WO2014106924A1 - Shock-absorbing member for automotive vehicle and body structure of automotive vehicle - Google Patents

Abstract

Non-continuous fiber reinforced layers (54) are laminated onto both sides of a continuous fiber reinforced resin layer (53) formed by causing continuous fibers (61, 62) arranged in a grid pattern to be bonded together using a first thermosetting resin, the non-continuous fiber reinforced layers (54) being formed by causing non-continuous fibers (63) oriented at random to be bonded together using a second thermosetting resin. A shock-absorbing member has great strength against a shock load impacting from a first or second direction, whereas when a shock load impacts from a diagonal direction, the grid of continuous fibers (61, 62) undergoes out-of-plane deformation and the intersections of the continuous fibers (61, 62) rupture, which reduces the strength thereof. However, by making a length (L2) of the non-continuous fibers (63) greater than a length (L1) of a diagonal line of each cell of the grid of the continuous fibers (61, 62), the grid shape of the continuous fibers (61, 62) can be effectively strengthened by the non-continuous fibers (63) when a shock load impacts from the diagonal direction, with out-of-plane deformation being mitigated, and it is possible to increase the shock-absorbing effect by increasing the strength of the shock-absorbing member against compressive failure.

Description

Shock absorbing member of automobile and vehicle body structure of automobile

TECHNICAL FIELD The present invention relates to a shock absorbing member for an automobile formed by laminating discontinuous fiber reinforced resin layers on both sides of a continuous fiber reinforced resin layer. The present invention also relates to a vehicle body structure of an automobile combining a bumper beam made of fiber reinforced resin press-molded in the front-rear direction and a bumper beam extension made of fiber-reinforced resin press-molded in the vertical direction.

By forming a plurality of discontinuous fiber reinforced resin layers and a plurality of continuous fiber reinforced resin layers alternately by laminating parts such as automobile bumpers, the continuous fibers of the continuous fiber reinforced resin layer are intertwined and the strength is uneven. Even if it becomes, what smoothes it with the discontinuous fiber of a discontinuous fiber reinforced resin layer is known from the following patent documents 1.

When molding a fiber reinforced resin component by pressing a sheet in which resin layers containing discontinuous fibers are laminated on both sides of a continuous fiber layer with a mold, a resin containing discontinuous fibers in grooves formed in the mold is used. The thing which forms a reinforcement rib integrally by making it flow is known by the following patent document 2. FIG.

Further, in the energy absorber formed by laminating a plurality of continuous fiber reinforced resin layers into a truncated cone shape, the continuous fibers on the outer surface thereof are oriented in two directions of the axial direction and the circumferential direction as described in Patent Document 3 below. Are known.

Japanese Patent No. 3273 968 Japanese Patent No. 3800974 Japanese Patent No. 4085980

However, what was described in the said patent document 1 and the said patent document 2 is not disclosing about the relationship between the input direction of a collision load, and the orientation direction of a continuous fiber.

In addition, since the continuous fiber is disposed on the outer surface of the energy absorber, the one described in Patent Document 3 described above is inclined in a direction inclined with respect to the input direction of the collision load set in advance (the axial direction of the truncated cone). When a collision load is input, the strength may be significantly reduced because continuous fibers can not support the collision load.

The present invention has been made in view of the above-mentioned circumstances, and an object thereof is to provide a shock absorbing member for an automobile capable of effectively absorbing a collision load input from various directions.

In order to achieve the above object, according to the present invention, a continuous fiber reinforced resin in which continuous fibers oriented in a lattice shape in a first direction and a second direction orthogonal thereto are bonded by a first thermoplastic resin. The layer is constructed by laminating a discontinuous fiber reinforced resin layer in which randomly oriented discontinuous fibers are bonded with a second thermoplastic resin on both sides of the layer, and the length of the discontinuous fibers is the lattice of the continuous fibers. A shock absorber for a motor vehicle is firstly characterized in that it is larger than the diagonal length.

Further, according to the present invention, in addition to the first feature, a shock absorbing member for an automobile according to a second feature is proposed in which the continuous fiber reinforced resin layer has a fragile portion which partially reduces the strength. Ru.

Further, according to the present invention, in addition to the second feature, the continuous fiber reinforced resin layer is composed of a plurality of layers including a layer having the fragile portion and a layer not having the fragile portion. A shock absorbing member for a car is proposed.

Further, according to the present invention, in addition to any one of the first to third features, the discontinuous fiber reinforced resin layer wraps all of both surfaces and ends of the continuous fiber reinforced resin layer. The shock-absorbing member of the present invention is proposed.

According to the present invention, in addition to any one of the first to fourth features, the fifth thermoplastic resin may be nylon and the second thermoplastic resin may be polypropylene. The shock-absorbing member of the present invention is proposed.

According to the present invention, in addition to any one of the first to fifth features, the discontinuous fiber reinforced resin layer may further include a press-formed reinforcing rib. An absorbent member is proposed.

Further, according to the present invention, in addition to any one of the first to sixth features, discontinuous fibers of the discontinuous fiber reinforced resin layer can be obtained by cutting the impact absorbing member into a predetermined length. The seventh aspect of the present invention is a shock absorbing member for a motor vehicle.

Further, according to the present invention, in addition to any one of the first to seventh features, the impact absorbing member is a bumper disposed between a vehicle body frame extending in the front-rear direction and a bumper beam extending in the vehicle width direction. A beam extension, wherein the bumper beam extension is composed of an upper member and a lower member having a hat-like cross section in the front-rear direction, and is formed on both ends in the vehicle width direction of the upper member and covered with the discontinuous fiber reinforced resin layer An automobile according to an eighth aspect of the present invention is characterized in that laser welding is performed by overlapping the edge of the flange and the edge of the joint flange formed at both ends in the vehicle width direction of the lower member and covered with the discontinuous fiber reinforced resin layer. Shock-absorbing members are proposed.

Further, according to the present invention, in addition to the eighth feature, a ninth feature of the automobile is that a first reinforcing rib is integrally protruded from an end edge of a joining flange of the discontinuous fiber reinforced resin layer. An impact absorbing member is proposed.

Further, according to the present invention, in addition to the eighth or ninth feature, a second reinforcing rib extending in the front-rear direction from the discontinuous fiber reinforced resin layer covering the outer surface of the upper member and the lower member is integrated. A tenth reinforcing rib is integrally formed projecting from the discontinuous fiber reinforced resin layer covering the upper surface of the upper member and the lower surface of the lower member and extending in a direction inclined with respect to the front and rear direction. A shock absorbing member of a car characterized by the present invention is proposed.

According to the present invention, in addition to the tenth feature, fastening flanges extending in the vertical direction from the front end and the rear end of the discontinuous fiber reinforced resin layer covering the outer surfaces of the upper member and the lower member are integrated. According to an eleventh aspect of the present invention, there is provided a shock absorbing member for an automobile according to an eleventh aspect of the present invention, characterized in that the projecting flanges are connected by the second reinforcing rib between the front and rear fastening flanges.

According to the present invention, in addition to the eleventh feature, a shock absorbing member for an automobile according to a twelfth feature is characterized in that a nut for connecting the bumper beam is inserted into the front fastening flange. Ru.

Further, according to the present invention, in addition to the twelfth feature, a shock absorbing member for an automobile according to a thirteenth feature is characterized in that a tip end of the fastening flange on the front side is inclined outward in the vehicle width direction. Ru.

Further, according to the present invention, in addition to any one of the eleventh to thirteenth features, the thickness of the discontinuous fiber reinforced resin layer before press molding is t0, and the discontinuous fiber reinforced resin layer is generally T1 <t0 <t2 where t1 is the thickness after press molding of the part and t2 is the thickness after press molding of the second reinforcing rib and the third reinforcing rib of the discontinuous fiber reinforced resin layer According to a fourteenth aspect of the present invention, there is provided a shock absorbing member for a motor vehicle.

