JPWO2012077196A1 - 部材の接続方法 - Google Patents
部材の接続方法 Download PDFInfo
- Publication number
- JPWO2012077196A1 JPWO2012077196A1 JP2011514998A JP2011514998A JPWO2012077196A1 JP WO2012077196 A1 JPWO2012077196 A1 JP WO2012077196A1 JP 2011514998 A JP2011514998 A JP 2011514998A JP 2011514998 A JP2011514998 A JP 2011514998A JP WO2012077196 A1 JPWO2012077196 A1 JP WO2012077196A1
- Authority
- JP
- Japan
- Prior art keywords
- resin
- rivet
- members
- piercing
- fiber
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
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Images
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
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- B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C66/80—General aspects of machine operations or constructions and parts thereof
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/90—Measuring or controlling the joining process
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
- B29C65/64—Joining a non-plastics element to a plastics element, e.g. by force
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/82—Testing the joint
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- B29C65/8215—Tensile tests
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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- B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/7394—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/74—Joining plastics material to non-plastics material
- B29C66/742—Joining plastics material to non-plastics material to metals or their alloys
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/90—Measuring or controlling the joining process
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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- B29C66/90—Measuring or controlling the joining process
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/90—Measuring or controlling the joining process
- B29C66/92—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools
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Abstract
2以上の部材を接続する接続方法であってそのうちの少なくとも一方は樹脂部材からなる接続方法に関し、この接続方法にセルフピアスリベットによる接合方法を適用した場合でも、マトリックス樹脂が割れることがなく、リベットを介して強固に2以上の部材を接続することのできる部材の接続方法を提供する。2以上の部材の重ね合わせ箇所を接続する部材の接続方法であって、重ね合わせ箇所を形成する少なくとも最下層に熱可塑性樹脂をマトリックス樹脂とする樹脂部材を配し、重ね合わせ箇所の少なくとも樹脂部材を熱処理してマトリックス樹脂を溶融させた状態で、重ね合わせ箇所の最上層の部材の上方からセルフピアスリベットを打ち込んで樹脂部材の内部まで到達させ、マトリックス樹脂の硬化によって重ね合わせ箇所の接続をおこなう部材の接続方法である。
Description
本発明は、2以上の部材の重ね合わせ箇所を接続する部材の接続方法に係り、特に、重ね合わせ箇所を形成する少なくとも最下層に熱可塑性樹脂をマトリックス樹脂とする樹脂部材が配され、重ね合わせ箇所の最上層の部材の上方からセルフピアスリベットを打ち込んで部材同士を接続する方法に関するものである。
樹脂に強化用繊維材が混入されてなる繊維強化プラスチック(FRP)は、軽量かつ高強度であることから、自動車産業、建設産業、航空産業など、様々な産業分野で使用されている。
そして、FRP部材同士の接合方法に関しては、接着剤を介して接合する方法やボルトによる接合方法、さらにはそれらを組み合わせた接合方法などが一般に用いられている。
ところで、部材同士の接合に関し、被接合部材がアルミ板や鋼板等からなる場合に、スポット溶接や摩擦攪拌接合、メカニカルクリンチ、ろう付け、ネジ留めといった様々な接合方法がある中で、セルフピアスリベットによる接合方法が適用されることがある。
このセルフピアスリベットによる接合方法は、その載置面に凹溝を具備するリベットダイスの上にたとえば2枚の金属板を積層姿勢で載置し、端面とこの端面から突出するピアスとからなる側面視が門形を呈したリベットを金属板の上方で位置決めし、パンチでこのリベットを金属板に打ち込むことでリベットを上板に貫通させ、この過程でリベットの2つのピアスの先端を外側に広げ、さらにリベットを打ち込むことでピアスの先端が下板内でさらに広げられ、ピアスの打ち込み過程で上下の金属板を塑性変形させて双方をピアスを介してインターロック接続するものである。
セルフピアスリベットによる接合方法によれば、たとえば金属上板に対して事前に穴あけをおこなう必要がなく、さらに3枚、4枚といった金属板同士の接合も可能であることから、効率的に2以上の金属部材同士を高強度で接合することができる。
このように様々なメリットを奏するセルフピアスリベットによる接合方法を上記するFRP部材同士の接合に適用せんとする試みもおこなわれており、さらには公開技術である特許文献1にもその内容が開示されている。ここで開示される接合方法は、接合される2つのFRP部材間に接着剤を塗工し、この接着剤が未硬化の状態でセルフピアスリベットを打ち込んで、リベットを上方のFRP部材を貫通させて下方のFRP部材内にその先端を留まらせるものである。
しかし、このように被接続部材の少なくとも一方がFRP部材である部材同士の接続にセルフピアスリベットによる接合方法を適用すると、リベットの先端の突き刺さりによってマトリックス樹脂が割れたり、FRP繊維が切れたりしてしまい、リベットとFRP部材が金属板のように十分に固定され難いことが本発明者等によって特定されている。このことから、特許文献1に開示される接続方法では、FRP部材同士の接続箇所が接着剤のみで接合されるのと実質的に同じとなり、セルフピアスリベット接合の奏する強固なインターロック接続構造を形成できないことから、せん断や曲げといった外力に弱い接続構造となってしまう。
本発明は上記する問題に鑑みてなされたものであり、2以上の部材を接続する接続方法であってそのうちの少なくとも一方は樹脂部材からなる接続方法に関し、この接続方法にセルフピアスリベットによる接合方法を適用した場合でも、マトリックス樹脂が割れることがなく、リベットを介して強固に2以上の部材を接続することのできる部材の接続方法を提供することを目的とする。
