in the circumferential direction.

  The position where the overlapping portion is formed is not particularly limited, but it is preferable that the non-axial fiber layers are overlapped at their end portions where stress is likely to be concentrated in the vertical cross-sectional shape of the hollow body, for example, near the corner portion.

  When the hollow body has a rectangular shape in the vertical cross section, from the viewpoint of further improving the strength of the hollow body, the non-axial fiber layers 3 are preferably overlapped at their end portions in the vicinity of the corners of the rectangular shape. This is because stress is likely to be concentrated at the corners in these shapes, and the strength is further improved by forming the overlapping portion near the corners. Therefore, from the same viewpoint, the non-axial fiber layer is formed into two or more fiber layers (particularly 2 to 4 fiber layers) in the circumferential direction of the hollow body, like the outer non-axial fiber layer 3 in FIG. It is preferable to divide in the vicinity of the corner. As a result, of the two or more (particularly 2 to 4) fiber layers, adjacent fiber layers overlap each other at their ends in the circumferential direction near the corners, and the overlapping portion 4b is formed near the corners. The vicinity of the corner means that the distance between the top of the corner and the overlapping portion is within 5 mm in the vertical cross section, and the distance is preferably 0 mm as in the overlapping portion 4b in FIG. 5, for example.

  The inner non-axial fiber layer 2, in particular, the non-axial fiber layer constituting the innermost surface of the hollow body, from the viewpoint of transport utilization of the hollow portion of the hollow body, without being divided in the circumferential direction of the hollow body, It is preferable that the ends of the fiber layer 2 themselves overlap each other.

  The overlapping width t of the overlapping portion in the vertical cross section is not particularly limited as long as the effect of the present invention can be obtained. For example, when the dimension of the hollow body is d, it is usually 0.01 × d to 0.5 × d. Yes, preferably 0.1 × d to 0.2 × d. The dimension d of the hollow body is the total outer peripheral length / 4 in the vertical cross section.

  In the present invention, from the viewpoint of further improving the strength of the hollow body, it is preferable that the overlapping portions be formed at all the end portions of the non-axial fiber layer, but at least at one position in the vertical cross section as described above. It is also preferable that the non-axial fiber layers overlap each other at the ends in the circumferential direction.

  In FIG. 5, the non-axial fiber layers 2 and 3 (the inner non-axial fiber layer 2 and the outer non-axial fiber layer 3) are each composed of one kind of fiber layer, but each of them is independent of each other. As shown, it may be composed of two or more kinds of fiber layers. That is, the non-axial fiber layers 2 and 3 are independently selected from the group consisting of, for example, the above-mentioned circumferential fiber layer, non-oriented fiber layer, woven fiber layer, braided fiber layer, and knitted fiber layer. You may include 2 or more types of fiber layers. In this case, the weight ratio of all the reinforcing fibers of the axial fiber layer and the total reinforcing fibers of all the non-axial fiber layers may be within the above range. In the hollow body of FIG. 6, the non-axial fiber layers of both the inner non-axial fiber layer 2 and the outer non-axial fiber layer 3 are composed of two or more kinds of fiber layers. Only the layer may be composed of two or more kinds of fiber layers.

  The hollow body 10a of FIG. 6 is the same as the hollow body of FIG. 5 unless otherwise specified. For example, the hollow body 10a of FIG. 6 is different from that of FIG. 5 except that both the inner non-axial fiber layers 2 and the outer non-axial fiber layers 3 are composed of two or more types of fiber layers. It is similar to the hollow body of. Specifically, the hollow body 10a shown in FIG. 6 has a rectangular vertical cross section, and includes the axial fiber layer 1, the first inner non-axial fiber layer 21a and the first inner non-axial fiber layer 21a laminated inside the axial fiber layer 1. It has two inner non-axial fiber layers 22a, and a first outer non-axial fiber layer 31a and a second outer non-axial fiber layer 32a laminated on the outside of the axial fiber layer 1. In FIG. 6, the axial fiber layer 1 is the same as the axial fiber layer 1 described above. The first inner non-axial fiber layer 21a, the second inner non-axial fiber layer 22a, the first outer non-axial fiber layer 31a and the second outer non-axial fiber layer 32a are independent of each other in the non-axial direction described above. It may be selected from the same range as the fiber layers 2 and 3.