Further, according to the present invention, in addition to any one of the first to seventh features, the impact absorbing member is a bumper beam extending in the vehicle width direction, and the bumper beam is made of the continuous fiber reinforced resin layer. A plurality of U-shaped cross-sections formed in a U-shaped cross-section opening toward the outside in the front-rear direction are made continuous in the vertical direction, and a longitudinal rib consisting of the discontinuous fiber reinforced resin layer is placed on the U-shaped cross-section According to a fifteenth feature of the present invention, there is proposed an automobile shock absorbing member comprising a main body having a wall, a lower wall and a bottom wall connected to each other.

Further, according to the present invention, in addition to the fifteenth feature, the bumper beam includes an initial load absorbing portion coupled to the front-rear direction outer side of the main body portion, and the discontinuous fiber reinforced resin layer is provided on the main body portion. The initial load absorbing portion is connected to the main body by melting the head of the pin through which the pin formed in the initial load absorbing portion penetrates and forming the initial load absorbing portion; Shock absorbers for automobiles are proposed.

Further, according to the present invention, a bumper beam made of fiber reinforced resin press-molded in the front-rear direction and a bumper beam extension made of fiber-reinforced resin press-molded in the vertical direction are the shock absorbing members described in the first feature. An automobile body structure connecting the bumper beam and the bumper beam extension, wherein a pin projecting inward in the front-rear direction from the bumper beam is fitted in a pin hole formed in the bumper beam extension According to a seventeenth aspect of the present invention, there is proposed an automobile body structure, characterized in that the bumper beam and the bumper beam extension are joined by thermally caulking the head of the pin.

Further, according to the present invention, in addition to the seventeenth feature, the bumper beam includes a discontinuous fiber reinforced resin layer laminated at least on the inner side in the front-rear direction of the continuous fiber reinforced resin layer, the discontinuous fiber reinforced resin layer An eighteenth feature of the present invention is a vehicle body structure of an automobile, wherein the pin is integrally provided.

Further, according to the present invention, in addition to the seventeenth or eighteenth feature, the bumper beam and the bumper beam extension include a continuous fiber reinforced resin layer in which continuous fibers are oriented in two directions orthogonal to each other. According to a nineteenth aspect of the present invention, a vehicle body structure of an automobile is proposed.

Further, according to the present invention, in addition to the nineteenth feature, the bumper beam and the bumper beam extension include a discontinuous fiber reinforced resin layer laminated on the continuous fiber reinforced resin layer, and the discontinuous fiber reinforced According to a twentieth feature of a vehicle body structure of an automobile, a reinforcing rib extending in a collision load input direction is formed on a resin layer.

Further, according to the present invention, in addition to any one of the seventeenth to twentieth features, a fastening flange made of discontinuous fiber resin in which the pin hole is formed is integrated from the front-rear direction outer end of the bumper beam extension. According to a twenty-first aspect of the present invention, there is proposed a vehicle body structure of an automobile according to the twenty-first aspect of the present invention, wherein the fastening flange has a tip end side inclined outward in the front-rear direction.

The front side frame front portion 14 of the embodiment corresponds to the vehicle body frame of the present invention, and the bumper beam extension 18 and the bumper beam 19 of the embodiment correspond to the shock absorbing member of the present invention. The one pin 33g corresponds to the pin of the present invention, and the second pin 33k of the embodiment corresponds to the pin of the present invention, and the longitudinal rib 33f, the first reinforcing ribs 51f and 52f, and the second reinforcing rib 51h of the embodiment. , 52h and the third reinforcing ribs 51i, 52i correspond to the reinforcing ribs of the present invention, and the front fastening flanges 51b, 52b and the rear fastening flanges 51c, 52c of the embodiment correspond to the fastening flanges of the present invention.

According to a first aspect of the present invention, an impact-absorbing member of a motor vehicle has a first thermoplastic resin bonded with continuous fibers oriented in a lattice shape in a first direction and a second direction orthogonal thereto. A discontinuous fiber reinforced resin layer in which randomly oriented discontinuous fibers are bonded with a second thermoplastic resin is laminated on both sides of the continuous fiber reinforced resin layer. The impact absorbing member exhibits high strength against the collision load input in the first direction or the second direction, but when the collision load in the oblique direction is input, the lattice shape of the continuous fiber is out-of-plane deformed and breaks at the intersection Strength is reduced. However, by making the length of the randomly oriented discontinuous fibers greater than the length of the diagonal of the grid of continuous fibers, the grid of continuous fibers is effectively reinforced with the discontinuous fibers when an oblique collision load is input. As a result, it is possible to suppress the out-of-plane deformation, to increase the compressive fracture strength of the impact absorbing member, and to enhance the impact absorbing effect to the collision load input from various directions.

Further, according to the second feature of the present invention, since the continuous fiber reinforced resin layer has a weak portion which lowers the strength partially, the buckling strength of the impact absorbing member is locally reduced and transmitted to the vehicle body frame. It is possible to secure the impact absorption amount of the impact absorbing member by the discontinuous fiber reinforced resin layer laminated on the continuous fiber reinforced resin layer while reducing the peak load.

Further, according to the third feature of the present invention, since the continuous fiber reinforced resin layer is composed of a plurality of layers including the layer having the fragile portion and the layer not having the fragile portion, the influence of providing the fragile portion is minimized. Thus, the impact absorption amount of the impact absorbing member can be sufficiently secured.

Further, according to the fourth feature of the present invention, since the discontinuous fiber reinforced resin layer wraps all the both sides and ends of the continuous fiber reinforced resin layer, the continuous fiber reinforced resin layer breaks from the end in the early stage of the oblique collision. This can be avoided by reinforcing the end with a discontinuous fiber reinforced resin layer.

Further, according to the fifth feature of the present invention, the first thermoplastic resin is nylon and the second thermoplastic resin is polypropylene. Can.

Further, according to the sixth aspect of the present invention, since the discontinuous fiber reinforced resin layer is provided with a press-formed reinforcing rib, not only it is possible to easily form the reinforcing rib from discontinuous fibers having high formability, The second moment of area of the shock absorbing member can be increased by the reinforcing rib to increase the strength.

Further, according to the seventh aspect of the present invention, since the discontinuous fibers of the discontinuous fiber reinforced resin layer are obtained by cutting the shock absorbing member into a predetermined length, the continuous of the shock absorbing member to be discarded The fibers can be recycled as discontinuous fibers of a new impact-absorbing member.

According to an eighth aspect of the present invention, the bumper beam extension disposed between the vehicle body frame extending in the front-rear direction and the bumper beam extending in the vehicle width direction has an upper member having a hat-like cross section in the front-rear direction and A discontinuous fiber reinforced resin layer formed of the lower member, formed at the both ends in the vehicle width direction of the upper member and covered with the discontinuous fiber reinforced resin layer, and formed on both ends in the vehicle width direction of the lower member The laser beam welding is performed by overlapping the edge of the joint flange covered with the resin, so that the upper member and the lower member are firmly bonded without using a transparent resin having high adhesiveness to the resin of the discontinuous fiber reinforced resin layer. Can.

Further, according to the ninth aspect of the present invention, since the first reinforcing rib is integrally protruded from the edge of the joining flange of the discontinuous fiber reinforced resin layer, the first reinforcing rib can be formed of discontinuous fiber having high formability. Not only can it be molded easily, but also the cross-sectional secondary moment of the bumper beam extension can be increased by the reinforcing ribs to increase the strength.

Further, according to a tenth feature of the present invention, the second reinforcing rib extending in the front-rear direction is integrally protruded from the discontinuous fiber reinforced resin layer covering the outer surface of the upper member and the lower member, and the upper member and the lower member The third reinforcing rib extending integrally in a direction inclined with respect to the front-rear direction from the discontinuous fiber reinforced resin layer covering the inner surface of the second member, the second and third reinforcing ribs are formed of discontinuous fibers having high formability. Not only can it be molded easily, but the second moment of area of the bumper beam extension can be increased by reinforcing ribs to increase strength, and second and third reinforcing ribs extending in different directions can be input from various directions. Shock absorption effect to the collision load.

