JP7144253B2 - Method for producing fiber-reinforced composite material - Google Patents

Method for producing fiber-reinforced composite material Download PDF

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JP7144253B2
JP7144253B2 JP2018171565A JP2018171565A JP7144253B2 JP 7144253 B2 JP7144253 B2 JP 7144253B2 JP 2018171565 A JP2018171565 A JP 2018171565A JP 2018171565 A JP2018171565 A JP 2018171565A JP 7144253 B2 JP7144253 B2 JP 7144253B2
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正太 松元
和也 高橋
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Subaru Corp
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本発明は、繊維強化複合材料の製造方法及び締結部材を具備した繊維強化複合材料に関し、特に、金型内にて強化繊維シートの積層体を伸長させた状態にて樹脂の含浸工程を行うことで、強化繊維シートの繊維のヨレを防止し、外観品質を向上させる繊維強化複合材料の製造方法及び締結部材を具備した繊維強化複合材料に関する。 TECHNICAL FIELD The present invention relates to a method for producing a fiber-reinforced composite material and a fiber-reinforced composite material provided with a fastening member, and in particular, performs a resin impregnation step in a state in which a laminate of reinforcing fiber sheets is stretched in a mold. and relates to a method for producing a fiber-reinforced composite material that prevents twisting of fibers of a reinforcing fiber sheet and improves appearance quality, and a fiber-reinforced composite material provided with a fastening member.

近年、繊維強化複合材料の製造方法として、レジントランスファモールディング(RTM)法や、反応射出成形(RIM)法等が用いられている。これらの方法では、複数の強化繊維シートを積層した積層体を金型内にセットし、型締めした後、未硬化の樹脂を注入し、積層体に含浸させて硬化させている。この方法によれば、樹脂が含浸されていないドライ基材からなる積層体を賦形するため、比較的複雑な形状の成形品を製造することが可能である。 In recent years, a resin transfer molding (RTM) method, a reaction injection molding (RIM) method, and the like have been used as methods for producing fiber-reinforced composite materials. In these methods, a laminate obtained by laminating a plurality of reinforcing fiber sheets is set in a mold, and after the molds are clamped, an uncured resin is injected, impregnated into the laminate, and cured. According to this method, since a laminate made of a dry base material not impregnated with a resin is shaped, it is possible to produce a molded article having a relatively complicated shape.

しかしながら、樹脂を含浸させる前の強化繊維シートは、搬送中に積層された強化繊維シートがバラバラになるなど、取扱性が悪い。そのため、通常、樹脂を含浸させる本賦形工程の前に、予備賦形工程を設定している。 However, the reinforcing fiber sheets before being impregnated with a resin are poor in handleability, such as the laminated reinforcing fiber sheets falling apart during transportation. Therefore, a pre-shaping step is usually set before the main shaping step of impregnating the resin.

予備賦形工程では、予備賦形用の金型に一枚の強化繊維シートをセットし、その表面にパウダー状の固着材を散布し、その上に次の強化繊維シートを積層する。これらを順次繰り返して強化繊維シートの積層体を形成し、その後、予備賦形型によって型締めを行う。これにより、強化繊維シート同士を固着するとともに、その後の本賦形に適した形状に予備賦形されたプリフォーム体を形成している。本賦形工程では、このプリフォーム体を本賦形用の金型にセットすることにより、位置決めを容易にし、本賦形時の位置ずれを防止している(例えば、特許文献1参照。)。 In the preshaping step, one reinforcing fiber sheet is set in a preshaping mold, a powder-like fixing material is sprinkled on its surface, and the next reinforcing fiber sheet is laminated thereon. These steps are sequentially repeated to form a laminate of reinforcing fiber sheets, and then the molds are clamped by a pre-shaping mold. As a result, the reinforcing fiber sheets are fixed to each other, and a preform preformed into a shape suitable for subsequent main forming is formed. In the main shaping step, by setting the preform body in the main shaping mold, positioning is facilitated and misalignment during the main shaping is prevented (see, for example, Patent Document 1). .

また、上記予備賦形工程を省略する繊維強化複合材料の製造方法として、以下の製造方法が知られている。ドライ基材である複数枚の強化繊維シートの積層体に対して複数の接合部と、その接合部の中央部に積層体を貫通する貫通孔とを形成する。 Moreover, the following manufacturing method is known as a method for manufacturing a fiber-reinforced composite material that omits the preforming step. A plurality of joints and a through-hole penetrating through the laminate are formed in a central portion of the joints in a laminate of a plurality of reinforcing fiber sheets, which is a dry base material.

ここで、接合部とは、積層体の最上面の強化繊維シートから最下面の強化繊維シートまで接着剤を浸透させ、積層体の全ての強化繊維シートを部分的に接合した部位である。そして、本賦形を行う成形型に積層体を配設する際に、接合部に形成された貫通孔に成形型のピン状部材を挿入させることで、簡易に積層体の位置決めを行うことができる(例えば、特許文献2参照。)。 Here, the joint portion is a portion where all the reinforcing fiber sheets of the laminate are partially joined by infiltrating an adhesive from the uppermost reinforcing fiber sheet to the lowermost reinforcing fiber sheet of the laminate. Then, when the laminate is placed in the mold for the main shaping, the laminate can be easily positioned by inserting pin-shaped members of the mold into the through holes formed in the joints. (For example, see Patent Document 2.).

特開2008-179130号公報Japanese Patent Application Laid-Open No. 2008-179130 特開2017-213819号公報JP 2017-213819 A

しかしながら、上記特許文献1に記載した繊維強化複合材料の製造方法では、本賦形工程の前に予備賦形工程を行うため、製造工程が複雑化すると共に、製造に用いる金型が増加するため、製造コストが増加してしまう課題があった。 However, in the method for producing a fiber-reinforced composite material described in Patent Document 1, the pre-shaping step is performed before the main shaping step, which complicates the manufacturing process and increases the number of molds used for manufacturing. , there is a problem that the manufacturing cost increases.

一方、上記特許文献2に記載した繊維強化複合材料の製造方法では、予備賦形工程を省略することはできるが、本賦形工程の際に、樹脂の流動圧や成形型の型面からの外圧により、繊維が撚れた状態にて硬化し、成形後の繊維強化複合材料の外観不良を招いてしまう恐れがある。そして、上記外観不良は成形後に補修することが出来ないため、外観不良が発生した繊維強化複合材料は破棄せざるを得ず、歩留りの悪化に繋がるという課題があった。 On the other hand, in the method for producing a fiber-reinforced composite material described in Patent Document 2, although the preliminary shaping step can be omitted, during the main shaping step, the flow pressure of the resin and the pressure from the mold surface of the mold Due to the external pressure, the fibers are hardened in a twisted state, and there is a possibility that the appearance of the fiber-reinforced composite material after molding may be poor. In addition, since the defective appearance cannot be repaired after molding, the fiber-reinforced composite material with the defective appearance must be discarded, leading to a problem of deterioration in yield.

上記外観不良は、繊維の位置がずれることが原因のため、外観面の問題だけでなく、強度面のばらつきにも繋がるため、上記外観不良の程度が低い場合でも、安全面から破棄した方が良い場合もあり、歩留りの悪化に繋がるという課題があった。 The above-mentioned poor appearance is caused by misalignment of the fibers, so it is not only a problem in terms of appearance, but also leads to variations in strength. In some cases, it was good, but there was a problem that it led to a deterioration in yield.

また、上記積層体では、適宜、接合部と貫通孔を設けることで、簡易に積層体の位置決めを行うと共に、位置決めの際の強化繊維シート同士のズレも防止している。しかしながら、貫通孔は成形後の繊維強化複合材料の意匠面にも残るため、少なくとも貫通孔の形成領域は、成形後の繊維強化複合材料を製品形状に加工する際に切断する必要があり、材料の歩留りの悪化や加工費用の増大に繋がるという課題があった。 In addition, in the above-described laminate, by appropriately providing the joints and the through holes, the laminate can be easily positioned and the reinforcing fiber sheets can be prevented from being displaced during positioning. However, since the through-holes remain on the design surface of the fiber-reinforced composite material after molding, at least the region where the through-holes are formed must be cut when processing the fiber-reinforced composite material after molding into a product shape. However, there was a problem that it leads to a deterioration in the yield of the product and an increase in the processing cost.

また、成形後の繊維強化複合材料を他部品と締結させるためには、成形後の繊維強化複合材料に対して後加工により穴あけ等を行い、リベット、ボルトやナット等を配設し、機械的締結点を形成する必要があり、加工費用の増大に繋がるという課題があった。 In addition, in order to fasten the fiber reinforced composite material after molding to other parts, the fiber reinforced composite material after molding is subjected to post-processing such as drilling holes, rivets, bolts, nuts, etc. are arranged, mechanically There was a problem that it was necessary to form a fastening point, leading to an increase in processing costs.

