JP7339562B2 - 金属-繊維強化樹脂材料複合体 - Google Patents
金属-繊維強化樹脂材料複合体 Download PDFInfo
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- JP7339562B2 JP7339562B2 JP2021543066A JP2021543066A JP7339562B2 JP 7339562 B2 JP7339562 B2 JP 7339562B2 JP 2021543066 A JP2021543066 A JP 2021543066A JP 2021543066 A JP2021543066 A JP 2021543066A JP 7339562 B2 JP7339562 B2 JP 7339562B2
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- F16B11/00—Connecting constructional elements or machine parts by sticking or pressing them together, e.g. cold pressure welding
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Landscapes
- Laminated Bodies (AREA)
Description
かかる知見に基づき完成された本発明の要旨は、以下の通りである。
[2]前記樹脂層が前記単層構造を有している場合における前記常温硬化接着剤の室温における貯蔵弾性率、及び、前記樹脂層が前記複層構造を有している場合における前記所定の樹脂の室温における貯蔵弾性率は、それぞれ、1MPa以上500MPa以下である、[1]に記載の金属-繊維強化樹脂材料複合体。
[3]前記樹脂層が前記単層構造を有している場合における前記常温硬化接着剤の室温における貯蔵弾性率、及び、前記樹脂層が前記複層構造を有している場合における前記所定の樹脂の室温における貯蔵弾性率は、それぞれ、10MPa以上100MPa以下である、[1]又は[2]に記載の金属-繊維強化樹脂材料複合体。
[4]前記樹脂層は、前記複層構造を有しており、前記所定の樹脂は、硬化性樹脂又は熱可塑性樹脂からなる、[1]~[3]の何れか1つに記載の金属-繊維強化樹脂材料複合体。
[5]前記樹脂層は、前記複層構造を有しており、前記所定の樹脂は、硬化性樹脂からなる、[1]~[4]の何れか1つに記載の金属-繊維強化樹脂材料複合体。
[6]前記樹脂層は、前記複層構造を有しており、前記所定の樹脂は、前記常温硬化接着剤により前記金属層と接合されている、[1]~[5]の何れか1つに記載の金属-繊維強化樹脂材料複合体。
[7]前記樹脂層は、前記複層構造を有しており、前記所定の樹脂は、前記常温硬化接着剤により前記繊維強化樹脂材料層と接合されている、[1]~[6]の何れか1つに記載の金属-繊維強化樹脂材料複合体。
[8]前記金属層は、鉄鋼材料、ステンレス材料、チタン材料、アルミニウム合金材料、又は、マグネシウム合金材料で形成されている、[1]~[7]の何れか1つに記載の金属-繊維強化樹脂材料複合体。
[9]前記金属層は、鋼板で形成されている、[1]~[8]の何れか1つに記載の金属-繊維強化樹脂材料複合体。
本発明者らは、先だって言及したように、通常は加熱による熱応力を避けるために使用される常温硬化接着剤により金属材料と繊維強化樹脂材料(FRP)とを接着した部材であっても、常温硬化後に接着後の部材を加熱処理することで常温硬化接着剤中の未硬化部分が流動することを見出した。かかる場合、加熱処理により金属材料が膨張した状態で、接着剤の未硬化部分が追加硬化するために、金属材料とFRPとの間で熱応力のミスフィットが生じ、部材が変形してしまう。
樹脂層に含まれる樹脂は、金属よりも線膨張係数が大きい。樹脂層の熱応力は厚みに応じて増加するため、上記樹脂層の厚みが特定範囲より厚い場合には、樹脂層の熱応力と金属材料との熱応力の差が、大きくなりすぎてしまう。このため、樹脂層の厚みが特定範囲より厚くなると、金属-繊維強化樹脂材料複合体に変形が生じてしまうことを見出した。また、上記樹脂層の厚みが特定範囲よりも薄い場合には、十分な熱応力緩和効果が得られないことを見出した。