Further, according to an eleventh feature of the present invention, fastening flanges extending vertically from the front end and the rear end of the discontinuous fiber reinforced resin layer covering the outer surfaces of the upper and lower members are integrally protruded. Since the side fastening flanges are connected by the second reinforcing rib, not only the fastening flange can be easily formed by the high formability discontinuous fiber but also the bumper beam extension is firmly connected to the bumper beam and the vehicle body frame At the same time, the collision load input from the bumper beam can be efficiently transmitted to the vehicle body frame by the reinforcing rib.

Further, according to the twelfth aspect of the present invention, since the nut for coupling the bumper beam to the front side fastening flange is inserted, the workability at the time of coupling the bumper beam to the bumper beam extension can be enhanced.

Further, according to the thirteenth feature of the present invention, since the tip end of the front side fastening flange is inclined outward in the front-rear direction, the collision load input from the bumper beam can be reliably transmitted to the bumper beam extension.

According to a fourteenth feature of the present invention, the thickness of the discontinuous fiber reinforced resin layer before press molding is t0, and the thickness of the general part of the discontinuous fiber reinforced resin layer after press molding is t1. Assuming that the thickness of the second reinforcing rib and the third reinforcing rib of the continuous fiber reinforced resin layer after press molding is t2, since t1 <t0 <t2, the discontinuous fiber is a continuous fiber reinforced resin in the thin general part It is possible not only to increase the reinforcement effect against oblique collision load by approaching the layer, but also to increase the filling rate of discontinuous fibers and effectively increase the geometrical moment of inertia in the thick second and third reinforcing ribs Can.

According to a fifteenth feature of the present invention, the impact absorbing member is a bumper beam extending in the vehicle width direction, and the bumper beam is formed in a U-shaped cross section in which the continuous fiber reinforced resin layer is opened outward in the front and rear direction. Since the upper wall, the lower wall, and the bottom wall of the U-shaped cross section are connected by the longitudinal ribs formed of the discontinuous fiber reinforced resin layer, the plurality of U-shaped cross sections are continuously connected in the vertical direction. The U-shaped cross section is lightweight and has high bending and torsional rigidity.

Further, according to a sixteenth feature of the present invention, the bumper beam includes an initial load absorbing portion coupled to the front-rear direction outer side of the main body portion, and a pin made of a discontinuous fiber reinforced resin layer is protruded on the main body portion The initial load absorbing portion is joined to the main body by melting the head of the pin penetrating the pin hole formed in the load absorbing portion, so that not only can the initial load absorbing portion be easily connected to the main body, but also the bumper beam Can be closed to increase bending rigidity.

According to a seventeenth feature of the present invention, when combining a bumper beam made of fiber reinforced resin that is press molded in the front-rear direction and a bumper beam extension made of fiber reinforced resin that is press molded in the vertical direction, the bumper beam A pin projecting inward from the front and rear direction is fitted into a pin hole formed in the bumper beam extension, and the head of the pin is thermally crimped to join the bumper beam and the bumper beam extension. The bumper beam and the bumper beam extension can be coupled with a simple structure without the need for various fastening members. In addition, since the pins are integrally formed on the bumper beam that is press-formed in the front-rear direction, the pins do not get in the way when the bumper beam is punched out, and the pins extend in the front-rear direction which is the collision load input direction. Therefore, it is possible to prevent breakage of the pin due to collision load and to make it difficult for the bumper beam and the bumper beam extension to be disconnected.

According to an eighteenth feature of the present invention, the bumper beam comprises a discontinuous fiber reinforced resin layer laminated at least on the inner side in the front-rear direction of the continuous fiber reinforced resin layer, and the discontinuous fiber reinforced resin layer integrally comprises pins. Therefore, in a continuous fiber reinforced resin layer with low moldability, it is possible to easily form a pin that is difficult to mold with a discontinuous fiber reinforced resin layer with high moldability, and the pin is sufficiently reinforced by discontinuous fibers. The bumper beam and the bumper beam extension can be firmly fixed.

According to a nineteenth feature of the present invention, the bumper beam and the bumper beam extension include continuous fiber reinforced resin layers in which continuous fibers are oriented in two directions orthogonal to each other, so bending of the bumper beam and the bumper beam extension Not only the strength can be increased, but also the bumper beam and the bumper beam extension can be crushed sequentially from the tip side at the time of collision load input to improve the shock absorbing performance.

Further, according to a twentieth feature of the present invention, the bumper beam and the bumper beam extension have a discontinuous fiber reinforced resin layer laminated on a continuous fiber reinforced resin layer, and the impact load direction is applied to the discontinuous fiber reinforced resin layer Since the reinforcing rib extending to the top is formed, it is possible to easily form a reinforcing rib of complicated shape by discontinuous fiber reinforced resin with excellent formability, and the reinforcing rib increases the moment of inertia of area of bumper beam and bumper beam extension Not only can the bending strength be enhanced, but also the impact absorbing performance can be enhanced by the crushing of the reinforcing rib.

Further, according to a twenty-first feature of the present invention, a fastening flange made of discontinuous fiber reinforced resin in which pin holes are formed is integrally protruded from the front and rear direction outer end of the bumper beam extension. Because it slopes outward, when a collision load is input from the bumper beam to the fastening flange of the bumper beam extension, the collision load can be efficiently received by the fastening flange. As a result, the fastening flange acts as a trigger (trigger to cause breakage) and the bumper beam extension is sequentially crushed from the tip side, and the shock absorbing performance of the bumper beam extension can be maximized.

FIG. 1 is a perspective view of a front portion of a car body. First Embodiment FIG. 2 is a view in the direction of arrows in FIG. First Embodiment FIG. 3 is a perspective view of a bumper beam. First Embodiment FIG. 4 is an enlarged view of part 4 of FIG. First Embodiment FIG. 5 is an enlarged view of part 5 of FIG. First Embodiment 6 is a cross-sectional view taken along line 6-6 of FIG. First Embodiment 7 is a cross-sectional view taken along line 7-7 of FIG. First Embodiment FIG. 8 is an exploded perspective view of a bumper beam extension. First Embodiment FIG. 9 is a view in the direction of arrows 9 (A) to 9 (D) in FIG. First Embodiment FIG. 10 is an explanatory view of a method of manufacturing a bumper beam extension. First Embodiment FIG. 11 is a schematic view of a cross section of a bumper beam extension. First Embodiment FIG. 12 is an operation explanatory view at the time of input of an oblique load. First Embodiment FIG. 13 is a schematic view showing the relationship between the lattice of continuous fibers and the length of discontinuous fibers. First Embodiment FIG. 14 is an explanatory view of cutting for recycling of the shock absorbing member. First Embodiment FIG. 15 is a diagram comparing the effects of the present invention and the comparative example. First Embodiment FIG. 16 is a schematic view of a cross section of a bumper beam extension. Second Embodiment FIG. 17 is a diagram corresponding to FIG. Third Embodiment FIG. 18 is an explanatory view of a method of manufacturing the main body of the bumper beam. Third Embodiment FIG. 19 is an operation explanatory view at the time of input of collision load. Third Embodiment

14 Front side frame front (body frame)
18 Bumper beam extension (impact absorbing member)
18a Laser welding 19 Bumper beam (impact absorbing member)
31 body portion 32 initial load absorbing portion 32 d pin hole 33 U-shaped cross section portion 33 a upper wall 33 b lower wall 33 c bottom wall 33 f vertical rib (reinforcing rib)
33g 1st pin (pin)
33k second pin (pin)
51 upper member 51b front fastening flange (fastening flange)
51c Rear fastening flange (fastening flange)
51d joint flange 51e joint flange 51f first reinforcement rib (reinforcement rib)
51h second reinforcement rib (reinforcement rib)
51i 3rd reinforcement rib (reinforcement rib)
51m Pin hole 52 Lower member 52b Front fastening flange (fastening flange)
52c Rear fastening flange (fastening flange)
52d Joint flange 52e Joint flange 52f First reinforcement rib (reinforcement rib)
52h 2nd reinforcement rib (reinforcement rib)
52i 3rd reinforcement rib (reinforcement rib)
52 m Pin hole 53 Continuous fiber reinforced resin layer 53 a Fragile portion 54 Discontinuous fiber reinforced resin layer 61 Continuous fiber 62 Continuous fiber 63 Discontinuous fiber 64 Nut

MODE FOR CARRYING OUT THE INVENTION

Hereinafter, an embodiment of the present invention will be described based on the attached drawings.