本発明は、上記の事情に鑑みてなされたものであり、金型内にて強化繊維シートの積層体を伸長させた状態にて樹脂の含浸工程を行うことで、強化繊維シートの繊維のヨレを防止し、外観品質を向上させる繊維強化複合材料の製造方法及び締結部材を具備した繊維強化複合材料を提供することにある。 The present invention has been made in view of the above circumstances. It is an object of the present invention to provide a method for producing a fiber-reinforced composite material and a fiber-reinforced composite material equipped with a fastening member, which prevent this and improve appearance quality.

本発明の繊維強化複合材料の製造方法では、強化繊維シートの積層体を成形金型内に配設し、前記積層体に樹脂を含浸して硬化させることで繊維強化複合材料を成形する繊維強化複合材料の製造方法において、前記積層体をその間に挟み込む挟持板にて、少なくとも前記積層体の対向する両端部近傍をそれぞれ固定する工程と、前記挟持板の上下位置が反転するように前記積層体の前記両端部をそれぞれ内側へと折り返すと共に、前記成形金型の下金型の型面の凹部に少なくとも前記挟持板の一部を嵌め込むように、前記積層体を前記成形金型のキャビティ内に配置する工程と、前記積層体を伸長させた状態にて前記キャビティ内に前記樹脂を注入し、前記積層体に前記樹脂を含浸して硬化させることで前記繊維強化複合材料を成形する工程と、を有することを特徴とする。 In the method for producing a fiber-reinforced composite material of the present invention, a fiber-reinforced composite material is formed by arranging a laminate of reinforcing fiber sheets in a molding die, impregnating the laminate with a resin and curing the fiber-reinforced composite material. In a method for producing a composite material, a step of fixing at least the vicinities of opposite end portions of the laminate with sandwiching plates sandwiching the laminate therebetween; are folded inward, and the laminate is placed in the cavity of the molding die such that at least a part of the clamping plate is fitted into the recess of the mold surface of the lower die of the molding die. and a step of injecting the resin into the cavity while the laminate is stretched, and molding the fiber-reinforced composite material by impregnating the laminate with the resin and curing it. , is characterized by having

また、本発明の繊維強化複合材料の製造方法では、前記挟持板は、その一主面側に前記積層体を拘束する複数の係止部が形成される一方の板状体と、前記係止部が挿入される複数の係止孔が形成される他方の板状体と、を有し、前記一方の板状体と前記他方の板状体との間に前記積層体を挟持した状態にて、前記他方の板状体の一主面側にて前記係止孔から突出する前記係止部を加工することで、前記一方の板状体と前記他方の板状体とを連結状態にすることを特徴とする。 Further, in the method for producing a fiber-reinforced composite material of the present invention, the clamping plate includes one plate-like body having a plurality of locking portions formed on one main surface thereof for restraining the laminate, and the locking plate-like body. and a second plate-like body formed with a plurality of locking holes into which the parts are inserted, wherein the laminated body is sandwiched between the one plate-like body and the other plate-like body. Then, the one plate-like body and the other plate-like body are connected to each other by processing the locking portion protruding from the locking hole on one main surface side of the other plate-shaped body. characterized by

また、本発明の繊維強化複合材料の製造方法では、前記挟持板は、その一主面側へと向けて突起する突起係止部が形成される一方の板状体と、その一主面側へと向けて突起し、前記突起係止部が挿入される突起係合部が形成される他方の板状体と、を有し、前記一方の板状体と前記他方の板状体との間に前記積層体を挟持した状態にて、前記突起係止部及び少なくとも前記積層体の一部が、前記突起係合部内に挿入されることで、前記一方の板状体と前記他方の板状体とを連結状態とすることを特徴とする。 Further, in the method for producing a fiber-reinforced composite material of the present invention, the clamping plate includes one plate-like body formed with a projection locking portion projecting toward one main surface thereof, and the other plate-like body projecting toward the other side and formed with a protrusion engaging portion into which the protrusion locking portion is inserted; By inserting the projection engaging portion and at least a part of the laminated body into the projection engaging portion with the laminated body sandwiched therebetween, the one plate-like body and the other plate It is characterized in that the two bodies are in a connected state.

また、本発明の繊維強化複合材料の製造方法では、前記他方の板状体の前記一主面には金属部材が固定され、前記積層体を前記成形金型の前記キャビティ内に配置する工程では、前記一方の板状体を前記積層体の内側に包み込むように、前記積層体の前記両端部をそれぞれ内側へと折り返すと共に、前記金属部材を前記下金型の前記凹部へ嵌め込むことを特徴とする。 Further, in the method for producing a fiber-reinforced composite material of the present invention, a metal member is fixed to the one main surface of the other plate-shaped body, and in the step of arranging the laminate in the cavity of the mold, , wherein the both ends of the laminate are folded inward so as to wrap the one plate-like body inside the laminate, and the metal member is fitted into the recess of the lower mold. and

また、本発明の繊維強化複合材料の製造方法では、前記一方の板状体の前記一主面には金属部材が固定され、前記他方の板状体には前記金属部材が挿通する挿通孔が形成され、前記積層体を前記成形金型の前記キャビティ内に配置する工程では、前記金属部材を前記他方の板状体の前記一主面側へと突出させた後、前記一方の板状体を前記積層体の内側に包み込むように、前記積層体の前記両端部をそれぞれ内側へと折り返すと共に、前記金属部材を前記下金型の前記凹部へ嵌め込むことを特徴とする。 Further, in the method for producing a fiber-reinforced composite material of the present invention, a metal member is fixed to the one main surface of the one plate-like body, and the other plate-like body has an insertion hole through which the metal member is inserted. In the step of arranging the laminated body in the cavity of the molding die, after projecting the metal member toward the one main surface side of the other plate-shaped body, the one plate-shaped body are folded inwardly so as to wrap the inside of the laminate, and the metal member is fitted into the concave portion of the lower mold.

また、本発明の繊維強化複合材料の製造方法では、前記金属部材は、締結部材または溶接部材であることを特徴とする。 Moreover, in the method for producing a fiber-reinforced composite material of the present invention, the metal member is a fastening member or a welding member.

また、本発明の繊維強化複合材料の製造方法では、前記積層体に前記樹脂を含浸して硬化させる工程では、前記下金型の前記凹部に前記金属部材及び少なくとも前記挟持板の一部を嵌め込んだ状態にて前記下金型の前記凹部を可動させ、前記積層体を伸長した状態とすることを特徴とする。 Further, in the method for producing a fiber-reinforced composite material of the present invention, in the step of impregnating and curing the resin in the laminate, the metal member and at least part of the clamping plate are fitted into the recess of the lower mold. The recessed portion of the lower mold is moved in the closed state to extend the laminate.

本発明の繊維強化複合材料の製造方法では、強化繊維シートの積層体の両端部近傍をそれぞれ挟持板にて固定する工程と、挟持板の上下位置が反転するように積層体の両端部をそれぞれ内側へと折り返すと共に、成形金型の下金型の型面の凹部に少なくとも挟持板の一部を嵌め込むように、積層体を成形金型のキャビティ内に配置する工程と、積層体を伸長させた状態にてキャビティ内に樹脂を注入し、積層体に樹脂を含浸して硬化させることで繊維強化複合材料を成形する工程と、を有する。この製造方法により、挟持板を利用して積層体を伸長した状態とし、キャビティ内に樹脂を充填することで、樹脂の流動圧により強化繊維シートの繊維束が撚れ難くなり、成形後の繊維強化複合材料の外観不良を大幅に低減することができる。 In the method for producing a fiber-reinforced composite material of the present invention, the step of fixing the vicinity of both ends of a laminate of reinforcing fiber sheets with clamping plates, respectively, and fixing both ends of the laminate so that the clamping plates are vertically inverted. arranging the laminate in the cavity of the molding die so that at least a part of the clamping plate is fitted in the concave portion of the mold surface of the lower mold of the molding die while folding the laminate inward; and stretching the laminate. a step of injecting a resin into the cavity in a state where the laminated body is placed, impregnating the resin into the laminate and curing the resin to form a fiber-reinforced composite material. According to this manufacturing method, the sandwiching plate is used to extend the laminate, and the cavity is filled with resin, so that the flow pressure of the resin makes it difficult for the fiber bundles of the reinforcing fiber sheet to twist, and the fibers after molding are not easily twisted. The appearance defects of the reinforced composite material can be greatly reduced.