  Even when the non-axial fiber layer includes two or more kinds of fiber layers, it is preferable that the overlapping portions are formed at all end portions of the non-axial fiber layer from the viewpoint of further improving the strength of the hollow body. However, it is also preferable that the non-axial fiber layers overlap each other at their ends in the circumferential direction at least at one position in the vertical cross section. In particular, when the non-axial fiber layer includes two or more kinds of fiber layers, it is preferable that the non-axial fiber layers overlap each other in the circumferential direction at at least one position in each fiber layer. Unless otherwise specified, the non-axial fiber layer has one kind of fiber layer, unless otherwise specified, the forming position of the overlapping portion in each fiber layer constituting the non-axial fiber layer, the overlapping width t, the form of division, and the vertical cross-sectional shape of the hollow body. It is the same as the above-mentioned case composed of.

  For example, the first inner non-axial fiber layer 21a, the first outer non-axial fiber layer 31a, and the second outer non-axial fiber layer 32a are preferably overlapped at their ends in the circumferential direction. From the viewpoint of further improving the strength, as shown in FIG. 6, it is more preferable that the hollow body is divided into four fiber layers near the corners in the circumferential direction. As a result, the first inner non-axial fiber layer 21a, the first outer non-axial fiber layer 31a, and the second outer non-axial fiber layer 32a each have adjacent four of the four fiber layers in the circumferential direction. In, the end portions overlap each other, and four overlapping portions 4b are formed near the corners. It is preferable that the innermost layers of the inner non-axial fiber layers, that is, the second inner non-axial fiber layers 22a also overlap each other at their ends in the circumferential direction, but from the viewpoint of transporting and utilizing the hollow part of the hollow body, FIG. As shown in, it is more preferable that the end portions of the fiber layer 22a themselves overlap each other without being divided in the circumferential direction of the hollow body.

  When the non-axial fiber layer includes two or more fiber layers, the non-axial fiber layer (at least one of the inner non-axial fiber layer 2 and the outer non-axial fiber layer 3, preferably both) has a hollow body strength. From the viewpoint of further improving the above, it is preferable to include one or more circumferential fiber layers and one or more non-oriented fiber layers. This is because the reinforcing fibers in the circumferential fiber layer adjacent to the non-oriented fiber layer are easily oriented parallel to the circumferential direction, and the strength of the hollow body is further improved. For example, as shown in FIG. 6, each of the non-axial fiber layers 2 and 3 preferably includes at least one circumferential fiber layer and at least one non-oriented fiber layer.

  When the non-axial fiber layer includes at least one circumferential fiber layer and at least one non-oriented fiber layer, the non-oriented fiber layer is preferably disposed on at least the outermost surface of the hollow body. At this time, it is more preferable that the non-oriented fiber layer on the outermost surface is adjacent to the circumferential fiber layer. The non-oriented fiber layer on the outermost surface mitigates the direct influence from the mold, and the reinforcing fibers in the circumferential fiber layer adjacent to the non-oriented fiber layer are more easily oriented in parallel to the circumferential direction. This is because the strength of the hollow body is further improved. The non-oriented fiber layer is arranged on at least the outermost surface of the hollow body means that the non-oriented fiber layer is arranged on the innermost surface of the hollow body in the inner non-axial fiber layer 2, or the outer non-axial fiber. It means that the layer 3 is arranged on the outermost surface of the hollow body. For example, as shown in FIG. 6, the first inner non-axial fiber layer 21a and the first outer non-axial fiber layer 31a are circumferential fiber layers, and the second inner non-axial fiber layer 22a and the second outer non-axial fiber layer 31a are circumferential fiber layers. The axial fiber layer 32a is preferably a non-oriented fiber layer, particularly a circumferential fiber-containing nonwoven fabric layer. Further, for example, in a preferred embodiment of FIG. 7 described later, the fourth inner non-axial fiber layer 24b is preferably a non-oriented fiber layer, particularly a circumferential fiber-containing nonwoven fabric layer. Further, for example, in a preferred embodiment of FIG. 8 described later, the fourth outer non-axial fiber layer 34c is preferably a non-oriented fiber layer, particularly a circumferential fiber-containing nonwoven fabric layer. The arrangement of the fiber layers in the hollow body is the arrangement on the assumption that the curable resin does not exist.