First embodiment

First, a first embodiment of the present invention will be described based on FIGS. 1 to 15. In the present specification, the front-back direction (collision load input direction), the left-right direction (vehicle width direction) and the up-down direction are defined based on the occupant seated in the driver's seat.

As shown in FIGS. 1 and 2, the vehicle body of the automobile according to the embodiment includes a cabin 11 integrally formed in the shape of a bathtub with FRP such as GFRP (glass fiber reinforced resin), and a dash panel 12 standing from its front end A pair of left and right suspension support members 13 and 13 which are die-casted with an aluminum alloy are fixed to the front of the housing. Suspension support members 13, 13 include damper housings 13a, 13a for supporting upper ends of suspension dampers (not shown), and front side frame rear portions 13b, 13b connected to lower portions of damper housings 13a, 13a and extending forward. A pair of left and right front side frame front parts 14, 14 made of an aluminum extruded material or a steel plate pressed material is connected to the front ends of the front side frame rear parts 13b, 13b. A pair of left and right FRP side members 16 and 16 are connected to front ends of the left and right FRP upper members 15 and 15 extending forward from the left and right upper portions of the dash panel 12.

The FRP front bulkhead 17 formed in a rectangular frame shape in a front view is fixed to the front end of the front side frame front parts 14 and 14, and the front ends of the side members 16 and 16 are on the left and right tops of the front bulkhead 17. Connected A pair of left and right FRP bumper beam extensions 18, 18 are fixed to the front ends of the front side frame front parts 14, 14, and the FRP bumper beams 19 extend in the vehicle width direction to the front ends of the bumper beam extensions 18, 18. Is fixed. The front of the bumper beam 19 is covered by a bumper face 20. An FRP shroud 21 formed in a rectangular frame shape in a front view is disposed at a position surrounded by the front bulkhead 17, the bumper beam 19 and the pair of left and right bumper beam extensions 18, 18. In addition, cooling system parts (not shown) such as an engine cooling radiator, an air conditioning condenser, and a battery cooling radiator are stacked and supported in the front-rear direction.

Next, the structure of the bumper beam 19 will be described based on FIGS. 3 and 6.

The FRP bumper beam 19 includes a rear main body portion 31 and a front initial load absorbing portion 32. The main body portion 31 has a pair of U-shaped cross sections 33, 33 having an upper wall 33a, a lower wall 33b and a bottom wall 33c and opening forward, and the lower U-shaped cross section 33 The upper flange 33 d and the lower flange 33 e of the upper U-shaped cross section 33 are overlapped in the front-rear direction and integrally welded to form a substantially W-shaped cross section. A plurality of vertical ribs 33f extending in the vertical direction and connecting the upper wall 33a, the lower wall 33b, and the bottom wall 33c are separated by a predetermined distance in the longitudinal direction of the bumper beam 19 inside the U-shaped cross section 33 It is formed. A plurality of first pins 33g that project forward are formed on the upper flange 33d of the upper U-shaped cross section 33 and the lower flange 33e of the lower U-shaped cross section 33. A plurality of fastening collars 34 are inserted into the bottom wall 33 c of the U-shaped cross section 33.

The initial load absorbing portions 32 are divided into three in the longitudinal direction of the bumper beam 19, each having substantially the same structure. Each initial load absorbing portion 32 includes a flat connection wall 32a, and a plurality of longitudinal ribs 32b and a plurality of transverse ribs 32c formed on the front surface of the connection wall 32a. The longitudinal ribs 32b extending in the vertical direction and the transverse ribs 32c extending in the lateral direction intersect with each other in a lattice shape. Pin holes 32d to which the first pins 33g of the main body 31 can be fitted are formed at the upper edge and the lower edge of the connecting wall 32a. The first pins 33g of the main body 31 are fitted to the pin holes 32d of the initial load absorbing portion 32, and the first pins 33g are melted by a vibrating tool, whereby the initial load absorbing portions 32 are fixed to the main body 31. Combined.

Next, the structure of the bumper beam extension 18 will be described based on FIGS. 4 to 13.

The bumper beam extension 18 is configured by vertically combining an upper member 51 and a lower member 52 having a hat-like cross section in a front view. Since the upper member 51 and the lower member 52 of the bumper beam extension 18 have a substantially plane-symmetrical structure, the structure will be described below with the upper member 51 as a representative.

As shown in FIG. 7, the upper member 51 is composed of a continuous fiber reinforced resin layer 53 and discontinuous fiber reinforced resin layers 54, 54 covering the outer surface and the inner surface of the continuous fiber reinforced resin layer 53. As shown in FIGS. 8 and 10, the second prepreg 59 for forming the continuous fiber reinforced resin layer 53 is a continuous fiber 61... 62 of glass fiber UD (a sheet in which continuous fibers are aligned in one direction). .. Which are laminated in three layers of 0 ° direction, 90 ° direction and 0 ° direction are used as a reinforcing material and impregnated with a thermoplastic resin (nylon 6 or nylon 66). The 0 ° direction refers to a state in which the UD extends in the front-rear direction (including the vertical direction) in a state in which the bumper beam extension 18 is mounted on the vehicle body, and the 90 ° direction in a state in which the bumper beam extension 18 is mounted to the vehicle body It refers to a state in which UD extends in the vehicle width direction (including the vertical direction). The length of one side of the lattice shape constituted by the continuous fibers 61 in the 0 ° direction and the continuous fibers 62 in the 90 ° direction is, for example, 5 mm.

On the other hand, the first and third prepregs 58 and 60 for molding the discontinuous fiber reinforced resin layers 54 and 54 laminated on both sides of the continuous fiber reinforced resin layer 53 are mats of discontinuous fibers 63 of glass fiber. As a reinforcing material, they are impregnated with a thermoplastic resin (polypropylene etc.). The length L2 of the discontinuous fibers 63 is equal to or greater than the length L1 (for example, 7.1 mm) of the diagonal of the lattice formed by the continuous fibers 61... 62 in the 0 ° and 90 ° directions (see FIG. 8). ). Although the lengths of the discontinuous fibers 63 vary, the length of the discontinuous fibers 63 in the present invention is defined as an average value thereof.

In addition, as shown in FIG. 14, the bumper beam extension 18 to be discarded is cut into chips at intervals longer than the diagonal length L1, and the continuous fibers 61 ..., 62 ... contained therein are cut. The discontinuous fibers 63 can be recycled as the discontinuous fibers 63. As a result, it is possible to contribute to cost reduction by reusing the continuous fibers 61... 62 more expensive than the discontinuous fibers 63.

The upper member 51 is manufactured as follows. As shown in FIG. 10A, the mold 55 for press-molding the upper member 51 of the bumper beam extension 18 has a female mold 56 having a concave cavity 56 a for molding the outer surface of the upper member 51, and the upper member 51. , And 57b are formed in the cavity 56a and the core 57a, respectively. The mold 55 is opened, and the first prepreg 58 of the discontinuous fiber reinforced resin, the second prepreg 59 of the continuous fiber reinforced resin, and the third prepreg 60 of the discontinuous fiber reinforced resin are preheated on the female die 56 After being placed in a fixed state, the male mold 57 is clamped and pressure-molded, and then cooled to obtain a fiber reinforced resin product of the bumper beam extension 18.

FIG. 11 schematically shows a cross section of the bumper beam extension 18, and both surfaces of the central continuous fiber reinforced resin layer 53 are covered with the discontinuous fiber reinforced resin layers 54, 54. As shown in FIG. In the continuous fiber reinforced resin layer 53, weak portions 53a are formed by cutting a part thereof. It is to be noted that instead of forming the fragile portions 53a by cutting, the surface treatment for increasing the adhesive strength between the continuous fibers 61 of the continuous fiber reinforced resin layer 53 and the resin is partially nonfunctionalized to be weak The portions 53a may be formed.