また、本発明の繊維強化複合材料の製造方法では、挟持板は、その一主面側に積層体を拘束する複数の係止部が形成される一方の板状体と、係止部が挿入される複数の係止孔が形成される他方の板状体と、を有している。そして、一方の板状体と他方の板状体との間に積層体を挟持した状態にて、他方の板状体の一主面側にて係止孔から突出する係止部を加工することで、一方の板状体と他方の板状体とを連結状態にする。この製造方法により、複数の強化繊維シートが正確に位置合わせされた状態の積層体を形成し、予備賦形工程を行うことなく、積層体を成形金型のキャビティ内に位置精度良く配置することができる。 Further, in the method for producing a fiber-reinforced composite material of the present invention, the clamping plate includes one plate-like body formed with a plurality of locking portions for restraining the laminate on one principal surface side thereof, and the locking portions inserted into the plate-like body. and the other plate-like body in which a plurality of locking holes are formed. Then, in a state in which the laminated body is sandwiched between one plate-like body and the other plate-like body, a locking portion protruding from the locking hole is processed on one main surface side of the other plate-like body. Thus, one plate-like body and the other plate-like body are brought into a connected state. According to this manufacturing method, a laminate in which a plurality of reinforcing fiber sheets are accurately aligned is formed, and the laminate is placed in a cavity of a molding die with high positional accuracy without performing a pre-shaping step. can be done.

また、本発明の繊維強化複合材料の製造方法では、挟持板は、その一主面側へと向けて突起する突起係止部が形成される一方の板状体と、その一主面側へと向けて突起し、突起係止部が挿入される突起係合部が形成される他方の板状体と、を有している。そして、一方の板状体と他方の板状体との間に積層体を挟持した状態にて、突起係止部及び少なくとも積層体の一部が、突起係合部内に挿入されることで、一方の板状体と他方の板状体とを連結状態とする。この製造方法により、複数の強化繊維シートが正確に位置合わせされた状態の積層体を形成し、予備賦形工程を行うことなく、積層体を成形金型のキャビティ内に位置精度良く配置することができる。 In addition, in the method for producing a fiber-reinforced composite material of the present invention, the clamping plate includes one plate-like body in which a protrusion locking portion that protrudes toward one main surface side is formed, and and the other plate-shaped body projecting toward and formed with a projection engaging portion into which the projection locking portion is inserted. By inserting the projection engaging portion and at least a part of the laminated body into the projection engaging portion while the laminated body is sandwiched between one plate-shaped body and the other plate-shaped body, One plate-like body and the other plate-like body are brought into a connected state. According to this manufacturing method, a laminate in which a plurality of reinforcing fiber sheets are accurately aligned is formed, and the laminate is placed in a cavity of a molding die with high positional accuracy without performing a pre-shaping step. can be done.

また、本発明の繊維強化複合材料の製造方法では、積層体を成形金型のキャビティ内に配置する工程では、一方の板状体を積層体の内側に包み込むように、積層体の両端部をそれぞれ内側へと折り返すと共に、金属部材を下金型の凹部へ嵌め込む。この製造方法により、板状体及び金属部材をキャビティ内に配置する際の位置合わせ部材として用いると共に、板状体を用いてキャビティ内にて積層体を均一に伸長させることができる。 Further, in the method for producing a fiber-reinforced composite material of the present invention, in the step of placing the laminate in the cavity of the molding die, both ends of the laminate are wrapped so that one plate-like body is wrapped inside the laminate. Each is folded inward, and the metal member is fitted into the concave portion of the lower mold. According to this manufacturing method, the plate-like body and the metal member can be used as alignment members when arranging them in the cavity, and the laminate can be uniformly stretched in the cavity using the plate-like body.

また、本発明の繊維強化複合材料の製造方法では、積層体を成形金型のキャビティ内に配置する工程では、金属部材を他方の板状体の一主面側へと突出させた後、一方の板状体を積層体の内側に包み込むように、積層体の両端部をそれぞれ内側へと折り返すと共に、金属部材を下金型の凹部へ嵌め込む。この製造方法により、板状体及び金属部材をキャビティ内に配置する際の位置合わせ部材として用いると共に、板状体に沿って積層体を折り返した状態にて積層体を引っ張ることで、キャビティ内にて積層体を均一に伸長させることができる。 Further, in the method for producing a fiber-reinforced composite material of the present invention, in the step of arranging the laminate in the cavity of the molding die, the metal member is protruded toward one main surface of the other plate-like body, Both ends of the laminated body are folded inward so as to wrap the plate-like bodies of (1) inside the laminated body, and the metal members are fitted into the concave portions of the lower mold. According to this manufacturing method, the plate-like body and the metal member are used as an alignment member when the plate-like body and the metal member are arranged in the cavity. The laminate can be stretched uniformly by

また、本発明の繊維強化複合材料の製造方法では、挟持板に配設される金属部材は、締結部材または溶接部材であり、金属部材も成形金型のキャビティ内に配設する。この製造方法により、成形金型から繊維強化複合材料を離形した後に、締結部材等を後加工にて取り付けることなく、繊維強化複合材料を車体フレームに組み付けることができる。そして、加工費用の増大を抑えると共に、材料の歩留りも向上させることができる。 Further, in the method for producing a fiber-reinforced composite material of the present invention, the metal member arranged on the clamping plate is a fastening member or a welding member, and the metal member is also arranged in the cavity of the molding die. According to this manufacturing method, the fiber-reinforced composite material can be assembled to the vehicle body frame without attaching a fastening member or the like in post-processing after releasing the fiber-reinforced composite material from the molding die. In addition, it is possible to suppress an increase in processing costs and improve the yield of materials.

また、本発明の繊維強化複合材料の製造方法では、積層体に樹脂を含浸して硬化させる工程では、下金型の凹部に金属部材及び少なくとも挟持板の一部を嵌め込んだ状態にて下金型の凹部を可動させる。この製造方法により、キャビティ内にて積層体を均一に伸長させた状態にて、積層体に樹脂を含浸させることができ、樹脂の流動圧により強化繊維シートの繊維束が撚れ難くなり、成形後の繊維強化複合材料の外観不良を大幅に低減することができる。 Further, in the method for producing a fiber-reinforced composite material of the present invention, in the step of impregnating the laminate with a resin and curing it, the metal member and at least part of the clamping plate are fitted in the recess of the lower mold. Move the recess of the mold. With this manufacturing method, the laminate can be impregnated with the resin while the laminate is uniformly stretched in the cavity, and the flow pressure of the resin makes it difficult for the fiber bundles of the reinforcing fiber sheet to twist, and the molding is performed. Poor appearance of the subsequent fiber-reinforced composite material can be greatly reduced.

本発明の締結部材を具備した繊維強化複合材料では、積層された強化繊維シートに対して樹脂が含浸されて硬化している積層体には、少なくともその両端部に挟持板が固定され、その挟持板上面には締結部材が固定されている。そして、挟持板は、その一主面側に積層体を拘束する複数の係止部が形成される一方の板状体と、係止部が挿入される複数の係止孔が形成される他方の板状体と、を有している。この構造により、一方の板状体と他方の板状体との間に積層体を挟持した状態にて、他方の板状体の一主面側にて係止孔から突出する係止部を加工することで、一方の板状体と他方の板状体とを連結状態とすることができる。 In the fiber-reinforced composite material provided with the fastening member of the present invention, a sandwiching plate is fixed to at least both ends of the laminated body in which the laminated reinforcing fiber sheets are impregnated with a resin and hardened. A fastening member is fixed to the upper surface of the plate. The clamping plate has one main surface formed with a plurality of engaging portions for restraining the laminated body, and the other plate-like member formed with a plurality of engaging holes into which the engaging portions are inserted. and a plate-like body of With this structure, in a state in which the laminated body is sandwiched between one plate-like body and the other plate-like body, the locking portion protruding from the locking hole is formed on one main surface side of the other plate-like body. By processing, one plate-like body and the other plate-like body can be brought into a connected state.

また、本発明の締結部材を具備した繊維強化複合材料では、積層された強化繊維シートに対して樹脂が含浸されて硬化している積層体には、少なくともその両端部に挟持板が固定され、その挟持板上面には締結部材が固定されている。そして、挟持板は、その一主面側へと向けて突起する突起係止部が形成される一方の板状体と、その一主面側へと向けて突起し、突起係止部が挿入される突起係合部が形成される他方の板状体と、を有している。この構造により、一方の板状体と他方の板状体との間に積層体を挟持した状態にて、突起係止部及び少なくとも積層体の一部が、突起係合部内に挿入されることで、一方の板状体と他方の板状体とを連結状態とすることができる。 In addition, in the fiber-reinforced composite material equipped with the fastening member of the present invention, clamping plates are fixed to at least both ends of the laminated body in which the laminated reinforcing fiber sheets are impregnated with a resin and hardened. A fastening member is fixed to the upper surface of the clamping plate. The clamping plate includes one plate-like body formed with a protrusion locking portion projecting toward one main surface side, and a plate-like body formed with a protrusion locking portion projecting toward the one main surface side, into which the projection locking portion is inserted. and a plate-like body on which a protrusion engaging portion is formed. With this structure, the protrusion engaging portion and at least a part of the laminate can be inserted into the protrusion engaging portion while the laminate is sandwiched between one plate-like member and the other plate-like member. Then, one plate-like body and the other plate-like body can be brought into a connected state.