  In particular, when the circumferential fiber-containing nonwoven fabric layer is arranged on the outermost surface of the hollow body as the non-oriented fiber layer, it is more preferable that the nonwoven fabric layer of the circumferential fiber-containing nonwoven fabric layer is arranged on the outermost surface of the hollow body. That is, the circumferential fiber-containing nonwoven fabric layer is more preferably used in the inner non-axial fiber layer 2 such that the nonwoven fabric layer is arranged on the innermost surface of the hollow body, and in the outer non-axial fiber layer 3. Is more preferably used such that the non-woven fabric layer is arranged on the outermost surface of the hollow body. This is because the reinforcing fibers in the adjacent circumferential fiber layers are more easily oriented parallel to the circumferential direction, and the strength of the hollow body is further improved. For example, in FIG. 6, the circumferential fiber-containing nonwoven fabric layer as the second inner non-axial fiber layer 22a is preferably used so that the nonwoven fabric layer is arranged on the innermost surface of the hollow body. The circumferential fiber-containing nonwoven fabric layer as the second outer non-axial fiber layer 32a is preferably used such that the nonwoven fabric layer is arranged on the outermost surface of the hollow body. Further, for example, in a preferred embodiment of FIG. 7 described later, the circumferential fiber-containing nonwoven fabric layer as the fourth inner non-axial fiber layer 24b is used such that the nonwoven fabric layer is arranged on the innermost surface of the hollow body. It is preferable. Further, for example, in a preferred embodiment of FIG. 8 described later, the circumferential fiber-containing nonwoven fabric layer as the fourth outer non-axial fiber layer 34c is used such that the nonwoven fabric layer is arranged on the outermost surface of the hollow body. It is preferable.

When the circumferential fiber-containing non-woven fabric layer is arranged as a non-oriented fiber layer at a position other than the outermost surface of the hollow body, the circumferential fiber-containing non-woven fabric layer is used so that the non-woven fabric layer faces the axial fiber layer 1 side. Or may be used so as to face the side opposite to the axial fiber layer 1 side.
Two or more non-oriented fiber layers may be continuously arranged.

  When the non-axial fiber layer includes two or more circumferential fiber layers, the two or more circumferential fiber layers may be continuously arranged, or a non-oriented fiber layer is arranged between them. May be.

When the non-axial fiber layer includes one or more circumferential fiber layers and one or more non-oriented fiber layers, the weight ratio of all the reinforcing fibers of the axial fiber layer to all the reinforcing fibers of the circumferential fiber layer is usually 100. : 1 to 100: 100, preferably 100: 10 to 100: 100, more preferably 100: 20 to 100: 80, and further preferably 100: 30 to 100: 70 from the viewpoint of the strength of the hollow body. The total reinforcing fibers of the circumferential fiber layer are all the reinforcing fibers contained in all the circumferential fiber layers constituting the hollow body, and when the circumferential fiber-containing nonwoven fabric layer is used as the non-oriented fiber layer, the peripheral fibers are It also includes the reinforcing fibers constituting the circumferentially oriented fibers contained in the directional fiber-containing nonwoven fabric layer.
In the same case, the weight ratio of the total reinforcing fibers of the axial fiber layer to the total reinforcing fibers of the non-oriented fiber layer is usually 100: 10 to 100: 100, and preferably 100: 10 from the viewpoint of the strength of the hollow body. ˜100: 70, more preferably 100: 20 to 100: 50. All the reinforcing fibers of the non-oriented fiber layer is all the reinforcing fibers contained in all the non-oriented fiber layers constituting the hollow body, when using the circumferential fiber-containing nonwoven fabric layer as the non-oriented fiber layer, The reinforcing fibers forming the nonwoven fabric layer included in the circumferential fiber-containing nonwoven fabric layer are included, but the reinforcing fibers forming the circumferentially oriented fibers of the circumferential fiber containing nonwoven fabric layer are not included.

  Another embodiment in which the non-axial fiber layer comprises two or more fiber layers is shown in FIGS. 7 and 8. From the viewpoint of further improving the strength of the hollow body, the embodiment of FIG. 6 described above and the embodiment of FIG. 7 described later are preferable, and the embodiment of FIG. 6 is more preferable.

(Embodiment of FIG. 7)
A hollow body 10b shown in FIG. 7 has a rectangular vertical cross section, and has an axial fiber layer 1, a first inner non-axial fiber layer 21b laminated inside the axial fiber layer 1, and a second inner non-fiber. It has an axial fiber layer 22b, a third inner non-axial fiber layer 23b and a fourth inner non-axial fiber layer 24b. In FIG. 7, the axial fiber layer 1 is the same as the axial fiber layer 1 described above. The first inner non-axial fiber layer 21b, the second inner non-axial fiber layer 22b, the third inner non-axial fiber layer 23b and the fourth inner non-axial fiber layer 24b are independent of each other in the non-axial direction described above. It may be selected from the same range as the fiber layers 2 and 3.