前記目的を達成すべく、本発明による部材の接続方法は、2以上の部材の重ね合わせ箇所を接続する部材の接続方法であって、重ね合わせ箇所を形成する少なくとも最下層に熱可塑性樹脂をマトリックス樹脂とする樹脂部材を配し、前記重ね合わせ箇所の少なくとも前記樹脂部材を熱処理してマトリックス樹脂を溶融させた状態で、重ね合わせ箇所の最上層の部材の上方からセルフピアスリベットを打ち込んで前記樹脂部材の内部まで到達させ、マトリックス樹脂の硬化によって重ね合わせ箇所の接続をおこなうものである。
本発明の部材の接続方法は、2以上の部材をセルフピアスリベットを用いて接続するに当たり、少なくともピアスの先端が留まる最下層の部材に熱可塑性樹脂をマトリックス樹脂とする樹脂部材を配し、少なくともこの最下層の樹脂部材を熱処理してマトリックス樹脂を溶融させた状態でセルフピアスリベットを打ち込んで接続するものである。
リベットが最上層の部材の上方から打ち込まれて最下層の部材以外の部材をリベットが貫通し、この過程でリベットの先端が側方へ変位して広がり、最下層の部材内部にこの先端が留まろうとする際に、この最下層の部材が溶融していることで、リベット打ち込みの際に最下層の樹脂部材が割れるといった課題は効果的に解消される。
ここで、「少なくとも最下層に熱可塑性樹脂をマトリックス樹脂とする樹脂部材を配し」とは、複数部材のうちの最下層の部材のみが熱可塑性樹脂をマトリックス樹脂とする樹脂部材であることのほかに、2つの部材を接続する場合にその双方の部材がともに熱可塑性樹脂をマトリックス樹脂とする樹脂部材からなる形態や、3つの部材を接続する場合に全ての部材が熱可塑性樹脂をマトリックス樹脂とする樹脂部材からなる形態、3つの部材のうちの最上層および最下層もしくは中間層および最下層の2つの部材が熱可塑性樹脂をマトリックス樹脂とする樹脂部材からなり、残りの部材が熱硬化性樹脂をマトリックス樹脂とする樹脂部材やアルミニウムやその合金、高張力鋼板などの金属板からなる形態など、接合部材の組み合わせのバリエーションは多様に存在する。
この熱可塑性樹脂としては、ポリプロピレン、ポリエチレン等のポリオレフィン樹脂、ポリスチレン樹脂、ABS樹脂、ポリ塩化ビニル樹脂、ポリアミド樹脂、ポリエステル樹脂、ポリアセタール樹脂、ポリカーボネート樹脂などのほか、熱可塑性を有するエポキシ樹脂などを適用することができる。
2以上の部材を重ね合わせた際に少なくともその最下層の部材が熱硬化性樹脂をマトリックス樹脂とする部材からなることで、リベット打ち込みに際して少なくとも最下層の部材を加熱してマトリックス樹脂を溶融させることができる。
ここで、「少なくとも前記樹脂部材を熱処理してマトリックス樹脂を溶融させた状態で」とは、たとえば2つの部材を接続する場合に、最下層の部材のみを溶融させることのほかに、双方の部材をともに溶融させることをも含む意味である。
たとえばリベットの先端の内側をテーパー状の先鋭形状に加工しておくことで、上層の部材が溶融していない状態でこのリベットを打ち込んだ際には、非溶融状態で剛性の高い上層の部材をリベットが貫通する過程でリベットの内側にある高剛性の上層部材によってその先端が外側に開き易くなり、溶融した最下層の部材内にその先端が入り込んだ後に最下層の部材を硬化させることでこの先端を最下層の樹脂部材内に配設することができる。
一方、最下層の部材に加えて上層の部材が溶融した場合であっても、マトリックス樹脂の溶融の程度によっては部材内に打ち込まれているリベットを外側に押し広げるだけの剛性を溶融状態の樹脂部材が有し得る場合もある。このように溶融状態の上層部材のマトリックス樹脂が所望する剛性を有する場合には、接続されるすべての部材を溶融させてリベット打ち込みをおこなっても、リベットを所望に変形させて部材内で開かせることができる。
2以上の部材がセルフピアスリベット接続されることにより、各部材内で側方に広げられたリベットと各部材との間の摩擦力によって2以上の部材を強固にインターロック接続することができる。
さらに、上記する樹脂部材がマトリックス樹脂の内部に繊維材を含む繊維強化樹脂部材からなる形態であってもよい。
この繊維材としては、セラミック繊維である炭化ケイソ繊維やアルミナ繊維、チッ化ケイ素繊維、無機繊維であるガラス繊維や炭素繊維、金属繊維である銅繊維や鋼繊維、ステンレス繊維、アルミニウム繊維、アルミニウム合金繊維、有機繊維であるポリエステル繊維、ポリアミド繊維、アラミド繊維などを挙げることができる。