また、本発明の締結部材を具備した繊維強化複合材料では、前記締結部材は、車両の車体フレームに機械的に締結する部材である。この構造により、繊維強化複合材料に対して締結部材を後加工にて取り付けることなく、繊維強化複合材料を車体フレームに組み付けることができる。そして、加工費用の増大を抑えると共に、材料の歩留りも向上させることができる。 Moreover, in the fiber-reinforced composite material provided with the fastening member of the present invention, the fastening member is a member that is mechanically fastened to the body frame of the vehicle. With this structure, the fiber-reinforced composite material can be assembled to the vehicle body frame without attaching the fastening member to the fiber-reinforced composite material by post-processing. In addition, it is possible to suppress an increase in processing costs and improve the yield of materials.

本発明の一実施形態に係る繊維強化複合材料の製造方法で製造される繊維強化複合材料を説明する(A)斜視図、(B)斜視図、(C)斜視図である。BRIEF DESCRIPTION OF THE DRAWINGS It is (A) perspective view, (B) perspective view, (C) perspective view explaining the fiber reinforced composite material manufactured with the manufacturing method of the fiber reinforced composite material which concerns on one Embodiment of this invention. 本発明の一実施形態に係る繊維強化複合材料の製造方法で製造される繊維強化複合材料を説明する(A)斜視図、(B)斜視図である。BRIEF DESCRIPTION OF THE DRAWINGS It is (A) perspective view and (B) perspective view explaining the fiber reinforced composite material manufactured with the manufacturing method of the fiber reinforced composite material which concerns on one Embodiment of this invention. 本発明の一実施形態に係る繊維強化複合材料の製造方法で用いられる成形金型を説明する(A)断面図、(B)上面図である。BRIEF DESCRIPTION OF THE DRAWINGS It is (A) sectional drawing and (B) top view explaining the molding die used with the manufacturing method of the fiber reinforced composite material which concerns on one Embodiment of this invention. 本発明の一実施形態に係る繊維強化複合材料の製造方法を説明する(A)断面図、(B)断面図である。It is (A) sectional drawing explaining the manufacturing method of the fiber reinforced composite material which concerns on one Embodiment of this invention, and (B) sectional drawing. 本発明の一実施形態に係る繊維強化複合材料の製造方法を説明する(A)断面図、(B)断面図である。It is (A) sectional drawing explaining the manufacturing method of the fiber reinforced composite material which concerns on one Embodiment of this invention, and (B) sectional drawing.

以下、本発明の一実施形態に係る繊維強化複合材料10及びその製造方法を図面に基づき詳細に説明する。以下の説明では、同一の部材には原則として同一の符番を用い、繰り返しの説明は省略する。 A fiber-reinforced composite material 10 and a method for producing the same according to an embodiment of the present invention will be described in detail below with reference to the drawings. In the following description, in principle, the same reference numerals are used for the same members, and repeated descriptions are omitted.

最初に、図1から図2を参照して、本実施形態の繊維強化複合材料10の製造方法で製造される繊維強化複合材料10を説明する。 First, a fiber-reinforced composite material 10 produced by the method for producing a fiber-reinforced composite material 10 of the present embodiment will be described with reference to FIGS. 1 and 2. FIG.

図1(A)は、本実施形態の繊維強化複合材料10を説明する斜視図である。図1(B)及び図1(C)は、本実施形態の繊維強化複合材料10に固定される挟持板11、12を説明する斜視図である。図2(A)及び図2(B)は、図1に示す挟持板11、12の変形例であり、本実施形態の繊維強化複合材料10に固定される挟持板21を説明する斜視図である。 FIG. 1(A) is a perspective view illustrating a fiber-reinforced composite material 10 of this embodiment. FIGS. 1(B) and 1(C) are perspective views illustrating clamping plates 11 and 12 fixed to the fiber-reinforced composite material 10 of this embodiment. FIGS. 2(A) and 2(B) are perspective views illustrating a modification of the clamping plates 11 and 12 shown in FIG. 1, and the clamping plate 21 fixed to the fiber-reinforced composite material 10 of the present embodiment. be.

図1(A)に示す如く、繊維強化複合材料10は、例えばCFRP(Carbon Fiber Reinforced Plastics)である。繊維強化複合材料10は、ドライ基材である複数枚の強化繊維シート41(図4(A)参照)が積層した積層体18(図1(C)参照)に樹脂を含浸させ、硬化させることで形成される。そして、繊維強化複合材料10は、航空機や自動車等に使用可能であり、軽量効果の高い材料として用いられる。 As shown in FIG. 1A, the fiber-reinforced composite material 10 is CFRP (Carbon Fiber Reinforced Plastics), for example. The fiber-reinforced composite material 10 is produced by impregnating a laminate 18 (see FIG. 1(C)) in which a plurality of reinforcing fiber sheets 41 (see FIG. 4(A)) are laminated as a dry base material and curing the resin. formed by The fiber-reinforced composite material 10 can be used in aircraft, automobiles, and the like, and is used as a material that is highly effective in reducing weight.

強化繊維シート41を構成する強化繊維としては、例えば、炭素繊維やガラス繊維、アラミド繊維等を用いることができる。強化繊維シート41の形態として、織物や編物等のファブリック材、UD材(単一方向材)を採用することができる。 As the reinforcing fibers forming the reinforcing fiber sheet 41, for example, carbon fibers, glass fibers, aramid fibers, or the like can be used. As a form of the reinforcing fiber sheet 41, a fabric material such as a woven fabric or a knitted fabric, or a UD material (unidirectional material) can be adopted.

樹脂52(図5(B)参照)としては、エポキシ樹脂等の熱硬化型樹脂、または、ポリアミド(PA)やポリプロピレン(PP)等の熱可塑性樹脂を採用することができる。樹脂52は、強化繊維シート41の積層体18に含浸された状態、即ち強化繊維シート41の積層体18に入り込んだ状態で硬化されている。 As the resin 52 (see FIG. 5B), thermosetting resin such as epoxy resin, or thermoplastic resin such as polyamide (PA) or polypropylene (PP) can be used. The resin 52 is hardened while impregnating the laminate 18 of the reinforcing fiber sheets 41 , that is, entering the laminate 18 of the reinforcing fiber sheets 41 .

繊維強化複合材料10は、例えば、車両(図示せず)のルーフパネルとして成形され、図1(A)では、ルーフパネルを裏面側から見た状態を示している。繊維強化複合材料10は、緩やかな曲面形状に成形され、その表面10Aは、ルーフパネルの意匠面として用いられる。そして、繊維強化複合材料10の両端部近傍には、その裏面10B側へと折り返すように挟持板11、12が配設されている。挟持板11、12には、車両の車体フレームに機械的に締結するための複数の締結部材13が固定されている。 The fiber-reinforced composite material 10 is molded, for example, as a roof panel of a vehicle (not shown), and FIG. 1(A) shows the roof panel viewed from the rear side. The fiber-reinforced composite material 10 is molded into a gently curved shape, and its surface 10A is used as the design surface of the roof panel. Sandwiching plates 11 and 12 are disposed in the vicinity of both ends of the fiber-reinforced composite material 10 so as to fold back toward the back surface 10B. A plurality of fastening members 13 are fixed to the clamping plates 11 and 12 for mechanical fastening to the body frame of the vehicle.

尚、挟持板11、12は、一方向(車両の車幅方向)の両端部近傍に配設される場合に限定されるものではない。例えば、ルーフパネルが、ルーフの剛性を高めるため、ルーフクロスメンバー(図示せず)に機械的に締結される場合には、上記一方向との直交方向(車両の前後方向)の両端部にも新たな挟持板が配設され、その挟持板に複数の締結部材13が固定される場合でも良い。 Note that the clamping plates 11 and 12 are not limited to being arranged near both ends in one direction (the width direction of the vehicle). For example, when the roof panel is mechanically fastened to a roof cross member (not shown) in order to increase the rigidity of the roof, it is also possible to apply A new clamping plate may be provided and a plurality of fastening members 13 may be fixed to the clamping plate.

図1(B)に示す如く、挟持板11は、主に、長尺の板状体14、15と、板状体14の一主面14A側に形成される複数の係止部16と、板状体15を貫通して形成される複数の係止孔17と、板状体15の一主面15A側に固定される締結部材13と、を有している。 As shown in FIG. 1B, the clamping plate 11 mainly includes long plate-like bodies 14 and 15, a plurality of locking portions 16 formed on one main surface 14A side of the plate-like body 14, It has a plurality of locking holes 17 formed through the plate-like body 15 and a fastening member 13 fixed to the one main surface 15A side of the plate-like body 15 .