以下で詳述する、本発明の実施形態に係る金属-繊維強化樹脂材料複合体(以下、「金属-FRP複合体」ともいう。)は、図1~4に示すように金属層11、樹脂層12、繊維強化樹脂材料(FRP)層13を少なくとも含む。すなわち、本発明の実施形態における金属-FRP複合体は3層以上の積層構造を有し、金属層11とFRP層13との間に樹脂層12を有する、サンドウィッチ構造を有する。
以下では、上記で概要を説明した金属-FRP複合体について、図1~図6を参照しながら、より詳細に説明する。
金属層11、樹脂層12、FRP層13、接着剤層14,15の厚みは、以下のようにJIS K 5600-1-7、5.4項の光学的方法の断面法に準拠して、測定することができる。すなわち、試料に有害な影響を及ぼさずに、隙間なく埋め込める常温硬化樹脂を用い、リファインテック株式会社製の低粘性エポマウント27-777を主剤に、27-772を硬化剤に用い、試料を埋め込む。切断機にて観察すべき箇所において、厚さ方向と平行となるように試料を切断して断面を出し、JIS R 6252又は6253で規定する番手の研磨紙(例えば、280番手、400番手又は600番手)を用いて研磨して、観察面を作製する。研磨材を用いる場合は、適切な等級のダイヤモンドペースト又は類似のペーストを用いて研磨して、観察面を作製する。また、必要に応じてバフ研磨を実施して、試料の表面を観察に耐えられる状況まで平滑化してもよい。
図8に、本実施例で作製した短冊試験片の大きさを模式的に示した模式図を示した。図8では、短冊試験片の大きさを誇張して示しており、正確な値を反映したものではない。
すなわち、動的粘弾性測定から得られるDTMA曲線において、樹脂層12に用いる樹脂のガラス転移点あるいは融点以上、分解温度未満の温度領域において、損失係数が1を超えるか否かに着目する。かかる場合において、損失係数が1を超える場合には、架橋構造を有しておらず、上記温度領域にて損失係数が1を超えない場合には架橋構造有している、と判断することができる。上記の方法により、架橋構造が存在すると判定されたものについては、評点「A」と評価し、架橋構造が存在しないと判定されたものについては、評点「B」と評価した。
用いたCFRPの厚みを0.50mmとした以外は実施例1と同様にして、短冊試験片を作製した。得られた短冊試験片について、実施例1と同様に暴露を行った後、実施例1と同様に評価を行った。
実施例1と同様の0.40mm厚の鋼板に対し、硬化後の厚みが0.50mmとなるように常温硬化接着剤(セメダイン株式会社製スーパーXG)を塗布し、実施例1と同様の1.00mm厚のCFRPと張り合わせた。得られた積層体を、室温で12時間保持することで、常温硬化接着剤を硬化させて、3層構造の短冊試験片を作製した。用いた常温硬化接着剤について、動的粘弾性測定結果から得られた弾性率は、上記のように10MPaであったため、かかる常温硬化接着剤からなる層は、樹脂層としての機能と、接着機能と、の双方を満足するものである。得られた短冊試験片について、実施例1と同様にして評価を行った。
用いた鋼板の厚みを1.60mmと変更した以外は実施例1と同様にして、短冊試験片を作製した。得られた短冊試験片について、実施例1と同様に暴露を行った後、実施例1と同様に評価を行った。
用いた常温硬化接着剤を、未硬化部分を有する常温硬化接着剤(セメダイン株式会社製Y600)に変更した以外は実施例1と同様にして、短冊試験片を作製した。得られた短冊試験片について、実施例1と同様に暴露を行った後、実施例1と同様に評価を行った。なお、本実施例で用いた常温硬化接着剤の動的粘弾性測定結果は、図5に示した通りである。かかる常温硬化接着剤が未硬化部分を有する常温硬化接着剤であることは、図5に示した動的粘弾性測定結果において、繰り返し加熱によるヒステリシスが存在することからも確認できる。
樹脂層として、ポリエステルエラストマー(東レ・デュポン株式会社製、ハイトレル4057WL20)からなる層を用いた以外は実施例1と同様にして、短冊試験片を作製した。得られた短冊試験片について、実施例1と同様に暴露を行った後、実施例1と同様に評価を行った。なお、用いたポリエステルエラストマーについて、動的粘弾性測定を実施したところ、その弾性率は、90MPaであった。