The upper member 51 having a hat-like cross section formed as described above has a main body 51a, a front fastening flange 51b that bends upward from the front edge of the main body 51a, and a rear that bends upward from the rear edge of the main body 51a. A fastening flange 51c and a pair of joining flanges 51d and 51e extending inward and outward from the vehicle width direction from both ends in the vehicle width direction of the main body 51a are provided. First reinforcement ribs 51f, 51f bent upward are integrally formed at the end in the vehicle width direction of the pair of joining flanges 51d, 51e, and extend in the front-rear direction on the outer surface of the main body 51a to achieve front fastening Two second reinforcing ribs 51h, 51h for connecting the flange 51b and the rear fastening flange 51c are formed, and three third reinforcing ribs 51i are provided on the inner surface of the main body 51a and intersect in three directions at intervals of 60 °. Is formed. Further, three nuts 64 are inserted into the front fastening flange 51b, and three fastening holes 51j are formed in the rear fastening flange 51c.

The lower member 52 has the same shape as the upper member 51 substantially in plane symmetry with the upper member 51 described above, so that the same subscript as that of each part of the upper member 51 is attached to the reference numeral 52 of the lower member 52 to overlap I omit explanation. Bumper beam extensions 18 in which the joining flanges 51d, 51e of the upper member 51 and the joining flanges 52d, 52e of the lower member 52 are joined together constitute closed cylindrical sections that extend in the front-rear direction.

In the process of pressing the bumper beam extension 18, when the male die 57 is lowered with respect to the female die 56, the second prepreg 59 is pressed by the cavity 56a of the female die 56 and the core 57a of the male die 57, and the upper member 51 (or the lower member 52) is formed. At this time, since the first and third prepregs 58 and 60 having a discontinuous fiber as a reinforcing material can be easily deformed, the first prepreg 58 sandwiched by the second prepreg 59 and the cavity 56 a of the female die 56 is The first reinforcing ribs 51f, 51f, the front fastening flange 51b, the rear fastening flange 51c, and the second reinforcing ribs 51i, 51i are simultaneously formed while flowing into the grooves 56b of the cavity 56a, and the outer surface of the upper member 51 The thin film is laminated along the entire surface of the Similarly, the third prepreg 60 sandwiched by the second prepreg 59 and the core 57a of the male mold 57 flows into the groove 57b of the core 57a, and simultaneously the third reinforcing rib 51i on the inner surface of the upper member 51 While being molded, it is laminated in a thin film along the inner surface of the upper member 51.

All the end portions of the continuous fiber reinforced resin layer 53 are covered with the discontinuous fiber reinforced resin layers 54, 54 which wrap around from the surface of the continuous fiber reinforced resin layer 53. The thickness of the first and third prepregs 58 and 60 before press molding is t0, and the thickness of the general portion (portion covering the continuous fiber reinforced resin layer 53) after press molding is t1, and the first reinforcing rib 51 f, Assuming that the thicknesses of 51f, the second reinforcing ribs 51h and 51h, and the third reinforcing ribs 51i are t2, t1 <t0 <t2 is set (see FIG. 10B). That is, by press-molding the first and third prepregs 58 and 60, the thickness t0 is reduced and the thickness of the general part becomes t1 thinner than t0, and the first and third prepregs 58 become excessive. , 60 are extruded and formed, the thicknesses of the first reinforcing ribs 51f, 51f, the second reinforcing ribs 51h, 51h and the third reinforcing ribs 51i... Become t2 larger than t0.

The inner surfaces (portions abutting on each other) of the bonding flanges 51d and 51e of the upper member 51 and the bonding flanges 52d and 52e of the lower member 52 are not covered by the discontinuous fiber reinforced resin layers 54 and 54, but are continuous fiber reinforced resin Although the layer 53 is exposed, the continuous fiber reinforced resin layer 53 is not exposed when the upper member 51 and the lower member 52 are integrally joined, so that the entire surface of the bumper beam extension is covered with the discontinuous fiber reinforced resin layers 54, 54. It will be

The continuous fiber reinforced resin layer 53 having a long fiber UD as a reinforcing material has relatively high strength, but because there is a limit to the amount of deformation of UD, the formability becomes low, and thin and high ribs are formed Is difficult. On the other hand, although discontinuous fiber reinforced resin layers 54 and 54 having short randomly intertwined fibers as a reinforcing material have relatively low strength, the formability becomes high because the fibers are easily deformed, and the thin and high ribs It is easy to shape etc. Therefore, by laminating the discontinuous fiber reinforced resin layers 54, 54 on the continuous fiber reinforced resin layer 53 to form the upper member 51 and the lower member 52, both the strength and the formability of the upper member 51 and the lower member 52 can be achieved. be able to.

Similar to the bumper beam extension 18 described above, the body portion 31 of the bumper beam 19 also has a structure in which the entire surface of the continuous fiber reinforced resin layer 53 is covered with the discontinuous fiber reinforced resin layers 54 and 54. It is molded in the same manner as the extension 18.

The upper member 51 and the lower member 52 having the above-mentioned shape are integrally joined by laser welding 18a, 18a (see FIG. 7) of their joint flanges 51d, 51e, 52d, 52e. When the upper member 51 and the lower member 52 are bonded by adhesion, it is necessary to use a transparent resin having high adhesiveness to the resin constituting the discontinuous fiber reinforced resin layers 54, 54, but the laser welding is not always necessary. Also, it is not necessary to use a transparent resin.

Next, the mounting structure of the bumper beam extension 18 with respect to the front bulkhead 17 and the bumper beam 19 will be described based on FIGS. 4 to 6.

A mounting plate 81 made of a metal plate is welded to the front end of the front side frame front portion 14. Then, by screwing six bolts 83 passing through the rear fastening flanges 51c, 52c of the bumper beam extension 18 from the front to the weld nut 84 provided on the rear surface of the mounting plate 81, the bumper beam extension 18 and the front The bulkhead 17 is fastened to the mounting plate 81.

Further, by screwing bolts 85 through which fastening collars 34 inserted in the main body 31 of the bumper beam 19 from the front to the rear are inserted into front fastening flanges 51b and 52b of the bumper beam extension 18, they are screwed together. A bumper beam 19 is fastened to the front ends of the bumper beam extensions 18, 18.

Next, the operation of the first embodiment of the present invention having the above configuration will be described.

When a light collision load such as a collision with a leg of a pedestrian is input to the bumper beam 19, the longitudinal ribs 32b and the transverse ribs 32c of the initial load absorbing portion 32 are crushed and exhibit shock absorbing performance. When a large collision load is input due to a frontal collision with another car or the like, the main body portion 31 of the bumper beam 19 and the bumper beam extension 18 are crushed to exhibit shock absorbing performance.

At this time, the discontinuous fiber reinforced resin layers 54, 54 covering the surfaces of the upper member 51 and the lower member 52 to the first reinforcing ribs 51f, 51f, 52f, 52f, the second reinforcing ribs 51h, 51h, 52h, 52h and the third Since the reinforcing ribs 51i, 52i are integrally protruded, not only the reinforcing ribs can be easily formed by the discontinuous fibers 63 having high formability, but also the second moment of area of the bumper beam extension 18 The strength can be enhanced by increasing each reinforcing rib.

Further, front fastening flanges 51b and 52b and rear fastening flanges 51c and 52c extending in the vertical direction are integrally projected from discontinuous fiber reinforced resin layers 54 and 54 covering the surfaces of upper member 51 and lower member 52, and front fastening is performed. Since the flanges 51b and 52b and the rear fastening flanges 51c and 52c are connected by the second reinforcing ribs 51h, 51h, 52h and 52h (see FIG. 9), the fastening flanges can be easily formed with discontinuous fibers having high formability. Not only can the bumper beam extension 18 be firmly connected to the bumper beam 19 and the front side frame front part 14, but also the collision load inputted from the bumper beam 19 can be fronted by the second reinforcing ribs 51h, 51h, 52h, 52h It can be efficiently transmitted to the side frame front part 14.