In this embodiment, the second inner non-axial fiber layer 22b and the third inner non-axial fiber layer 23b are each, independently, preferably a circumferential fiber layer.
The first inner non-axial fiber layer 21b is not particularly limited and is, for example, a non-oriented fiber layer, particularly a circumferential fiber-containing nonwoven fabric layer.
The fourth inner non-axial fiber layer 24b is preferably a non-oriented fiber layer, especially a circumferential fiber containing nonwoven layer.
The circumferential fiber-containing non-woven fabric layer as the first inner non-axial fiber layer 21b may be used such that the non-woven fabric layer is in contact with the second inner non-axial fiber fabric layer 22b, or the non-woven fabric layer is axial fiber. It may be used to contact layer 1. The circumferential fiber-containing non-woven fabric layer as the fourth inner non-axial fiber layer 24b has a non-woven fabric layer on the innermost surface of the hollow body from the viewpoint of the orientation of the circumferential fiber layer as the third inner non-axial fiber layer 23b. It is preferably used as arranged.

  Also in this embodiment, the non-axial fiber layers may overlap at their ends in the circumferential direction at least at one location in the vertical cross section, but from the viewpoint of further improving the strength of the hollow body, the first inner non-axial direction. Each of the fiber layer 21b, the second inner non-axial fiber layer 22b, and the third inner non-axial fiber layer 23b is divided into four fiber layers near the corners in the circumferential direction of the hollow body, as shown in FIG. Preferably. As a result, the first inner non-axial fiber layer 21b, the second inner non-axial fiber layer 22b, and the third inner non-axial fiber layer 23b each have adjacent four of the four fiber layers in the circumferential direction. It is preferable that the end portions overlap each other and the four overlapping portions 4b are formed near the corners.

  In the present embodiment, from the viewpoint of transporting and utilizing the hollow portion of the hollow body, the fourth inner non-axial fiber layer 24b is not divided in the circumferential direction of the hollow body, and the end portions of the fiber layer 24b themselves are not separated from each other. It is preferable that they overlap each other.

(Embodiment of FIG. 8)
A hollow body 10c shown in FIG. 8 has a rectangular vertical cross section, and has an axial fiber layer 1, a first outer non-axial fiber layer 31c laminated on the outer side of the axial fiber layer 1, and a second outer non-fiber. It has an axial fiber layer 32c, a third outer non-axial fiber layer 33c and a fourth outer non-axial fiber layer 34c. In FIG. 8, the axial fiber layer 1 is the same as the axial fiber layer 1 described above. The first outer non-axial fiber layer 31c, the second outer non-axial fiber layer 32c, the third outer non-axial fiber layer 33c and the fourth outer non-axial fiber layer 34c are independent of each other in the non-axial direction described above. It may be selected from the same range as the fiber layers 2 and 3.

In the present embodiment, the second outer non-axial fiber layer 32c and the third outer non-axial fiber layer 33c are each independently preferably a circumferential fiber layer.
The first outer non-axial fiber layer 31c is, for example, a non-oriented fiber layer, particularly a circumferential fiber-containing nonwoven fabric layer.
The fourth outer non-axial fiber layer 34c is preferably a non-oriented fiber layer, especially a circumferential fiber containing nonwoven layer.
The circumferential fiber-containing non-woven fabric layer as the first outer non-axial fiber layer 31c may be used such that the non-woven fabric layer is in contact with the second outer non-axial fiber layer 32c, or the non-woven fabric layer is axial fiber. It may be used to contact layer 1. The circumferential fiber-containing non-woven fabric layer as the fourth outer non-axial fiber layer 34c has a non-woven fabric layer on the outermost surface of the hollow body from the viewpoint of the orientation of the circumferential fiber layer as the third outer non-axial fiber layer 33c. It is preferably used as arranged.