板状体14、15は、例えば、板金や樹脂により形成され、薄膜であるがプレス成形にも耐え得る厚みを有している。板状体14、15は、同形状であり、複数枚の強化繊維シート41が積層した積層体18(図1(C)参照)をその上下面から挟み込むように配設される。図示したように、板状体14の一主面14Aには、板状体14の長手方向に沿って一定間隔にて複数の係止部16が配設されている。係止部16としては、例えば、針やピン等が用いられ、板状体14の一主面14Aの上面に接着固定されている。 The plate-like bodies 14 and 15 are made of sheet metal or resin, for example, and although they are thin films, they have a thickness that can withstand press molding. The plate-like bodies 14 and 15 have the same shape, and are arranged so as to sandwich a laminate 18 (see FIG. 1(C)) in which a plurality of reinforcing fiber sheets 41 are laminated from the upper and lower surfaces thereof. As illustrated, a plurality of engaging portions 16 are arranged at regular intervals along the longitudinal direction of the plate-like body 14 on one main surface 14A of the plate-like body 14 . As the engaging portion 16, for example, a needle, a pin, or the like is used, and is adhesively fixed to the upper surface of one main surface 14A of the plate-like body 14. As shown in FIG.

一方、板状体15の一主面15Aには、板状体15の長手方向に沿って一定間隔にて複数の係止孔17が形成されている。係止孔17は、板状体14、15を重ね合わせた際に、係止部16を挿通するための孔であり、係止部16と同等の間隔にて形成されている。また、板状体15の一主面15Aには、その長手方向の両端部近傍に締結部材13としてのリベット、ボルトやナットが、適宜接着固定されている。 On the other hand, one main surface 15A of the plate-like body 15 is formed with a plurality of locking holes 17 along the longitudinal direction of the plate-like body 15 at regular intervals. The locking hole 17 is a hole for inserting the locking portion 16 when the plate-like bodies 14 and 15 are superimposed, and is formed at the same interval as the locking portion 16 . Rivets, bolts, and nuts as fastening members 13 are appropriately adhered and fixed to one main surface 15A of the plate-like body 15 near both ends in the longitudinal direction.

図1(C)に示す如く、積層体18は、板状体14の一主面14Aの上面に配設される。そして、係止部16が、積層体18を構成する、例えば、各強化繊維シート41(図4(A)参照)の経糸の繊維束(図示せず)を刺すことで、積層体18は、板状体14の一主面14A上に固定される。その後、係止部16が、板状体15の係止孔17内に挿入されるように、積層体18の上面に板状体15を配設する。そして、板状体15の各係止孔17から突出する係止部16を折り曲げ加工することで、板状体14、15同士が連結し、積層体18が、挟持板11により挟持された状態が実現される。尚、係止部16は、係止孔17から突出した領域がカシメ加工されることで、板状体14、15同士が連結する場合でも良い。 As shown in FIG. 1C, the laminate 18 is arranged on the upper surface of one main surface 14A of the plate-like body 14. As shown in FIG. Then, the locking portion 16 pierces the fiber bundle (not shown) of the warp yarns of each reinforcing fiber sheet 41 (see FIG. 4A), which constitutes the laminate 18, for example, so that the laminate 18 is It is fixed on one main surface 14A of the plate-like body 14 . After that, the plate-like body 15 is arranged on the upper surface of the laminate 18 so that the locking portion 16 is inserted into the locking hole 17 of the plate-like body 15 . By bending the locking portions 16 protruding from the locking holes 17 of the plate-like body 15 , the plate-like bodies 14 and 15 are connected to each other, and the laminated body 18 is sandwiched between the sandwiching plates 11 . is realized. It should be noted that the plate-like members 14 and 15 may be connected to each other by crimping the region protruding from the locking hole 17 of the locking portion 16 .

尚、締結部材13が、板状体15の一主面15Aに固定される場合に限定するものではなく、例えば、締結部材13が、板状体14の一主面14Aに固定され、板状体15には、締結部材13が挿通される挿通孔が形成されることで、積層体18を挟持した際に、締結部材13が、板状体15の一主面15Aよりも突出する場合でも良い。また、挟持板12も挟持板11と同形状であり、同一の部材には同一の符番を用い、上述した説明を参照し、ここではその説明を割愛する。 In addition, the fastening member 13 is not limited to the case where it is fixed to the one main surface 15A of the plate-like body 15. For example, the fastening member 13 is fixed to the one main surface 14A of the plate-like body 14, Since an insertion hole through which the fastening member 13 is inserted is formed in the body 15, even when the fastening member 13 protrudes from one main surface 15A of the plate-like body 15 when the laminated body 18 is sandwiched, good. The clamping plate 12 also has the same shape as the clamping plate 11, and the same reference numerals are used for the same members.

図2(A)に示す如く、挟持板21は、主に、長尺の板状体22、23と、板状体22の一主面22A側へ突起する突起係止部24と、板状体23の一主面23A側へ突起し、突起係止部24と係合する突起係合部25と、板状体23の一主面23A側に固定される締結部材13と、を有している。 As shown in FIG. 2(A), the clamping plate 21 mainly includes elongated plate-like bodies 22 and 23, a projection engaging portion 24 that protrudes toward one main surface 22A of the plate-like body 22, and a plate-like body. It has a protrusion engaging portion 25 that protrudes toward one main surface 23A side of the body 23 and engages with the protrusion locking portion 24, and a fastening member 13 that is fixed to the one main surface 23A side of the plate-like body 23. ing.

板状体22、23は、例えば、板金や樹脂により形成される。板状体22、23は、複数枚の強化繊維シート41(図4(A)参照)が積層した積層体18(図2(B)参照)をその上下面から挟み込むように配設される。図示したように、板状体22の一主面22A側には、板状体22の長手方向に沿って、板状体22の一部が突起する突起係止部24が形成されている。突起係止部24は、例えば、板状体22をプレス成形することで形成される。 The plate-like bodies 22 and 23 are made of sheet metal or resin, for example. The plate-like bodies 22 and 23 are arranged so as to sandwich a layered body 18 (see FIG. 2(B)) in which a plurality of reinforcing fiber sheets 41 (see FIG. 4(A)) are laminated from the upper and lower surfaces thereof. As shown in the figure, on the main surface 22A side of the plate-like body 22, a projection engaging portion 24 is formed along the longitudinal direction of the plate-like body 22, from which a part of the plate-like body 22 projects. The protrusion engaging portion 24 is formed by press-molding the plate-like body 22, for example.

一方、板状体23の一主面23Aには、板状体23の長手方向に沿って、板状体23の一部が突起する突起係合部25が形成されている。突起係合部25は、例えば、板状体23をプレス成形することで形成される。そして、突起係合部25には、突起係止部24及び積層体18の一部が挿入されるため、突起係合部25の係合空間26は、突起係止部24より広い空間となると共に、突起係止部24及び積層体18が抜け難くなるように、入口よりもその奥側の空間が広くなっている。 On the other hand, on one main surface 23A of the plate-like body 23, a protrusion engaging portion 25 is formed along the longitudinal direction of the plate-like body 23, from which a part of the plate-like body 23 protrudes. The projection engaging portion 25 is formed, for example, by press-molding the plate-like body 23 . Since the projection engaging portion 24 and a part of the laminate 18 are inserted into the projection engaging portion 25, the engaging space 26 of the projection engaging portion 25 becomes wider than the projection engaging portion 24. In addition, the space on the far side of the entrance is widened so that the protrusion locking portion 24 and the laminate 18 are difficult to come off.

尚、突起係止部24及び突起係合部25は、上記一直線形状に1つ形成される場合に限定するものではない。例えば、突起係止部24と突起係合部25とが係合し、その間に積層体18を支持すれば良く、エンボス形状のように複数の突起係止部24と、それに対応する複数の突起係合部25が形成される場合でも良い。 It should be noted that the projection engaging portion 24 and the projection engaging portion 25 are not limited to the case where one is formed in the straight line shape. For example, the projection locking portion 24 and the projection engaging portion 25 are engaged with each other, and the laminate 18 may be supported therebetween. A case where the engaging portion 25 is formed may be used.

図2(B)に示す如く、積層体18は、板状体22の一主面22Aの上面に配設し、その積層体18の上面に板状体23を位置合わせして配設した後、板状体22の突起係止部24と積層体18とを突起係合部25の係合空間26へと押し込むことで、板状体22、23同士が連結し、積層体18が、挟持板21により挟持された状態が実現される。 As shown in FIG. 2B, the laminated body 18 is arranged on the upper surface of one main surface 22A of the plate-like body 22, and after the plate-shaped body 23 is positioned and arranged on the upper surface of the laminated body 18, , the plate-shaped bodies 22 and 23 are connected to each other by pushing the projection locking portion 24 of the plate-shaped body 22 and the laminate 18 into the engagement space 26 of the projection engagement portion 25, and the laminated body 18 is sandwiched. A state of being sandwiched by the plates 21 is realized.

次に、図3を参照して、本実施形態の繊維強化複合材料10の製造方法に用いられる成形金型31を説明する。 Next, with reference to FIG. 3, the molding die 31 used in the method for manufacturing the fiber-reinforced composite material 10 of this embodiment will be described.