At this time, since the nuts 64 for connecting the bumper beam 19 are inserted to the front fastening flanges 51b and 52b, the workability at the time of connecting the bumper beam 19 to the bumper beam extension 18 can be enhanced. Moreover, since the front end of the front fastening flanges 51b and 52b is inclined forward (see FIG. 6), the backward collision load input from the bumper beam 19 can be reliably transmitted to the bumper beam extension 18.

The thickness of the discontinuous fiber reinforced resin layers 54, 54 of the upper member 51 and the lower member 52 before press forming is t0, and the thickness of the general part of the discontinuous fiber reinforced resin layers 54, 54 after press forming is t1. And the first reinforcing ribs 51f, 51f, 52f, 52f of the discontinuous fiber reinforced resin layers 54, 54, the second reinforcing ribs 51h, 51h, 52h, 52h and the third reinforcing ribs 51i,. Since t1 <t0 <t2 when the thickness is t2, the discontinuous fibers 63 are made to approach the continuous fiber reinforced resin layer 53 in a thin general part to enhance the reinforcing effect against the collision load in the oblique direction. Not only can the discontinuous fibers be formed by the thick first reinforcing ribs 51f, 51f, 52f, 52f, the second reinforcing ribs 51h, 51h, 52h, 52h and the third reinforcing ribs 51i. To increase the 63 ... filling rate of can increase the second moment effectively.

Further, the main body 31 of the bumper beam 19 vertically connects the two U-shaped cross sections 33, 33 formed in the U-shaped cross section in which the continuous fiber reinforced resin layer 53 is opened forward. Since the upper wall 33a, the lower wall 33b and the bottom wall 33c of the U-shaped cross sections 33, 33 are connected by the longitudinal ribs 33f consisting of the continuous fiber reinforced resin layers 54, the U shape reinforced by the longitudinal ribs 33f The cross-sections 33, 33 are light in weight and high in bending rigidity and torsional rigidity.

In addition, the bumper beam 19 has an initial load absorbing portion 32 coupled to the front side of the main body portion 31, and the first pins 33g ... made of discontinuous fiber reinforced resin layers 54, 54 are provided in the main body portion 31 so as to protrude The initial load absorbing portion 32 is joined to the main body portion 31 by melting the head of the first pins 33g which penetrate the pin holes 32d of the portion 32, so that the initial load absorbing portion 32 is easily made to the main body portion 31. As well as being coupled, the bumper beam 19 can be closed in cross section to increase bending stiffness.

The bumper beam extension 18 and the bumper beam 19 described above are continuous fibers 61 arranged in the front-rear direction (including the vertical direction), which is the input direction of the collision load, and the vehicle width direction, which is a direction orthogonal to the input direction of the collision load. (Continuous fibers 62 arranged in a vertical direction) are arranged in a lattice, and discontinuous fibers 63 are randomly oriented on both surfaces of a continuous fiber reinforced resin layer 53 bonded with thermoplastic nylon. Since it is constituted by laminating the discontinuous fiber reinforced resin layers 54, 54 joined by thermoplastic polypropylene, it has a large strength against the collision load in the front-rear direction input parallel to the orientation direction of one continuous fiber 61. However, as shown in FIG. 12, when the collision load in the oblique direction is input, the lattice shapes of the continuous fibers 61. .

However, as shown in FIGS. 8 and 13, the length L2 of the randomly oriented discontinuous fibers 63... Is made longer than the diagonal length L1 of the lattice of the continuous fibers 61. Grids of continuous fibers 61 ... 62 are effectively reinforced by discontinuous fibers 63 ... to suppress out-of-plane deformation and increase the compressive fracture strength of bumper beam extension 18 and bumper beam 19 Thus, it is possible to enhance the impact absorbing effect on the collision load input from various directions.

Moreover, since the continuous fiber reinforced resin layer 53 has weak portions 53a ... which partially lowers the strength (see FIG. 11), the buckling strength of the bumper beam extension 18 and the bumper beam 19 is locally reduced to improve the front side frame. Ensuring impact absorption of bumper beam extension 18 and bumper beam 19 with discontinuous fiber reinforced resin layers 54, 54 laminated to continuous fiber reinforced resin layer 53 while reducing peak load transmitted to front part 14 it can.

In addition, since the discontinuous fiber reinforced resin layers 54 and 54 of the bumper beam extension 18 and the bumper beam 19 wrap all the both sides and ends of the continuous fiber reinforced resin layer 53, the continuous fiber reinforced resin layer 53 ends in the early stage of the oblique collision. Breaking from the part can be avoided by reinforcing the end with the discontinuous fiber reinforced resin layer 54, 54.

Also, the thermoplastic resin of the inner continuous fiber reinforced resin layer 53 is nylon, and the thermoplastic resin of the outer discontinuous fiber reinforced resin layers 54, 54 is polypropylene. Can be protected.

As shown in the comparative example of FIG. 15 (B), in the case where the impact absorbing member comprises only the continuous fiber reinforced resin layer 53 in which the first continuous fibers 61... And the second continuous fibers 62. When the input direction of the collision load coincides with the direction of the first continuous fiber 61 or the second continuous fiber 62, a large strength can be obtained, but when the input direction of the collision load is oblique, it is rapid. There is a problem that the strength decreases.

On the other hand, as shown in the embodiment of FIG. 15 (B), when the impact absorbing member is constructed by laminating the discontinuous fiber reinforced resin layers 54, 54 on the continuous fiber reinforced resin layer 53, the impact load Even if the input direction is oblique, the decrease in strength is slightly suppressed, and the impact load can be minimized with the influence of the input direction to ensure stable shock absorption performance.

Second embodiment

Next, a second embodiment of the present invention will be described based on FIG.

In the first embodiment described in FIG. 10, the continuous fiber reinforced resin layer 53 having the fragile portions 53a is a single layer, but in the second embodiment, the continuous fiber reinforced resin layer having the fragile portions 53a. 53 and a continuous fiber reinforced resin layer 53 having no fragile portion 53a are laminated in two layers, and discontinuous fiber reinforced resin layers 54, 54 are laminated on the outside thereof.

According to the present embodiment, since the continuous fiber reinforced resin layers 53, 53 are composed of two layers including the layer having the fragile portions 53a and the layer not having the fragile portions 53a, the fragile portions 53a are provided. The impact absorption amount of the bumper beam extension 18 and the bumper beam 19 can be sufficiently secured by minimizing the influence of the above.

Third embodiment

Next, a third embodiment of the present invention will be described based on FIG. 17 to FIG. In the first embodiment described above, the bumper beam 19 and the bumper beam extension 18 are connected by the bolts 85... And the nuts 64. However, in the third embodiment, the bumper beam 19 and the bumper beam extension 18 Bonded by heat caulking.

As shown in FIG. 17, the bumper beam 19 has a plurality of projecting frontwards to the upper flange 33 d of the upper U-shaped cross section 33 and the lower flange 33 e of the lower U-shaped cross section 33. First pins 33g are formed. Further, three second pins 33k,... Projecting backward are formed on both end portions of the bottom wall 33c of the U-shaped cross section 33 in the vehicle width direction. On the other hand, in the front fastening flanges 51b, 52b of the bumper beam extension 18, three pin holes 51m,.

Then, the left and right six second pins 33k protruding on the rear surface of the bumper beam 19 are inserted into the pin holes 51m and 52m of the front fastening flanges 51b and 52b at the front end of the bumper beam extension 18, and the second pins By melting (thermally caulking) 33 k, the bumper beam 19 is fastened to the front ends of the bumper beam extensions 18, 18.

The main body 31 of the bumper beam 19 is manufactured as follows. As shown in FIG. 18A, the mold 55 for press-molding the main body 31 of the bumper beam 19 has a female mold 56 having a concave cavity 56 a for molding the outer surface of the main body 31, and the main body 31. It consists of a male mold 57 having a convex core 57a for molding the inner surface, and in the cavity 56a and the core 57a, grooves 56b,..., 57b for molding ribs and pins are formed. The mold 55 is opened, and the first prepreg 58 of the discontinuous fiber reinforced resin, the second prepreg 59 of the continuous fiber reinforced resin, and the third prepreg 60 of the discontinuous fiber reinforced resin are preheated on the female die 56 The fiber-reinforced resin product of the main body portion 31 is obtained by arranging in the above-described state, pressing and molding the male mold 57 after clamping.