  Also in this embodiment, the non-axial fiber layers may overlap each other in the circumferential direction at at least one location in the vertical cross section, but from the viewpoint of further improving the strength of the hollow body, the first outer non-axial direction. Each of the fiber layer 31c, the second outer non-axial fiber layer 32c, the third outer non-axial fiber layer 33c and the fourth outer non-axial fiber layer 34c has a corner in the circumferential direction of the hollow body, as shown in FIG. It is preferably divided into four fiber layers near the part. As a result, the first outer non-axial fiber layer 31c, the second outer non-axial fiber layer 32c, the third outer non-axial fiber layer 33c, and the fourth outer non-axial fiber layer 34c each contain the four fibers. It is preferable that the adjacent fiber layers of the layers overlap each other at their end portions in the circumferential direction, and the four overlapping portions 4b are formed near the corners.

(Other materials)
The hollow body of the present invention contains the above-mentioned fiber layer and a curable resin impregnated in the fiber layer. As the curable resin, any curable resin conventionally used for hollow fiber-reinforced resin bodies can be used. Specific examples of the curable resin include thermosetting resins such as unsaturated polyester resin, epoxy resin, vinyl ester resin, and phenol resin.

  The curable resin is used by containing additives such as so-called catalysts, release agents, pigments, low-shrinking agents, silane coupling agents and the like.

(Size)
The hollow body of the present invention may have any thickness and may be appropriately determined depending on the application. The hollow body of the present invention has a thickness of, for example, 1 to 20 mm, particularly 1 to 10 mm, preferably 1 to 3 mm. The thickness of the hollow body means the thickness of the hollow body.

  The hollow body of the present invention may have any outer peripheral length and may be appropriately determined depending on the application. The hollow body of the present invention has an outer peripheral length of 125 to 300 mm, for example. The outer peripheral length of the hollow body is the outer peripheral length of the hollow body in a vertical cross section. The length of one side in the vertical cross-sectional shape of the hollow body is not particularly limited and is, for example, 45 to 75 mm.

[Method for producing fiber-reinforced resin hollow body]
The fiber-reinforced resin hollow body of the present invention can be manufactured by a pultrusion molding method. In the pultrusion molding method, as shown in detail in FIG. 9, first, the reinforcing fibers 51 forming the axial fiber layer 1 are impregnated with the curable resin 50. Next, the reinforcing fiber 51 impregnated with the curable resin is joined with the fiber sheet (fiber layer) 52 forming the inner non-axial fiber layer 2, and further joined with the fiber sheet 53 forming the outer non-axial fiber layer 3. Let The number of fiber sheets 52 may be appropriately adjusted according to the type and the number of divisions of the fiber layers forming the inner non-axial fiber layer 2. The number of the fiber sheets 53 may be appropriately adjusted according to the type and the number of divisions of the fiber layers forming the outer non-axial fiber layer 3. Then, while arranging these fibers and fiber sheets so as to have a predetermined layer configuration in a vertical cross section, the curable resin impregnated in the reinforcing fibers 51 is guided by the guide 54 and further the fiber sheet 52 and the fiber sheet. 53 is also impregnated and drawn from one end side of the mold 55. At this time, the fibrous sheets 52 and 53 are adjusted by the guide 54 so that the end portions overlap each other in the circumferential direction. In the mold 55, the curable resin is sufficiently cured by heating to obtain the fiber-reinforced resin hollow body 10. The fiber-reinforced resin hollow body 10 thus obtained is continuously taken from the die 55 by a take-up device 56 (for example, a double gripper system) and cut into a predetermined length by a cutting machine 57, for example, is post-processed.

[Use]
INDUSTRIAL APPLICABILITY The support structure of the fiber-reinforced resin hollow body of the present invention is useful in all fields in which the fiber-reinforced resin hollow body can be used, for example, fluid transportation field, construction field, automobile field and the like. INDUSTRIAL APPLICABILITY The support structure for a fiber-reinforced resin hollow body of the present invention is particularly useful as a support structure for a fiber-reinforced resin hollow body for directly or indirectly supporting and fixing an automobile instrument panel. As such a supporting structure, for example, a supporting structure of the cross car beam 100 as shown in FIG. FIG. 10 shows a schematic sketch of an example of a supporting structure for a hollow fiber-reinforced resin body of the present invention when applied to a supporting structure for supporting a cross car beam of an automobile by peripheral members.

  Examples of peripheral members that support the cross car beam include a cowl bracket 101, a brake pedal backward movement preventing bracket 102, and a center member 107 shown in FIG. 10.