本発明の接続方法を適用することで、リベットの打ち込みに際して最下層の部材のマトリックス樹脂が溶融しているために、最下層の部材がマトリックス樹脂内に繊維材を包含する繊維強化樹脂部材の場合であっても、リベットの打ち込みによって最下層の部材のマトリックス樹脂を割ることなく、さらには繊維材を切断することなくリベット先端を最下層の部材内に配設することができる。
最下層の樹脂部材の溶融に際しては、この最下層の樹脂部材をヒータ内蔵のリベットダイス上に載置し、ヒータによる熱処理によってマトリックス樹脂を溶融させることができる。
このようにヒータ内蔵のリベットダイスを適用することで、最下層の樹脂部材のみを効果的に溶融させることができる。
また、たとえばすべての部材を溶融させてもよい場合は、高温炉とセルフピアスリベット接続用のパンチを一体に構成した装置などを使用し、高温炉内を高温雰囲気としてすべての部材のたとえば接続箇所を溶融させた後にパンチを稼動させて、パンチ先端に仮に固定されたリベットの打ち込みをおこなうこともできる。
さらに、前記セルフピアスリベットは、端面と該端面から突出するピアスとからなる側面視が門形を呈するものであって、これが重ね合わせ箇所で打ち込まれた際にピアスが側方に変形しながらその先端が前記樹脂部材の内部でインターロックするようになっており、前記リベットダイスにおける樹脂部材の載置面には凹溝が設けてあり、前記ピアスが変形した際にその一部が該凹溝内に入り込んで重ね合わせ箇所の接続をおこなう形態であってもよい。
たとえばリング状の凹溝をリベットダイスの載置面に設けておき、この上で2以上の部材を接続する場合に、リベットダイスに直接載置される最下層の樹脂部材が溶融することで溶融樹脂は凹溝内に入り込むことになる。そして、最上層の部材の上方からリベットを打ち込んだ際の押し込み力により、最上層の部材や中間部材はリベットダイスの載置面上で蛇行する最下層の溶融樹脂の蛇行形状に呼応するように変形され、打ち込まれたリベットを構成するピアスはこの打ち込みの過程で外側に変位して広がり、最下層の溶融樹脂部材が入り込んでいる凹溝内にピアスの先端が入り込むこととなる。
この接続方法では、2以上の部材の接続箇所の最下面が、リベットダイスの載置面に形成された凹溝と相補的な形状で腑形されることになる。
以上の説明から理解できるように、本発明の部材の接続方法によれば、接続される2以上の部材の重ね合わせ箇所を形成する少なくとも最下層に熱可塑性樹脂をマトリックス樹脂とする樹脂部材を配し、これを熱処理してマトリックス樹脂を溶融させた状態で最上層の部材の上方からセルフピアスリベットを打ち込んでこの溶融した樹脂部材の内部まで到達させ、マトリックス樹脂の硬化によって重ね合わせ箇所の接続をおこなうことにより、リベット打ち込みの際に樹脂部材を割ることなく、高い接続強度で部材同士を接続することができる。
1…シリンダ、2…パンチ、3…リベットダイス、3a…載置面、3b…凹溝、4…ヒータ、5…リベット、5a…ピアス、5b…端面、6,6A…下方部材(繊維強化樹脂部材)、7,7A…上方部材(繊維強化樹脂部材)、8…補強部材
以下、図面を参照して本発明の部材の接続方法の実施の形態を説明する。なお、図示例は2つの部材を接続する方法を示したものであるが、図示する方法を用いて3以上の部材を接続してもよいことは勿論のことである。
図1〜4は順に、本発明の部材の接続方法を説明するフロー図となっている。具体的には、図1はセルフピアスリベット接続に供されるシリンダ機構とリベットダイスの縦断面図であり、図2は2つの部材がリベットダイスの載置台上に載置されている状態を説明した図であり、図3はリベットダイス内のヒータにて下方の樹脂部材が溶融され、リベットが打ち込まれている状態を説明した図であり、図4はリベットが完全に打ち込まれ、下方の樹脂部材が硬化して2つの部材が接続された状態を説明した図である。
以下、本発明の部材の接続方法を適用して上下2つの繊維強化樹脂部材同士を接続する方法を説明する。
図1aで示すように、2つの繊維強化樹脂部材の一部を重ね合わせた重ね合わせ箇所が載置されるリベットダイス3と、その上方に位置してシリンダ1内をパンチ2が摺動自在なシリンダ機構とからなる製造システムを用意する。