As shown in FIG. 18B, the main body 31 of the bumper beam 19 press-formed by the mold 55 has a continuous fiber reinforced resin layer 53 and a non-conductive surface covering the outer surface and the inner surface of the continuous fiber reinforced resin layer 53. It comprises the continuous fiber reinforced resin layers 54, 54.

The second prepreg 59 for forming the continuous fiber reinforced resin layer 53 is a continuous fiber 61... 62 of glass fiber UD (sheet in which continuous fibers are aligned in one direction) 0 ° direction, 90 ° direction and What was laminated | stacked on three layers of 0 degree direction is made into a reinforcing material, and they are impregnated with a thermoplastic resin (nylon 6 or nylon 66), and are comprised. The 0 ° direction refers to the state in which the UD extends in the front-rear direction (including the vertical direction) in a state where the bumper beam 19 is mounted on the vehicle body, and the 90 ° direction in a state where the bumper beam 19 is mounted on the vehicle body A state of extending in the vehicle width direction (including the vertical direction).

On the other hand, the first and third prepregs 58 and 60 for molding the discontinuous fiber reinforced resin layers 54 and 54 laminated on both sides of the continuous fiber reinforced resin layer 53 are mats of discontinuous fibers 63 of glass fiber. As a reinforcing material, they are impregnated with a thermoplastic resin (polypropylene etc.).

Vertical ribs 33 f and first pins 33 g are integrally formed on the discontinuous fiber reinforced resin layer 54 laminated on the inner surface (front surface) of the main body 31 of the bumper beam 19. Second pins 33k are integrally formed with the discontinuous fiber reinforced resin layer 54 laminated on the outer surface (rear surface).

In the process of pressing the main body portion 31 of the bumper beam 19, when the male die 57 is lowered with respect to the female die 56, the second prepreg 59 is pressed by the cavity 56 a of the female die 56 and the core 57 a of the male die 57. , And the main body 31 is formed. At this time, since the first and third prepregs 58 and 60 having a discontinuous fiber as a reinforcing material can be easily deformed, the first prepreg 58 sandwiched by the second prepreg 59 and the cavity 56 a of the female die 56 is While flowing into the groove 56b of the cavity 56a to simultaneously form the second pins 33k, the thin film is laminated along a part of the outer surface of the main body 311. Similarly, the third prepreg 60 sandwiched by the second prepreg 59 and the core 57a of the male mold 57 flows into the groove 57b of the core 57a, and the longitudinal rib 33f of the inner surface of the main body and the first pin 33g Are molded simultaneously, and are laminated in a thin film along the entire inner surface of the upper member 51.

The continuous fiber reinforced resin layer 53 having a long fiber UD as a reinforcing material has relatively high strength, but because there is a limit to the amount of deformation of UD, the formability becomes low, and thin and high ribs are formed Is difficult. On the other hand, although discontinuous fiber reinforced resin layers 54 and 54 having short randomly intertwined fibers as a reinforcing material have relatively low strength, the formability becomes high because the fibers are easily deformed, and the thin and high ribs It is easy to shape etc. Therefore, by laminating the discontinuous fiber reinforced resin layers 54, 54 on the continuous fiber reinforced resin layer 53 to form the body portion 31 of the bumper beam 19, both the strength and the formability of the body portion 31 of the bumper beam 19 can be achieved. be able to.

Similar to the body portion 31 of the bumper beam 19 described above, the bumper beam extension 18 also has a structure in which the upper and lower surfaces of the continuous fiber reinforced resin layer 53 are covered with the discontinuous fiber reinforced resin layers 54 and 54. It is shaped in the same way as the body 31 of the beam 19.

Next, the operation of the third embodiment of the present invention having the above configuration will be described.

When the bumper beam 19 which is press-formed in the front-rear direction and the bumper beam extension 18 which is press-formed in the vertical direction are coupled, second pins 33 k that are provided to project rearward from the bumper beam 19 are of the bumper beam extension 18. Because the bumper beam 19 and the bumper beam extension 18 are joined by fitting the pin holes 51m, 52m ... formed in the front fastening flanges 51b, 52b ..., 52m ... and melting the head of the second pins 33k ... (thermally caulking) The bumper beam 19 and the bumper beam extension 18 can be coupled with a simple structure without the need for fasteners, such as bolts and nuts.

In addition, since the first pins 33g and the second pins 33k are integrally formed with the bumper beam 18 which is press-formed in the front and rear direction, the first and second pins 33g are formed when the body portion 31 of the bumper beam 19 is punched out. ..., 33k ... do not get in the way, and the first and second pins 33g ..., 33k ... extend in the front-rear direction, which is the input direction of the collision load, so the first and second pins 33g ... due to the collision load Can be prevented, and the connection between the initial load absorbing portion 32 and the bumper beam extension 18 with respect to the main body portion 31 can be made difficult to remove.

Further, the main body portion 31 of the bumper beam 19 includes discontinuous fiber reinforced resin layers 54, 54 laminated on the surface of the continuous fiber reinforced resin layer 53, and the discontinuous fiber reinforced resin layers 54, 54 include the first pins 33g. Since the two pins 33k are integrally provided (see FIG. 18), the continuous fiber reinforced resin layer 53 having low formability makes the first and second pins 33g,. The first and second pins 33g,..., 33k... Can be easily molded with the resin layers 54, 54, and have sufficient strength to be reinforced with discontinuous fibers. Beam extensions 18 can be rigidly coupled.

Further, since the main body portion 31 of the bumper beam 19 and the bumper beam extension 18 are provided with the continuous fiber reinforced resin layer 53 in which the continuous fibers 61... 62 are oriented in two directions orthogonal to each other (see FIG. 8) Not only can the bending strength of the bumper beam extension 19 and the bumper beam extension 18 be enhanced, but also the bumper beam 19 and the bumper beam extension 18 can be crushed sequentially from the tip side upon impact load input to enhance the shock absorbing performance.

Further, the body portion 31 of the bumper beam 19 is provided with the longitudinal ribs 33f extending in the input direction of the collision load in the discontinuous fiber reinforced resin layer 54, and the bumper beam extension 18 is input in the collision load in the discontinuous fiber reinforced resin layer 54 Since the first reinforcing ribs 51f, 51f, 52f, 52f and the second reinforcing ribs 51h, 51h, 52h, 52h are extended (see FIG. 9), the longitudinal shape of complex shape is made of discontinuous fiber reinforced resin having excellent formability. The ribs 33f ..., the first reinforcing ribs 51f, 51f, 52f, 52f and the second reinforcing ribs 51h, 51h, 52h, 52h can be easily formed, and the longitudinal ribs 33f ..., the first reinforcing ribs 51f, 51f, 52f, 52f and the second reinforcing ribs 51h, 51h, 52h, 52h, the main body 31 of the bumper beam 19 and the Not only can increase the bending strength by increasing the second moment of the par beam extension 18, it is possible to improve the shock absorbing capacity due to their collapse.

Further, as shown in FIG. 19, the bumper beam extension 18 is provided with front fastening flanges 51b and 52b which are bent in a direction intersecting with the collision load input direction to solidify discontinuous fibers with a thermoplastic resin, Because the bumper beam 19 is connected to the fastening flanges 51b and 52b, when a collision load is input from the bumper beam 19 to the bumper beam extension 18, the front fastening flanges 51b and 52b having a large pressure receiving area trigger (trigger to cause destruction The shock absorbing performance can be enhanced by sequentially crushing the bumper beam extension 18 in the front-rear direction.

As mentioned above, although embodiment of this invention was described, this invention can perform various design changes in the range which does not deviate from the summary.

For example, the bumper beam extensions and bumper beams of the present invention are not limited to those on the front side of the vehicle, but may be those on the rear side.