  The cowl bracket 101 has a function of ensuring steering vibration performance and also a function of preventing the crosscar beam 100 from moving forward in the event of a collision. By applying the supporting structure of the present invention to the supporting structure of the cross car beam (hollow body) 100 and the cowl bracket (supporting member) 101 as shown in FIG. 11, the load is applied through the surrounding member 11x at the time of collision. Since it is transmitted, the crosscar beam 100 can exhibit a sufficiently high strength. FIG. 11 shows an enlarged schematic sketch of an example of the support structure for a hollow fiber-reinforced resin body of the present invention when applied to a support structure for supporting a cross car beam of an automobile by a cowl bracket.

  The brake pedal retreat prevention bracket 102 has a function of preventing the brake pedal from retreating in the event of a collision. As shown in FIG. 12, the support structure of the present invention is applied to a support structure of a cross car beam (hollow body) 100 and a brake pedal retraction prevention bracket (support member) 102, whereby the brake pedal retracts at the time of a collision. Thus, even if the drive unit 103 moves in the direction of the arrow and a load is applied to the bracket, the load is transmitted through the surrounding member 11y, so that the crosscar beam 100 can exhibit a sufficiently high strength. FIG. 12 is an enlarged schematic sketch of an example of the support structure for a hollow fiber-reinforced resin body of the present invention applied to a support structure for supporting a cross car beam of an automobile by a brake pedal backward movement preventing bracket.

  The center member 107 has a function of ensuring steering vibration performance, and also has a function of letting a load applied to an interior panel (not shown) to the crosscar beam 100 at the time of a collision. By applying the support structure of the present invention to the support structure of the cross car beam (hollow body) 100 and the center member (support member) 107, as shown in FIG. 12, the load at the time of collision is mediated by the surrounding member 11z. Since it is transmitted, the crosscar beam 100 can exhibit a sufficiently high strength.

[Fiber material]
(Roving layer A (axial fiber layer))
As the roving layer A, roving (a bundle of glass fibers) was used. In the roving layer A, the longitudinal direction of the roving is parallel to the axial direction of the fiber-reinforced resin hollow body, and the number of glass fibers constituting the roving layer is uniform in the circumferential direction of the fiber-reinforced resin hollow body. Used for.

(Sudare layer A (circumferential fiber layer))
As the dulling layer A, a so-called dulling glass fiber sheet (circumferential fiber layer) was used. Sudare-shaped glass fiber sheet has a plurality of rovings (a bundle of glass fibers) cut into a predetermined length as a width and arranged in parallel with each other at substantially equal intervals in the width direction. It is a fiber sheet that is connected in a direction perpendicular to the width direction. The slack layer A was used such that the width direction was parallel to the circumferential direction of the fiber-reinforced resin hollow body. The connecting yarn was a polyester yarn. The predetermined length is a length according to each Example or Comparative Example, for example, such a length that the fiber layer in the fiber-reinforced resin hollow body overlaps with the width described later at the end portions in the circumferential direction. is there.

(Composite layer A (non-oriented fiber layer))
As the composite layer A, a nonwoven fabric layer containing circumferential fibers was used. Specifically, the composite layer A is a composite layer in which cut reinforcing fibers are randomly sewn to the above-mentioned sloppy layer A. The composite layer A was used such that the width direction (the longitudinal direction of the roving of the circumferential fiber layer) was parallel to the circumferential direction of the fiber-reinforced resin hollow body. The sewing thread was polyester thread. Here again, the predetermined length is a length according to each Example or Comparative Example, and for example, in the fiber-reinforced resin hollow body, the fiber layers are overlapped with each other in the width described later at the end portions in the circumferential direction. Is the length.

[Example 1]
(Manufacture of fiber-reinforced resin hollow body)
A fiber-reinforced resin hollow body having a cross-sectional structure shown in FIG. 6 was manufactured by a pultrusion method. The fiber-reinforced resin hollow body 10a of FIG. 6 includes an axial fiber layer 1, a first inner non-axial fiber layer 21a and a second inner non-axial fiber layer 22a that are laminated inside the axial fiber layer 1, and It has a first outer non-axial fiber layer 31a and a second outer non-axial fiber layer 32a laminated on the outer side of the axial fiber layer 1. In this embodiment, the axial fiber layer 1 is composed of only the roving layer A, the first inner non-axial fiber layer 21a and the first outer non-axial fiber layer 31a are respectively composed of only the sloppy layer A, and the second inner non-axial fiber layer 21a. The directional fiber layer 22a and the second outer non-axial fiber layer 32a each consist of the composite layer A only. The composite layer A as the second inner non-axial fiber layer 22a was used in the front-back direction so that the nonwoven fabric layer of the composite layer A was arranged on the innermost surface of the hollow fiber-reinforced resin body. The composite layer A as the second outer non-axial fiber layer 32a was used in the front-back direction such that the nonwoven fabric layer of the composite layer A was arranged on the outermost surface of the fiber-reinforced resin hollow body.