リベットダイス3は、図1bで示すようにその平面視が円形であり、繊維強化樹脂材が載置される載置面3aにはリング状の凹溝3bが形成されている。
さらに、リベットダイス3内にはヒータ4が内蔵されている。
シリンダ1内では、その内部で摺動するパンチ2の下面にリベット5が吸着等で仮固定されるようになっている。
使用されるリベット5は、その平面視が円形の端面5bと、この端面5bから突出するピアス5aとからなる側面視が門形を呈したものであり、その素材はアルミニウムやその合金、鋼などから形成される。
図2で示すように、用意された製造システムを構成するリベットダイス3の載置面3a上に、繊維強化樹脂部材からなる上方部材7と下方部材6の重ね合わせ箇所を位置決めし、上方部材7上にシリンダ1をセットする。
ここで、上方部材7、下方部材6を形成する繊維強化樹脂部材のうち、少なくとも下方部材6のマトリックス樹脂は熱可塑性樹脂からなり、このマトリックス樹脂の内部に適宜の繊維材が混入されている。
少なくとも下方部材6のマトリックス樹脂として使用される熱可塑性樹脂としては、ポリプロピレン、ポリエチレン等のポリオレフィン樹脂、ポリスチレン樹脂、ABS樹脂、ポリ塩化ビニル樹脂、ポリアミド樹脂、ポリエステル樹脂、ポリアセタール樹脂、ポリカーボネート樹脂などのほか、熱可塑性を有するエポキシ樹脂などのうちのいずれか一種もしくはそれらの2種以上を混合した材料を適用することができる。
また、この熱可塑性樹脂内に混入される繊維材としては、セラミック繊維である炭化ケイ素繊維やアルミナ繊維、チッ化ケイ素繊維、無機繊維であるガラス繊維や炭素繊維、金属繊維である銅繊維や鋼繊維、ステンレス繊維、アルミニウム繊維、アルミニウム合金繊維、有機繊維であるポリエステル繊維、ポリアミド繊維、アラミド繊維のうちのいずれか一種もしくはそれらの2種以上を混合した材を適用することができる。
なお、下方部材6は熱可塑性樹脂をマトリックス樹脂としながら繊維材が混入されていない樹脂部材であってもよい。
また、上方部材7は、熱硬化性樹脂をマトリックス樹脂として繊維材が混入された繊維強化樹脂部材や繊維材が混入されていない樹脂部材、さらには、アルミニウムやその合金、高張力鋼板などの金属素材からなる部材であってもよい。
上方部材7と下方部材6の重ね合わせ箇所を載置面3a上に位置決めした状態で、リベットダイス3に内蔵されたヒータ4を稼動させ、リベットダイス3を介して下方部材6を加熱する。より具体的には、下方部材6のマトリックス樹脂として適用された熱可塑性樹脂の融点以上の温度で下方部材6を熱処理し、このマトリックス樹脂を溶融させる。
なお、下方部材6のマトリックス樹脂が溶融した際に、上方部材7のマトリックス樹脂は溶融しておらず、したがって下方部材6に比して上方部材7は高剛性を有している。
図3で示すように、下方部材6のみが溶融している状態でシリンダ1内でパンチ2を摺動させ、パンチ2からリベット5を上方部材7側に押し込むことにより(押圧力Q)、リベット5のピアス5aが上方部材7に打ち込まれてこれを貫通し、さらに溶融状態の下方部材6にピアス5aの先端が入り込むことになる。
そして、このピアス5aは上方部材7を貫通する過程で内側から圧力qを受けて外側に開き、さらに溶融した下方部材6内に打ち込まれる過程でも内側から圧力を受けて外側に開くことになる。このようにリベット5の打ち込み過程で2つのピアス5a,5aが外側へ変位するのは、ピアス5aの先端内側が先鋭テーパー状に形成されていること、リベットダイス3の載置面3aに設けられたリング状の凹溝3bで囲まれる中央部分が2つのピアス5a,5aの内側で上方凸をなしていること、2つのピアス5a,5aの内側で比較的剛性の高い部材が介在していること、などの種々の要素によるものである。
そして、リベット5の端面5bが上方部材7の上面と面一となるまでリベット5を打ち込み、次いで溶融状態の下方部材6を硬化させることにより、上方部材7と下方部材6の重ね合わせ箇所を接続することができる。
図4で示すように、リベット5のピアス5aは載置台3の凹溝3b内にその一部が収容されるように外側に開き、上方部材7および下方部材6とピアス5aの間の摩擦力によって双方の部材6,7を強固に接続することができる。
図5は、上記接続方法を適用した一つの実施例を説明した図であり、車両ボディーを構成する2つの繊維強化樹脂部材が接続された状態を示す模式図である。