図3(A)は、本実施形態の繊維強化複合材料10の製造方法に用いられる成形金型31を説明する断面図である。図3(B)は、図3(A)に示す成形金型31の下金型33の型面33Aを説明する上面図である。 FIG. 3(A) is a cross-sectional view illustrating a molding die 31 used in the method for producing the fiber-reinforced composite material 10 of this embodiment. FIG. 3(B) is a top view for explaining a mold surface 33A of the lower mold 33 of the molding mold 31 shown in FIG. 3(A).

図3(A)に示す如く、成形金型31は、上金型32と下金型33とから構成されている。上金型32と下金型33とを閉じた際に形成される両者の間隙としてキャビティ34が構成される。キャビティ34は、本形態で製造される繊維強化複合材料10(図1(A)参照)の形状と同一である。 As shown in FIG. 3A, the molding die 31 is composed of an upper die 32 and a lower die 33 . A cavity 34 is formed as a gap formed between the upper mold 32 and the lower mold 33 when they are closed. The cavity 34 has the same shape as the fiber-reinforced composite material 10 (see FIG. 1(A)) manufactured in this embodiment.

上金型32を貫通して注入孔35が形成されている。注入孔35には外部から成形金型31に液状または粘度が低い樹脂が供給される。ここでは、上金型32の中央部に一つの注入孔35が形成されているが、注入孔35は上金型32の周辺部に形成されても良いし、複数の注入孔35が形成されても良い。更に、注入孔35は下金型33に形成されても良い。 An injection hole 35 is formed through the upper mold 32 . Liquid or low-viscosity resin is supplied to the molding die 31 from the outside through the injection hole 35 . Here, one injection hole 35 is formed in the central portion of the upper mold 32, but the injection hole 35 may be formed in the peripheral portion of the upper mold 32, or a plurality of injection holes 35 may be formed. can be Furthermore, the injection hole 35 may be formed in the lower mold 33 .

図3(B)に示す如く、下金型33の型面33Aには、キャビティ34の両端部近傍に紙面上下方向に延在する2つの凹部36、37が形成されている。凹部36、37は、積層体18(図1(C)参照)の両端部近傍に配設された挟持板11、12(図1(A)参照)が嵌め込まれることで、積層体18がキャビティ34内に位置精度良く配置されるための領域でもある。上述したように、挟持板11、12の長手方向の両端部近傍には、締結部材13が、板状体15の一主面15A上面に固定されている。そのため、凹部36、37内には、紙面上下方向の両端部近傍に、更に、締結部材13が嵌め込まれる凹部38が連通して形成されている。 As shown in FIG. 3B, two concave portions 36 and 37 are formed in the mold surface 33A of the lower mold 33 near both ends of the cavity 34 so as to extend in the vertical direction of the drawing. Clamping plates 11 and 12 (see FIG. 1A) provided near both ends of the laminate 18 (see FIG. 1C) are fitted into the recesses 36 and 37, so that the laminate 18 forms a cavity. It is also an area for arranging within 34 with good positional accuracy. As described above, the fastening members 13 are fixed to the upper surface of the main surface 15A of the plate-like body 15 in the vicinity of both ends of the holding plates 11 and 12 in the longitudinal direction. Therefore, in the recesses 36 and 37, recesses 38 in which the fastening members 13 are fitted are further formed in communication near both ends in the up-down direction of the paper surface.

下金型33は、公知の分割金型にて構成され、下金型33の凹部36、37、38の形成領域は、積層体18をキャビティ34内に配置した後、矢印39にて示すように、紙面左右方向にスライド移動することができる。詳細は後述するが、下金型33の凹部36、37、38の形成領域がスライド移動することで、積層体18に樹脂52(図5(B)参照)を含浸させる工程にて、キャビティ34内の積層体18を伸長した状態に維持することができる。 The lower mold 33 is composed of a known split mold, and the forming regions of the recesses 36, 37, 38 of the lower mold 33 are formed as indicated by an arrow 39 after the laminate 18 is arranged in the cavity 34. In addition, it can be slid in the horizontal direction of the paper surface. Although the details will be described later, the forming regions of the recesses 36, 37, and 38 of the lower mold 33 are slid, so that the cavity 34 is formed in the step of impregnating the laminate 18 with the resin 52 (see FIG. 5B). The inner laminations 18 can be maintained in a stretched state.

次に、図4から図5を参照して、本実施形態の繊維強化複合材料10の製造方法について説明する。尚、上記製造方法の説明に際し、適宜、図1から図3及びその説明箇所を参照し、同一の部材には原則として同一の符番を用い、繰り返しの説明は省略する。 Next, a method for manufacturing the fiber-reinforced composite material 10 of the present embodiment will be described with reference to FIGS. 4 and 5. FIG. 1 to 3 and the description thereof will be referred to as needed in the description of the above manufacturing method, and in principle the same reference numerals will be used for the same members, and repeated description will be omitted.

図4(A)及び図4(B)は、上述した積層体18に挟持板11、12を取り付ける工程を説明する断面図である。図5(A)及び図5(B)は、上述した積層体18に樹脂を含浸させ繊維強化複合材料10を成形する工程を説明する断面図である。 4(A) and 4(B) are cross-sectional views illustrating the process of attaching the clamping plates 11 and 12 to the laminate 18 described above. 5(A) and 5(B) are cross-sectional views illustrating the process of impregnating the above-described laminate 18 with a resin to form the fiber-reinforced composite material 10. As shown in FIG.

図4(A)に示す如く、同一形状の複数枚の強化繊維シート41を準備し、それぞれを位置合わせしながら積層させ、積層体18を形成する。本実施形態では、強化繊維シート41は、例えば、3000本の炭素繊維が纏められた繊維束を経糸、緯糸として用いて織り込んだ織物である。 As shown in FIG. 4(A), a plurality of reinforcing fiber sheets 41 having the same shape are prepared and laminated while being aligned with each other to form a laminate 18 . In this embodiment, the reinforcing fiber sheet 41 is, for example, a fabric woven using fiber bundles in which 3000 carbon fibers are bundled together as warp and weft.

図示したように、強化繊維シート41はドライ基材であり、積層体18の両端部近傍を挟持板11、12にて挟み込むことで、各強化繊維シート41同士を位置合わせすると共に、積層体18として固定することができる。 As illustrated, the reinforcing fiber sheet 41 is a dry base material, and by sandwiching the vicinity of both ends of the laminate 18 between the sandwiching plates 11 and 12, the reinforcing fiber sheets 41 are aligned with each other and the laminate 18 is held. can be fixed as

本実施形態では、図1(B)に示す如く、板状体14の一主面14Aに一定間隔にて配設された針やピンから成る係止部16に対して、各強化繊維シート41の経糸の繊維束(図示せず)を刺すことで、積層体18は、板状体14の一主面14A上に固定される。尚、強化繊維シート41を1枚毎に係止部16に刺していく場合でも良く、積層体18にした状態から係止部16に刺していく場合でも良い。 In this embodiment, as shown in FIG. 1(B), each reinforcing fiber sheet 41 is attached to an engaging portion 16 consisting of needles or pins arranged on one main surface 14A of the plate-like body 14 at regular intervals. The laminated body 18 is fixed on one main surface 14A of the plate-like body 14 by pricking the warp fiber bundle (not shown). It should be noted that the reinforcing fiber sheets 41 may be pierced into the locking portion 16 one by one, or may be pierced into the locking portion 16 from the laminated body 18 state.

その後、図1(C)に示す如く、最上面の強化繊維シート41から突出する係止部16を板状体15の係止孔17に対して挿通させ、積層体18の上面に板状体15を配設する。そして、板状体15の各係止孔17から突出する係止部16を折り曲げ加工し、板状体14、15同士を連結し、積層体18が、挟持板11、12により挟持された状態とする。 Thereafter, as shown in FIG. 1(C), the engaging portion 16 protruding from the reinforcing fiber sheet 41 on the uppermost surface is inserted into the engaging hole 17 of the plate-like body 15, and the plate-like body is attached to the upper surface of the laminate 18. 15 are placed. Then, the locking portions 16 protruding from the locking holes 17 of the plate-like body 15 are bent, the plate-like bodies 14 and 15 are connected to each other, and the laminated body 18 is sandwiched between the sandwiching plates 11 and 12. and

図4(B)に示す如く、積層体18の両端部を挟持板11、12に沿って内側へと折り返す。具体的には、板状体14、15の上下方向位置が逆転すると共に、板状体14が、積層体18の内側へと隠れるように、積層体18の両端部を略180度回転させる。 As shown in FIG. 4B, both ends of the laminate 18 are folded inward along the clamping plates 11 and 12 . Specifically, the vertical positions of the plates 14 and 15 are reversed, and both ends of the laminate 18 are rotated approximately 180 degrees so that the plate 14 is hidden inside the laminate 18 .