実施例6と同様に、短冊試験片を作製した。ただし、実施例6とは異なり、樹脂層とFRP層とをあらかじめ加熱融着にて接合させた後、得られた接合体と鋼板とを、常温硬化接着剤にて接合した。これにより、樹脂層とCFRPとの間に接着剤層が存在しない、4層構造の短冊試験片を作製した。その後、得られた短冊試験片について、実施例1と同様に暴露を行った後、実施例1と同様に評価を行った。
金属層として、0.40mm厚のアルミニウム合金(JIS H4000:2014に規定されたA6061)を使用した以外は実施例1と同様にして、短冊試験片を作製した。得られた短冊試験片について、実施例1と同様に暴露を行った後、実施例1と同様に評価を行った。
樹脂層として、SIS(スチレン・イソプレン・スチレン、JSR株式会社製SIS5229)からなる層を用いた以外は実施例1と同様にして、短冊試験片を作製した。得られた短冊試験片について、実施例1と同様に暴露を行った後、実施例1と同様に評価を行った。なお、用いたSISについて、動的粘弾性測定を実施したところ、その弾性率は、1MPaであった。
樹脂層として、ポリウレタン樹脂(株式会社イーテック製MG5000)からなる層を用いた以外は実施例1と同様にして、短冊試験片を作製した。得られた短冊試験片について、実施例1と同様に暴露を行った後、実施例1と同様に評価を行った。なお、用いたポリウレタン樹脂について、動的粘弾性測定を実施したところ、その弾性率は、950MPaであった。
樹脂層として、メタクリル樹脂(Illinois Tool Works株式会社製PLEXUS MA530)からなる層を用いた以外は実施例1と同様にして、短冊試験片を作製した。得られた短冊試験片について、実施例1と同様に暴露を行った後、実施例1と同様に評価を行った。なお、用いたメタクリル樹脂について、動的粘弾性測定を実施したところ、その弾性率は、414~483MPaであった。
樹脂層として、ポリエステルエラストマー(東レ・デュポン株式会社製、ハイトレル4057WL20)からなる層を用い、その厚みを、2.50mmとした以外は実施例1と同様にして、短冊試験片を作製した。得られた短冊試験片について、実施例1と同様に暴露を行った後、実施例1と同様に評価を行った。なお、用いたポリエステルエラストマーについて、動的粘弾性測定を実施したところ、その弾性率は、90MPaであった。
厚み0.10mmのチタン合金(日本製鉄株式会社製)に対し、樹脂層として、厚み0.10mmのポリエステルエラストマー(東レ・デュポン株式会社製、ハイトレル4057WL20)からなる層を用いた以外は実施例1と同様にして、短冊試験片を作製した。得られた短冊試験片について、実施例1と同様に暴露を行った後、実施例1と同様に評価を行った。なお、用いたポリエステルエラストマーについて、動的粘弾性測定を実施したところ、その弾性率は、90MPaであった。
厚み0.10mmのマグネシウム合金(株式会社ニラコ製)に対し、樹脂層として、厚み0.10mmのポリエステルエラストマー(東レ・デュポン株式会社製、ハイトレル4057WL20)からなる層を用いた以外は実施例1と同様にして、短冊試験片を作製した。得られた短冊試験片について、実施例1と同様に暴露を行った後、実施例1と同様に評価を行った。なお、用いたポリエステルエラストマーについて、動的粘弾性測定を実施したところ、その弾性率は、90MPaであった。
用いた常温硬化接着剤を、未硬化部分を有しない常温硬化接着剤(セメダイン株式会社製ハイスーパー30)に変更した以外は実施例1と同様にして、短冊試験片を作製した。得られた短冊試験片について、実施例1と同様に暴露を行った後、実施例1と同様に評価を行った。なお、本実施例で用いた常温硬化接着剤の動的粘弾性を別途測定することで、かかる常温硬化接着剤が未硬化部分を有しない旨を確認している。
常温硬化接着剤を用いずに、樹脂層の加熱融着により金属層、樹脂層、CFRPを互いに複合化した以外は実施例7と同様にして、3層構造の短冊試験片を作製した。得られた短冊試験片について、実施例1と同様に暴露を行った後、実施例1と同様に評価を行った。