Further, the vehicle body frame of the present invention is not limited to the front side frame front portion 14 of the embodiment, but may be a frame disposed in the front and rear direction at the front or rear of the vehicle body.

The FRP of the present invention is not limited to the GFRP (glass fiber reinforced resin) of the embodiment, and may be another type of FRP such as a carbon fiber reinforced resin or an aramid fiber reinforced resin.

Further, the shock absorbing member of the present invention is not limited to the bumper beam extension 18 and the bumper beam 19 of the embodiment.

In the embodiment, the two U-shaped cross sections 33, 33 are combined to constitute the main body 31 of the bumper beam 19, but the two U-shaped cross sections 33, 33 are integrally formed. It is good.

Claims (21)

1. Randomly formed on both sides of a continuous fiber reinforced resin layer (53) in which continuous fibers (61, 62) oriented in a lattice shape in a first direction and a second direction orthogonal to the first direction are bonded by a first thermoplastic resin. A discontinuous fiber-reinforced resin layer (54) in which discontinuous fibers (63) oriented to each other are bonded with a second thermoplastic resin, and the length of the discontinuous fiber (63) is the continuous fiber An automobile shock absorbing member characterized in that it is larger than the diagonal length of the (61, 62) grid.
2. The automotive shock absorbing member according to claim 1, characterized in that the continuous fiber reinforced resin layer (53) has a weakened portion (53a) that partially lowers the strength.
3. The automobile according to claim 2, characterized in that the continuous fiber reinforced resin layer (53) comprises a plurality of layers including a layer having the fragile portion (53a) and a layer not having the fragile portion (53a). Shock absorbers.
4. The said discontinuous fiber reinforced resin layer (54) is characterized by wrapping all the both sides and the edge part of the said continuous fiber reinforced resin layer (53) in any one of Claims 1-3. Shock absorbers for automobiles.
5. The automotive shock absorbing member according to any one of claims 1 to 4, wherein the first thermoplastic resin is nylon and the second thermoplastic resin is polypropylene.
6. The vehicle according to any one of the preceding claims, characterized in that the discontinuous fiber reinforced resin layer (54) comprises press-formed reinforcing ribs (51h, 52h, 51i, 52i). Shock absorbers.
7. The discontinuous fiber (63) of the discontinuous fiber reinforced resin layer (54) is characterized in that it is obtained by cutting the impact absorbing member (18) into a predetermined length. The impact-absorbing member of the motor vehicle according to any one of claims 6 to 10.
8. The shock absorbing member is a bumper beam extension (18) disposed between a vehicle body frame (14) extending in the front-rear direction and a bumper beam (19) extending in the vehicle width direction, and the bumper beam extension (18) An upper member (51) and a lower member (52) having a hat-like cross section in a direction view, formed at both ends in the vehicle width direction of the upper member (51) and covered with the discontinuous fiber reinforced resin layer (54) Edges of the joining flange (51d, 51e) and edges of the joining flange (52d, 52e) formed at both ends in the vehicle width direction of the lower member (52) and covered with the discontinuous fiber reinforced resin layer (54) The shock absorbing member for an automobile according to any one of claims 1 to 7, characterized in that laser welding (18a) is carried out by overlapping them.
9. The first reinforcing rib (51f, 52f) is integrally protruded from the edge of the joining flange (51d, 52d, 51e, 52e) of the discontinuous fiber reinforced resin layer (54). The shock absorbing member of a car according to claim 1.
10. Second reinforcing ribs (51h, 52h) extending in the front-rear direction from the discontinuous fiber reinforced resin layer (54) covering the outer surfaces of the upper member (51) and the lower member (52) are integrally protruded. A third reinforcing rib (51i, 52i) extending in a direction inclined with respect to the front-rear direction is integrally formed from the discontinuous fiber reinforced resin layer (54) covering the inner surface of the upper member (51) and the lower member (52). The impact-absorbing member for an automobile according to claim 8 or 9, characterized in that
11. Fastening flanges (51b, 51c, 52b, 52c) extending vertically from the front end and the rear end of the discontinuous fiber reinforced resin layer (54) covering the outer surfaces of the upper member (51) and the lower member (52) 11. The device according to claim 10, characterized in that they are integrally provided and connected between the front and rear fastening flanges (51b, 51c, 52b, 52c) by the second reinforcing rib (51h, 52h). Shock absorbers for automobiles.
12. 12. A car shock absorber according to claim 11, characterized in that a nut (64) for connecting the bumper beam (19) is inserted into the front fastening flange (51b, 52b).
13. The impact-absorbing member for an automobile according to claim 12, characterized in that the front end of the fastening flange (51b, 52b) is inclined outward in the vehicle width direction.
14. The thickness of the discontinuous fiber reinforced resin layer (54) before press molding is t0, and the thickness of the general portion of the discontinuous fiber reinforced resin layer (54) after press molding is t1. Assuming that the thickness of the second reinforcing rib (51h, 52h) of the resin layer (54) and the thickness of the third reinforcing rib (51i, 52i) after press molding is t2, t1 <t0 <t2 The shock absorbing member for an automobile according to any one of claims 11 to 13, characterized in that
15. The shock absorbing member is a bumper beam (19) extending in the vehicle width direction, and the bumper beam (19) is formed in a U-shaped cross section opening the continuous fiber reinforced resin layer (53) outward in the front-rear direction The plurality of U-shaped cross sections (33) are vertically continuous, and the longitudinal rib (33f) composed of the discontinuous fiber reinforced resin layer (54) is the upper wall (33) of the U-shaped cross section (33). The impact-absorbing member for an automobile according to any one of claims 1 to 7, further comprising a main body (31) connecting the lower wall (33b) and the bottom wall (33c). .
16. The bumper beam (19) comprises an initial load absorbing portion (32) coupled to the front-rear direction outer side of the main body portion (31), and the main body portion (31) comprises the discontinuous fiber reinforced resin layer (54) A pin (33g) is provided in a protruding manner, and a head portion of the pin (33g) which penetrates a pin hole (32d) formed in the initial load absorbing portion (32) is melted to the main body portion (31) 16. An automotive shock absorber as claimed in claim 15, characterized in that the initial load absorber (32) is joined.
17. A bumper beam (19) made of a fiber reinforced resin press-formed in the front-rear direction and a bumper beam extension (18) made of a fiber-reinforced resin press-formed in the vertical direction are made of the shock absorbing member according to claim 1; An automobile body structure combining a bumper beam (19) and the bumper beam extension (18), comprising:
    A pin (33k) protruding inward in the front-rear direction from the bumper beam (19) is fitted in a pin hole (51m, 52m) formed in the bumper beam extension (18), and a head of the pin (33k) The car body structure of an automobile, characterized in that the bumper beam (19) and the bumper beam extension (18) are joined by heat caulking.
18. The bumper beam (19) comprises a discontinuous fiber reinforced resin layer (54) laminated at least in the front-rear direction inside of the continuous fiber reinforced resin layer (53), and the discontinuous fiber reinforced resin layer (54) The vehicle body structure of a car according to claim 17, characterized in that it comprises 33k).
19. The bumper beam (19) and the bumper beam extension (18) are characterized by comprising a continuous fiber reinforced resin layer (53) in which continuous fibers (61, 62) are oriented in two directions orthogonal to each other. A vehicle body structure of a car according to claim 17 or 18.
20. The bumper beam (19) and the bumper beam extension (18) include a discontinuous fiber reinforced resin layer (54) laminated to the continuous fiber reinforced resin layer (53), and the discontinuous fiber reinforced resin layer (54) 20. The vehicle body structure of an automobile according to claim 19, wherein reinforcement ribs (33f, 51f, 52f, 51h, 52h) extending in the collision load input direction) are formed.
21. A fastening flange (51b, 52b) made of discontinuous fiber resin in which the pin hole (51m, 52m) is formed is integrally protruded from the front and rear direction outer end of the bumper beam extension (18), and the fastening flange (51b) , 52b) is characterized in that the tip end side is inclined outward in the front-rear direction, The vehicle body structure of an automobile according to any one of claims 17 to 20.

Images