Specifically, as shown in FIG. 9, the curable resin composition 50 was first impregnated into the roving layer A (reinforcing fiber 51) forming the axial fiber layer 1. Next, the reinforcing fiber 51 impregnated with the curable resin composition is provided with a sudare layer A (fiber sheet 52) forming the first inner non-axial fiber layer 21a and a composite layer forming the second inner non-axial fiber layer 22a. A (fiber sheet 52) is joined together, and further, a slack layer A (fiber sheet 53) that constitutes the first outer non-axial fiber layer 31a and a composite layer A (fiber sheet that constitutes the second outer non-axial fiber layer 32a. 53) was merged. The total number of fiber sheets 52 was five. The number of fiber sheets 53 was eight. After that, while arranging these fibers and fiber sheets so as to have a predetermined layer configuration in a vertical cross section, the curable resin composition impregnated in the reinforcing fibers 51 is guided by the guide 54, and the fiber sheet 52 and The fiber sheet 53 was also impregnated and pulled in from one end of the mold 55. At this time, the fibrous sheets 52 and 53 were overlapped with each other at a width of 10 mm at all end portions in the circumferential direction. In the mold 55, the curable resin was sufficiently cured by heating to obtain the fiber-reinforced resin hollow body 10a. The obtained fiber-reinforced resin hollow body 10a was continuously taken from the die 55 by the take-up device 56 (for example, double gripper system) and cut into a predetermined length by the cutting machine 57. The dimensions of the fiber-reinforced resin hollow body 10a were as follows.
Hollow part dimensions (vertical cross section): 67 mm x 67 mm;
Thickness (vertical cross section): 2.4 mm;
Length: 1400 mm.

The curable resin composition was obtained by the following method.
An unsaturated polyester resin, a catalyst and a release agent were mixed to obtain a curable resin composition.

(test)
According to the following method, in the three-point bending test, a load was applied to the fiber-reinforced resin hollow body through the surrounding member, and a deflection amount-load graph was created (see FIG. 15). The surrounding member is made of steel, the thickness (t1 = t2 = t3) (see FIG. 13 (B)) is 10 mm, the surrounding depth (h1 = h2) (see FIG. 13 (B)) is 38.8 mm, the axial direction. The length (j) (see FIG. 13 (A)) was 100 mm. The hollow body and the surrounding member were not connected by bolts or the like.
Specifically, as shown in FIG. 13 (A), a test product (hollow body) 10a having a length of 1400 mm is installed on a U-shaped pedestal 61 at a support pitch k of 800 mm, and an enclosing member (co The test jig 62 was used to load the cross-head speed of 20 mm / min until it was broken. The amount of displacement is the amount of movement of the crosshead. 13B shows a BB cross section in FIG. 13A, and FIG. 13C shows a CC cross section.

[Comparative Example 1]
A three-point bending test was performed in the same manner as in Example 1 except that a load was applied to the fiber-reinforced resin hollow body via a flat plate. A flexure amount-load graph is shown in FIG. The flat plate was made of steel and had a thickness (t ′) (see FIG. 14) of 10 mm and an axial length of 100 mm. FIG. 14 corresponds to the BB cross section when the flat plate is used in FIG.

  INDUSTRIAL APPLICABILITY The support structure for a fiber-reinforced resin hollow body of the present invention is useful in all fields in which the fiber-reinforced resin hollow body can be used, for example, fluid transportation field, construction field, automobile field and the like. INDUSTRIAL APPLICABILITY The fiber-reinforced resin hollow body support structure of the present invention is particularly useful for supporting a fiber-reinforced resin hollow body for directly or indirectly supporting and fixing an automobile instrument panel.