図5(A)に示す如く、図4(B)に示す状態の積層体18を成形金型31のキャビティ34内へと配設する。ここで、図3(B)に示す如く、下金型33の型面33Aには、2つの凹部36、37、38が形成されており、その凹部36、37、38内に挟持板11、12(図1(A)参照)の少なくとも一部及び締結部材13を嵌め込むことで、積層体18はキャビティ34に対して位置合わせをした状態にて配設される。尚、積層体18は、予め予備賦形されたプリフォーム体ではない。 As shown in FIG. 5A, the laminate 18 in the state shown in FIG. Here, as shown in FIG. 3(B), two recesses 36, 37, 38 are formed in the mold surface 33A of the lower mold 33. 12 (see FIG. 1A) and the fastening member 13 are fitted, the laminate 18 is arranged in a state of being aligned with the cavity 34 . Note that the laminate 18 is not a preform that is preformed in advance.

その後、下金型33の凹部36、37、38の形成領域を矢印51にて示す方向、つまり、キャビティ34の外側へ向けてスライド移動させることで、積層体18は、キャビティ34内にて伸長した状態となる。尚、凹部36、37の離間距離を広めに設定し、積層体18を下金型33に設置する際に、積層体18を伸長した状態とする場合でも良く、この場合には、下金型の33の上記スライドさせる機構は省略される。 After that, the forming regions of the recesses 36 , 37 , 38 of the lower mold 33 are slid in the direction indicated by the arrow 51 , that is, toward the outside of the cavity 34 , so that the laminate 18 is elongated within the cavity 34 . state. It should be noted that the distance between the concave portions 36 and 37 may be set wider, and the laminate 18 may be in an extended state when the laminate 18 is installed in the lower mold 33. In this case, the lower mold The sliding mechanism of 33 is omitted.

このとき、下金型33の凹部36、37、38には、挟持板11、12の少なくとも一部及び締結部材13が嵌め込まれていることで、積層体18は、挟持板11、12と面接触し、積層体18全体を均一に伸長させることができる。特に、積層体18の両端部を挟持板11、12に沿って折り返した状態にて、積層体18を引っ張ることで、ただ単に係止部16にて繊維束を刺した状態を引っ張る場合と比較して、明らかに積層体18が挟持板11、12から抜け難くなる。 At this time, at least a portion of the clamping plates 11 and 12 and the fastening member 13 are fitted into the concave portions 36 , 37 , and 38 of the lower mold 33 , so that the stack 18 is aligned with the clamping plates 11 and 12 . contact and the entire laminate 18 can be stretched uniformly. In particular, when both ends of the laminate 18 are folded back along the clamping plates 11 and 12, the laminate 18 is pulled, and compared with the case where the fiber bundle is simply stabbed by the locking portion 16 and pulled. As a result, it becomes difficult for the laminate 18 to come off from the clamping plates 11 and 12 .

図5(B)に示す如く、矢印51にて示すように、下金型33の凹部36、37、38の形成領域をスライド移動させ、積層体18を伸長した状態にて、注入孔35を経由して樹脂52をキャビティ34に注入することで、キャビティ34の内部にて積層体18に樹脂52を含浸させる。尚、この樹脂52の含浸工程にて、成形金型31の型面により挟持板11、12がプレス成形される場合でも良い。この場合には、成形後の繊維強化複合材料10の製品形状の自由度を高めることができる。 As shown in FIG. 5(B), as indicated by arrow 51, the forming regions of the recesses 36, 37, 38 of the lower mold 33 are slid to extend the laminate 18, and the injection hole 35 is opened. By injecting the resin 52 into the cavity 34 via the cavity 34 , the laminate 18 is impregnated with the resin 52 inside the cavity 34 . It should be noted that, in the step of impregnating the resin 52, the clamping plates 11 and 12 may be press-molded by the mold surface of the molding die 31. FIG. In this case, the flexibility of the product shape of the fiber-reinforced composite material 10 after molding can be increased.

上記した樹脂52の注入工程が終了した後は、キャビティ34の内部で樹脂52を硬化させる。樹脂52がエポキシ樹脂等の熱硬化型樹脂である場合は、樹脂52を100℃程度以上に加熱することで、樹脂52を硬化反応させる。一方、樹脂52がポリプロピレン等の熱可塑性樹脂である場合は、樹脂52を20℃~60℃以下(好ましくは、例えば40℃程度)に冷却することで硬化させる。 After the step of injecting the resin 52 described above is completed, the resin 52 is cured inside the cavity 34 . When the resin 52 is a thermosetting resin such as an epoxy resin, the resin 52 is heated to about 100° C. or higher to cause a curing reaction. On the other hand, when the resin 52 is a thermoplastic resin such as polypropylene, the resin 52 is hardened by cooling to 20° C. to 60° C. or less (preferably, for example, about 40° C.).

キャビティ34の内部で樹脂52が十分に硬化したら、上金型32と下金型33とを離型させた後に、図1(A)に示す繊維強化複合材料10を取り出す。そして、本実施形態では、繊維強化複合材料10の表面10Aは、例えば、ルーフパネルの意匠面として用いられる。そして、繊維強化複合材料10の両端部近傍に配設された挟持板11、12には、車両の車体フレームに機械的に締結するための複数の締結部材13が固定されている。 After the resin 52 has sufficiently hardened inside the cavity 34, the upper mold 32 and the lower mold 33 are separated, and then the fiber-reinforced composite material 10 shown in FIG. 1(A) is taken out. In this embodiment, the surface 10A of the fiber-reinforced composite material 10 is used, for example, as the design surface of the roof panel. A plurality of fastening members 13 for mechanical fastening to the body frame of the vehicle are fixed to the clamping plates 11 and 12 arranged near both ends of the fiber-reinforced composite material 10 .

この構造により、成形金型31から繊維強化複合材料10を離形した後に、締結部材13等を後加工にて取り付けることなく、繊維強化複合材料10をルーフパネルとして、車体フレームに取り付けることができる。その結果、繊維強化複合材料10の成形後における加工費用の増大を抑えることができる。 With this structure, after releasing the fiber reinforced composite material 10 from the molding die 31, the fiber reinforced composite material 10 can be attached to the vehicle body frame as a roof panel without attaching the fastening member 13 or the like in post-processing. . As a result, an increase in processing costs after molding the fiber-reinforced composite material 10 can be suppressed.

更に、上記製造方法により、挟持板11、12及び締結部材13を利用して積層体18を伸長した状態とし、キャビティ34内に樹脂を充填することで、樹脂の流動圧により強化繊維シート41の繊維束が撚れ難くなり、成形後の繊維強化複合材料10の外観不良を大幅に低減することができる。また、挟持板11、12の配設領域を切り落とすことなく、車体フレームへの取り付け領域として活用することで、材料の歩留りも向上させることができる。 Furthermore, by the above-described manufacturing method, the sandwiching plates 11 and 12 and the fastening members 13 are used to extend the laminate 18, and the resin is filled in the cavity 34, whereby the reinforcing fiber sheet 41 is formed by the flow pressure of the resin. The fiber bundles are less likely to be twisted, and poor appearance of the molded fiber-reinforced composite material 10 can be greatly reduced. In addition, by using the areas where the clamping plates 11 and 12 are provided as attachment areas to the vehicle body frame without cutting them off, the yield of materials can be improved.

尚、本実施形態では、成形金型31のキャビティ34内に樹脂を充填するレジントランスファモールディング(RTM)法による繊維強化複合材料10の製造方法について説明したが、この場合に限定するものではない。例えば、強化繊維シートに樹脂を含浸させたプリプレグを成形金型のキャビティ内に配置し、プリプレグの強化繊維シートに高温・高圧を付与するPCM(Prepreg Compression Molding)法により繊維強化複合材料10を成形する場合でも良い。この場合においても、複数枚の強化繊維シートから成る積層体は、上述した製造方法と同様に、キャビティ内にて伸長された状態となることで、高温・高圧が付与されても強化繊維シートの繊維束が撚れ難くなり、成形後の繊維強化複合材料10の外観不良を大幅に低減することができる。 In this embodiment, a method for manufacturing the fiber-reinforced composite material 10 by a resin transfer molding (RTM) method in which resin is filled into the cavity 34 of the molding die 31 has been described, but the present invention is not limited to this case. For example, the fiber-reinforced composite material 10 is molded by a PCM (Prepreg Compression Molding) method in which a prepreg obtained by impregnating a reinforcing fiber sheet with a resin is placed in a cavity of a molding die and high temperature and high pressure are applied to the reinforcing fiber sheet of the prepreg. Even if you do. In this case as well, the laminate composed of a plurality of reinforcing fiber sheets is stretched in the cavity in the same manner as in the above-described manufacturing method, so that even if high temperature and high pressure are applied, the reinforcing fiber sheet will not be formed. The fiber bundles are less likely to be twisted, and poor appearance of the molded fiber-reinforced composite material 10 can be greatly reduced.