図示する実施例は、車両ボディーを2枚の繊維強化樹脂部材からなる上方部材7Aおよび下方部材6Aとこれらの間に介在する補強部材8から構成するものであり、上方部材7Aおよび下方部材6A同士、および上方部材7Aと補強部材8同士が上記する接続方法で接続される。なお、同図において図示されるリベット5の端面箇所が上記接続方法で接続された箇所である。
リベット接合条件としては、パンチによる押し込み力を0.6〜0.8MPa程度、リベットダイス温度に関しては、熱可塑性樹脂にポリプロピレンを使用した場合は85〜120℃、熱可塑性樹脂にポリアミド(PA6)を使用した場合は150〜200℃、ポリアミド(PA66)を使用した場合は190〜250℃程度に調整することができる。
図示する車両ボディーは、軽量かつ高強度の2枚の繊維強化樹脂部材が接続されて構成されている。
そして、繊維強化樹脂部材同士の接続にセルフピアスリベット接合を適用しながらも接続される繊維強化樹脂部材に割れが生じることはなく、繊維材が切断されることもないことから、高い接続強度を有した軽量かつ高強度の車両ボディーとなっている。
[本発明の接続方法で接続された2つの部材(実施例)と従来の接続方法で接続された2つの部材(比較例)それぞれの接続箇所のせん断強度を測定した実験とその結果]
本発明者等は、2枚の繊維強化樹脂部材を本発明の接続方法で接続した試験片(実施例)と、2枚の繊維強化樹脂部材の一方を加熱溶融させることなくリベットを打ち込んで接続した試験片(比較例)を用意し、それぞれを引張試験機にクランプして引張速度5mm/minで引っ張った際のせん断強度を測定した。この測定結果を図6に示している。
本発明者等は、2枚の繊維強化樹脂部材を本発明の接続方法で接続した試験片(実施例)と、2枚の繊維強化樹脂部材の一方を加熱溶融させることなくリベットを打ち込んで接続した試験片(比較例)を用意し、それぞれを引張試験機にクランプして引張速度5mm/minで引っ張った際のせん断強度を測定した。この測定結果を図6に示している。
同図においては、比較例のせん断強度を1に正規化し、実施例のせん断強度を比較例に対する比率で示している。
図6より、比較例に比して実施例のせん断強度は2.5倍も向上することが実証されている。実施例および比較例の各試験片を観察したところ、比較例の試験片はリベットの打ち込みによって下方の繊維強化樹脂部材の繊維が切断されていたのに対して、実施例の試験片は繊維の切断も繊維強化樹脂部材の割れも観察されなかった。
そして、この繊維が切断されることなく双方の繊維強化樹脂部材が接続されていることが、接続箇所のせん断強度を大きく高めている理由となっている。
以上、本発明の実施の形態を図面を用いて詳述してきたが、具体的な構成はこの実施形態に限定されるものではなく、本発明の要旨を逸脱しない範囲における設計変更等があっても、それらは本発明に含まれるものである。
Claims (5)
- 2以上の部材の重ね合わせ箇所を接続する部材の接続方法であって、
重ね合わせ箇所を形成する少なくとも最下層に熱可塑性樹脂をマトリックス樹脂とする樹脂部材を配し、
前記重ね合わせ箇所の少なくとも前記樹脂部材を熱処理してマトリックス樹脂を溶融させた状態で、重ね合わせ箇所の最上層の部材の上方からセルフピアスリベットを打ち込んで前記樹脂部材の内部まで到達させ、マトリックス樹脂の硬化によって重ね合わせ箇所の接続をおこなう部材の接続方法。 - 前記樹脂部材が前記マトリックス樹脂の内部に繊維材を含む繊維強化樹脂部材である請求項1に記載の部材の接続方法。
- 最下層の前記樹脂部材をヒータ内蔵のリベットダイス上に載置し、ヒータによる熱処理によってマトリックス樹脂を溶融させる請求項1または2に記載の部材の接続方法。
- 前記セルフピアスリベットは、端面と該端面から突出するピアスとからなる側面視が門形を呈するものであって、これが重ね合わせ箇所で打ち込まれた際にピアスが側方に変形しながらその先端が前記樹脂部材の内部でインターロックするようになっており、
前記リベットダイスにおける樹脂部材の載置面には凹溝が設けてあり、前記ピアスが変形した際にその一部が該凹溝内に入り込んで重ね合わせ箇所の接続をおこなう請求項1〜3のいずれかに記載の部材の接続方法。 - 接続される部材のすべてが熱可塑性樹脂をマトリックス樹脂としてその内部に繊維材を含む繊維強化樹脂部材である請求項1〜4のいずれかに記載の部材の接続方法。
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