10: 10a: 10b: 10c: Fiber reinforced resin hollow body 11: Enclosing member 12: Support member 1: Axial fiber layer 2: Non-axial fiber layer 3: Non-axial fiber layer 4a: 4b: Overlap portion 21a: 21b : First inner non-axial fiber layer 22a: 22b: Second inner non-axial fiber layer 23b: Third inner non-axial fiber layer 24b: Fourth inner non-axial fiber layer 31a: 31c: First outer non-axial Directional fiber layer 32a: 32c: Second outer non-axial fiber layer 33c: Third outer non-axial fiber layer 34c: Fourth outer non-axial fiber layer

Claims (14)

A fiber-reinforced resin hollow body having a rectangular cross-section perpendicular to the axial direction, an enveloping member surrounding three outer peripheral surfaces continuous in the circumferential direction of the hollow body, and a side of the enveloping member opposite to the fiber-reinforced resin hollow body side. It has a arranged support member, to transfer loads through the enclosing member, a support structure of the fiber-reinforced resin hollow body,
The surrounding member surrounds the three outer peripheral surfaces in a part of the hollow body in the axial direction,
The fiber-reinforced resin hollow body,
An axial fiber layer comprising reinforcing fibers oriented parallel to the axial direction of the hollow body; and
A non-axial fiber layer that is laminated on at least one of the inside and the outside of the axial fiber layer and that contains reinforcing fibers that have a different orientation from the axial fiber layer;
Have
The non-axial fiber layer comprises one or more circumferential fiber layers and one or more non-oriented fiber layers,
A support structure for a fiber-reinforced resin hollow body, wherein the non-oriented fiber layer is arranged on at least the outermost surface of the fiber-reinforced resin hollow body . When the load is applied to the hollow body side of the surrounding member, it is transmitted from the hollow body side to the supporting member side through the surrounding member,
The support of the fiber-reinforced resin hollow body according to claim 1 , wherein when the load is applied to the support member side of the surrounding member, the load is transmitted from the support member side to the hollow body side through the surrounding member. Construction. The non-axial fiber layer is a circumferential fiber layer containing reinforcing fibers oriented parallel to the circumferential direction of the fiber-reinforced resin hollow body, a non-oriented fiber layer containing reinforcing fibers not oriented in a specific direction, and a woven structure. One or more selected from the group consisting of a woven fiber layer containing reinforcing fibers forming a braid structure, a braiding fiber layer containing reinforcing fibers forming a braiding structure, and a knitting fiber layer containing reinforcing fibers forming a knitting structure. containing fibrous layer, the support structure of the fiber-reinforced resin hollow body according to claim 1 or 2. The support structure for a fiber-reinforced resin hollow body according to any one of claims 1 to 3, wherein the non-axial fiber layer is laminated on both inner and outer sides of the axial fiber layer. The non-axial fiber layer are overlapped at the end portions in the circumferential direction of the hollow body, the support structure of the fiber-reinforced resin hollow body according to any one of claims 1 to 4. The fiber reinforced according to claim 5 , wherein the non-axial fiber layer is divided into two or more layers in the circumferential direction, and adjacent layers of the two or more layers are overlapped at their ends in the circumferential direction. Hollow resin support structure. Said axial said the total reinforcing fibers of the fiber layer the weight ratio of the total reinforcing fibers of the non-axial fiber layer 100: 20 to 100: 200, fiber-reinforced resin hollow according to any one of claims 1 to 6, Body support structure. The weight ratio of all the reinforcing fibers of the axial fiber layer and the total reinforcing fibers of the circumferential fiber layer is 100: 1 to 100: 100,
The fiber-reinforced resin hollow body according to any one of claims 1 to 7, wherein the weight ratio of the total reinforcing fibers of the axial fiber layer to the total reinforcing fibers of the non-oriented fiber layer is 100: 10 to 100: 100. Support structure. The fiber-reinforced resin hollow body is impregnated body of the curable resin, the support structure of the fiber-reinforced resin hollow body according to any one of claims 1-8. The fiber-reinforced resin hollow body has a thickness of 1 to 20 mm, the support structure of the fiber-reinforced resin hollow body according to any one of claims 1-9. The fiber-reinforced resin hollow body has an outer peripheral length of 125～300Mm, the support structure of the fiber-reinforced resin hollow body according to any of claims 1-10. The support structure of the fiber-reinforced resin hollow body according to any one of the fiber-reinforced resin hollow body is a member for directly or indirectly supported and fixed to the instrument panel of a motor vehicle, according to claim 1 to 11. The fiber-reinforced resin hollow body is a cross car beam,
It said support member is a brake pedal anti-intrusion bracket or cowl bracket, the support structure of the fiber-reinforced resin hollow body according to any one of claims 1 to 12.   The support structure for a fiber-reinforced resin hollow body according to claim 1, wherein the non-oriented fiber layer on the outermost surface is adjacent to the circumferential fiber layer.

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