樹脂層として、酸変性ポリプロピレン(三井化学株式会社製QE060)からなる層を用いた以外は実施例1と同様にして、短冊試験片を作製した。得られた短冊試験片について、実施例1と同様に暴露を行った後、実施例1と同様に評価を行った。なお、用いた酸変性ポリプロピレン(以下、「酸変性PP」と略記することがある。)について、動的粘弾性測定を実施したところ、その弾性率は、1100MPaであった。
ポリエステルエラストマー(東レ・デュポン株式会社製、ハイトレル4057WL20)からなる、厚み3.0mmの樹脂層を形成した以外は実施例1と同様にして、短冊試験片を作製した。得られた短冊試験片について、実施例1と同様に暴露を行った後、実施例1と同様に評価を行った。
金属層と樹脂層との界面を常温で接合することで、熱応力を発生させずに金属層、樹脂層、CFRPを互いに接合させた後、焼付工程で常温硬化接着剤中の未硬化部分が加熱により流動すると、金属が膨張した状態で接着剤が追加硬化して、冷却後に熱応力の差が発生する。しかしながら、上記表1-1、表1-2からも明らかなように、実施例1~15の場合、熱応力の差を樹脂層が調整するため、短冊試験片全体では変形が極めて小さかったと考えられる。
11 金属層
12 樹脂層
13 FRP層
14,15 接着剤層
131 強化繊維材料
132 マトリックス樹脂
Claims (9)
- 金属層と、
マトリックス樹脂で構成される層中に強化繊維材料が保持された繊維強化樹脂材料層と、
前記金属層と前記繊維強化樹脂材料層との間に位置する樹脂層と、
を少なくとも備える、3層以上の積層構造を有し、
前記樹脂層は、常温硬化接着剤で構成される単層構造を有しているか、又は、所定の樹脂と常温硬化接着剤とで構成される複層構造を有しており、
前記常温硬化接着剤は、未硬化部分を有しない常温硬化接着剤であり、
前記樹脂層が前記単層構造を有している場合においては、
前記常温硬化接着剤の室温における貯蔵弾性率は、0.1MPa超1000MPa以下であり、
前記常温硬化接着剤の厚みが、前記金属層の厚みに対して、0.005倍以上7.500倍未満であり、
前記樹脂層が前記複層構造を有している場合においては、
前記所定の樹脂の室温における貯蔵弾性率は、0.1MPa超1000MPa以下であり、
前記所定の樹脂の厚みが、前記金属層の厚みに対して、0.005倍以上7.500倍未満である、金属-繊維強化樹脂材料複合体。 - 前記樹脂層が前記単層構造を有している場合における前記常温硬化接着剤の室温における貯蔵弾性率、及び、前記樹脂層が前記複層構造を有している場合における前記所定の樹脂の室温における貯蔵弾性率は、それぞれ、1MPa以上500MPa以下である、請求項1に記載の金属-繊維強化樹脂材料複合体。
- 前記樹脂層が前記単層構造を有している場合における前記常温硬化接着剤の室温における貯蔵弾性率、及び、前記樹脂層が前記複層構造を有している場合における前記所定の樹脂の室温における貯蔵弾性率は、それぞれ、10MPa以上100MPa以下である、請求項1又は2に記載の金属-繊維強化樹脂材料複合体。
- 前記樹脂層は、前記複層構造を有しており、
前記所定の樹脂は、硬化性樹脂又は熱可塑性樹脂からなる、請求項1~3の何れか1項に記載の金属-繊維強化樹脂材料複合体。 - 前記樹脂層は、前記複層構造を有しており、
前記所定の樹脂は、硬化性樹脂からなる、請求項1~4の何れか1項に記載の金属-繊維強化樹脂材料複合体。 - 前記樹脂層は、前記複層構造を有しており、
前記所定の樹脂は、前記常温硬化接着剤により前記金属層と接合されている、請求項1~5の何れか1項に記載の金属-繊維強化樹脂材料複合体。 - 前記樹脂層は、前記複層構造を有しており、
前記所定の樹脂は、前記常温硬化接着剤により前記繊維強化樹脂材料層と接合されている、請求項1~6の何れか1項に記載の金属-繊維強化樹脂材料複合体。 - 前記金属層は、鉄鋼材料、ステンレス材料、チタン材料、アルミニウム合金材料、又は、マグネシウム合金材料で形成されている、請求項1~7の何れか1項に記載の金属-繊維強化樹脂材料複合体。
- 前記金属層は、鋼板で形成されている、請求項1~8の何れか1項に記載の金属-繊維強化樹脂材料複合体。
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