また、挟持板11、12に固定される金属部材として締結部材13が用いられる場合について説明したが、この場合に限定するものではない。例えば、挟持板11、12に固定される金属部材としては、溶接部材が用いられる場合でも良い。この場合においても、上記溶接部材を溶接点として用い、成形後の繊維強化複合材料10を後加工することなく、車体のフレーム等に組み付けることができ、上記同様の効果を得ることができる。 Moreover, although the case where the fastening member 13 is used as the metal member fixed to the clamping plates 11 and 12 has been described, the present invention is not limited to this case. For example, welding members may be used as the metal members fixed to the clamping plates 11 and 12 . In this case, too, the welded member can be used as a welding point, and the molded fiber-reinforced composite material 10 can be assembled to a vehicle frame or the like without post-processing, and the same effect as described above can be obtained.

また、積層体18は、全て炭素繊維からなる強化繊維シート41を用いる場合について説明したが、この場合に限定するものではない。例えば、少なくとも積層体18の最上面及び最下面にガラス繊維からなる強化繊維シート41を配設し、積層体18を絶縁処理する場合でも良い。また、締結部材13等の挟持板11、12に固定される金属部材を塗装したり、樹脂52によりコーティングする等、上記金属部材を絶縁処理する場合でも良い。この場合には、より確実に積層体18の電食による腐食の恐れを防止することができる。その他、本発明の要旨を逸脱しない範囲にて種々の変更が可能である。 Moreover, although the case where the laminate 18 uses the reinforcing fiber sheet 41 made entirely of carbon fibers has been described, the present invention is not limited to this case. For example, a reinforcing fiber sheet 41 made of glass fiber may be disposed on at least the top surface and the bottom surface of the laminate 18 to insulate the laminate 18 . Alternatively, the metal member such as the fastening member 13 fixed to the clamping plates 11 and 12 may be insulated by painting or coating with the resin 52 . In this case, the risk of corrosion due to electrolytic corrosion of the laminate 18 can be more reliably prevented. In addition, various modifications are possible without departing from the gist of the present invention.

10 繊維強化複合材料
11、12、21 挟持板
13 締結部材
14、15、22、23 板状体
16 係止部
17 係止孔
18 積層体
24 突起係止部
25 突起係合部
26 係合空間
31 成形金型
32 上金型
33 下金型
34 キャビティ
36、37、38 凹部
41 強化繊維シート
52 樹脂
REFERENCE SIGNS LIST 10 Fiber-reinforced composite material 11, 12, 21 Clamping plate 13 Fastening member 14, 15, 22, 23 Plate-like body 16 Locking portion 17 Locking hole 18 Laminate 24 Projection locking portion 25 Projection engaging portion 26 Engaging space 31 molding die 32 upper die 33 lower die 34 cavity 36, 37, 38 concave portion 41 reinforcing fiber sheet 52 resin

Claims (7)

強化繊維シートの積層体を成形金型内に配設し、前記積層体に樹脂を含浸して硬化させることで繊維強化複合材料を成形する繊維強化複合材料の製造方法において、
前記積層体をその間に挟み込む挟持板にて、少なくとも前記積層体の対向する両端部近傍をそれぞれ固定する工程と、
前記挟持板の上下位置が反転するように前記積層体の前記両端部をそれぞれ内側へと折り返すと共に、前記成形金型の下金型の型面の凹部に少なくとも前記挟持板の一部を嵌め込むように、前記積層体を前記成形金型のキャビティ内に配置する工程と、
前記積層体を伸長させた状態にて前記キャビティ内に前記樹脂を注入し、前記積層体に前記樹脂を含浸して硬化させることで前記繊維強化複合材料を成形する工程と、を有することを特徴とする繊維強化複合材料の製造方法。
In a method for producing a fiber-reinforced composite material, a fiber-reinforced composite material is formed by arranging a laminate of reinforcing fiber sheets in a molding die, impregnating the laminate with a resin and curing the laminate,
a step of fixing at least the vicinities of opposite end portions of the laminate with clamping plates that sandwich the laminate between them;
Both ends of the laminate are folded inward so that the holding plate is vertically reversed, and at least a part of the holding plate is fitted into a concave portion of the mold surface of the lower mold of the molding die. placing the laminate in a cavity of the mold, such that
and forming the fiber-reinforced composite material by injecting the resin into the cavity while the laminated body is stretched, impregnating the laminated body with the resin and curing the resin. A method for producing a fiber-reinforced composite material.
前記挟持板は、その一主面側に前記積層体を拘束する複数の係止部が形成される一方の板状体と、前記係止部が挿入される複数の係止孔が形成される他方の板状体と、を有し、
前記一方の板状体と前記他方の板状体との間に前記積層体を挟持した状態にて、前記他方の板状体の一主面側にて前記係止孔から突出する前記係止部を加工することで、前記一方の板状体と前記他方の板状体とを連結状態にすることを特徴とする請求項1に記載の繊維強化複合材料の製造方法。
The clamping plate has one plate-like body formed with a plurality of locking portions for restraining the laminated body on one main surface thereof, and a plurality of locking holes into which the locking portions are inserted. and the other plate-shaped body,
In a state in which the laminated body is sandwiched between the one plate-shaped body and the other plate-shaped body, the locking protrudes from the locking hole on one main surface side of the other plate-shaped body. 2. The method for producing a fiber-reinforced composite material according to claim 1, wherein the one plate-like body and the other plate-like body are brought into a connected state by processing the portion.
前記挟持板は、その一主面側へと向けて突起する突起係止部が形成される一方の板状体と、その一主面側へと向けて突起し、前記突起係止部が挿入される突起係合部が形成される他方の板状体と、を有し、
前記一方の板状体と前記他方の板状体との間に前記積層体を挟持した状態にて、前記突起係止部及び少なくとも前記積層体の一部が、前記突起係合部内に挿入されることで、前記一方の板状体と前記他方の板状体とを連結状態とすることを特徴とする請求項1に記載の繊維強化複合材料の製造方法。
The clamping plate includes one plate-like body formed with a protrusion engaging portion protruding toward one main surface thereof, and a plate-like member protruding toward the one main surface thereof into which the protrusion engaging portion is inserted. and the other plate-shaped body formed with the projection engaging portion formed thereon,
With the laminated body sandwiched between the one plate-shaped body and the other plate-shaped body, the projection engaging portion and at least a part of the laminated body are inserted into the projection engaging portion. 2. The method for producing a fiber-reinforced composite material according to claim 1, wherein the one plate-like body and the other plate-like body are brought into a connected state.
前記他方の板状体の前記一主面には金属部材が固定され、
前記積層体を前記成形金型の前記キャビティ内に配置する工程では、前記一方の板状体を前記積層体の内側に包み込むように、前記積層体の前記両端部をそれぞれ内側へと折り返すと共に、前記金属部材を前記下金型の前記凹部へ嵌め込むことを特徴とする請求項2または請求項3に記載の繊維強化複合材料の製造方法。
A metal member is fixed to the one main surface of the other plate-shaped body,
In the step of placing the laminate in the cavity of the molding die, the both ends of the laminate are folded inward so that the one plate-like body is wrapped inside the laminate, and 4. The method for producing a fiber-reinforced composite material according to claim 2, wherein the metal member is fitted into the recess of the lower mold.
前記一方の板状体の前記一主面には金属部材が固定され、前記他方の板状体には前記金属部材が挿通する挿通孔が形成され、
前記積層体を前記成形金型の前記キャビティ内に配置する工程では、前記金属部材を前記他方の板状体の前記一主面側へと突出させた後、前記一方の板状体を前記積層体の内側に包み込むように、前記積層体の前記両端部をそれぞれ内側へと折り返すと共に、前記金属部材を前記下金型の前記凹部へ嵌め込むことを特徴とする請求項2または請求項3に記載の繊維強化複合材料の製造方法。
A metal member is fixed to the one main surface of the one plate-shaped body, and an insertion hole through which the metal member is inserted is formed in the other plate-shaped body,
In the step of arranging the laminate in the cavity of the molding die, the metal member is protruded toward the one main surface of the other plate-like body, and then the one plate-like body is placed in the laminate. 4. The method according to claim 2 or 3, wherein the both ends of the laminate are folded inward so as to wrap the laminated body inside the body, and the metal member is fitted into the recess of the lower mold. A method for producing the described fiber-reinforced composite material.
前記金属部材は、締結部材または溶接部材であることを特徴とする請求項4または請求項5に記載の繊維強化複合材料の製造方法。 6. The method for producing a fiber-reinforced composite material according to claim 4, wherein the metal member is a fastening member or a welding member. 前記積層体に前記樹脂を含浸して硬化させる工程では、前記下金型の前記凹部に前記金属部材及び少なくとも前記挟持板の一部を嵌め込んだ状態にて前記下金型の前記凹部を可動させ、前記積層体を伸長した状態とすることを特徴とする請求項4から請求項6のいずれか1項に記載の繊維強化複合材料の製造方法。
In the step of impregnating and curing the resin in the laminate, the recess of the lower mold is movable while the metal member and at least a part of the clamping plate are fitted in the recess of the lower mold. 7. The method for producing a fiber-reinforced composite material according to any one of claims 4 to 6, wherein the laminate is stretched.
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