WO2014200015A1 - 繊維強化樹脂部材 - Google Patents

繊維強化樹脂部材 Download PDF

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Publication number
WO2014200015A1
WO2014200015A1 PCT/JP2014/065445 JP2014065445W WO2014200015A1 WO 2014200015 A1 WO2014200015 A1 WO 2014200015A1 JP 2014065445 W JP2014065445 W JP 2014065445W WO 2014200015 A1 WO2014200015 A1 WO 2014200015A1
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WO
WIPO (PCT)
Prior art keywords
fiber
reinforced resin
layer
resin member
fibers
Prior art date
Application number
PCT/JP2014/065445
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English (en)
French (fr)
Inventor
重人 安原
朋也 彌武
Original Assignee
本田技研工業株式会社
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by 本田技研工業株式会社 filed Critical 本田技研工業株式会社
Priority to US14/897,541 priority Critical patent/US9884466B2/en
Priority to CN201480033471.0A priority patent/CN105324418B/zh
Priority to JP2015522824A priority patent/JP5988181B2/ja
Priority to EP14810476.3A priority patent/EP3009467B1/en
Publication of WO2014200015A1 publication Critical patent/WO2014200015A1/ja

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/22—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure
    • B29C70/228—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure the structure being stacked in parallel layers with fibres of adjacent layers crossing at substantial angles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/12—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/14—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by a layer differing constitutionally or physically in different parts, e.g. denser near its faces
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16F—SPRINGS; SHOCK-ABSORBERS; MEANS FOR DAMPING VIBRATION
    • F16F7/00—Vibration-dampers; Shock-absorbers
    • F16F7/12—Vibration-dampers; Shock-absorbers using plastic deformation of members
    • F16F7/124—Vibration-dampers; Shock-absorbers using plastic deformation of members characterised by their special construction from fibre-reinforced plastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/20—All layers being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B32B2260/023—Two or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/514—Oriented
    • B32B2307/518—Oriented bi-axially
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/56—Damping, energy absorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars

Definitions

  • the present invention relates to a fiber-reinforced resin member in which a fiber-reinforced resin layer in which continuous fibers are reinforced with a synthetic resin has a corner portion in a cross section perpendicular to the axial direction.
  • An energy absorber which is sewn so as to penetrate in a direction is known from US Pat.
  • the energy absorbing body exerts an energy absorbing effect by breaking so as to be divided into two layers at the central portion in the thickness direction while breaking the constraining yarn at the time of inputting the compressive load.
  • the above-mentioned conventional fibers not only increase the manufacturing cost because continuous fibers constitute a three-dimensional fabric, but also exhibit energy absorption effects by breakage of restraint yarns.
  • the number of sewing processes is increased, and the manufacturing cost is further increased.
  • the amount of energy absorption at the time of breaking increases so that the restraining yarn is hardly broken at the time of inputting a compressive load and divided into two layers at the center in the thickness direction, but they cross each other.
  • the amount of continuous fibers oriented as such may decrease and the strength itself of the energy absorber may decrease.
  • the influence of the energy absorption characteristics by the resin is large, and the energy absorption characteristics may not be stabilized due to environmental factors such as temperature change.
  • the present invention has been made in view of the above-described circumstances, and an object of the present invention is to provide a fiber-reinforced resin member which exhibits a large energy absorbing effect at the time of input of an axial compressive load while having a simple structure.
  • a fiber reinforced resin layer in which continuous fibers are reinforced with a synthetic resin has a corner portion in a cross section perpendicular to the axial direction and in a cross section perpendicular to the axial direction.
  • the continuous fiber comprises an axially-oriented axial fiber and an axially-perpendicular fiber, wherein the density of the axially-perpendicular fiber at the outside of the corner portion is
  • a fiber-reinforced resin member characterized in that the density of the fibers in the direction perpendicular to the axis at the inner side of the corner portion is made higher.
  • the fiber reinforced resin layer is composed of a plurality of laminated layers, and the synthetic resin of the layer disposed inside the corner portion has high compressive strength.
  • a fiber-reinforced resin member is proposed which is a thermoplastic resin which is hard to expand, and the synthetic resin of the layer disposed on the outside of the corner portion is a thermoplastic resin which has a low compressive strength and is easy to expand. Be done.
  • a fiber reinforced resin member in addition to the second feature, a fiber reinforced resin member is proposed, in which the fiber reinforced resin layer has a flat portion continuous with the corner portion.
  • the axial fiber in addition to any one of the first to third features, is disposed adjacent to a bending portion of the axial perpendicular direction fiber.
  • the fiber reinforced resin member which makes 4th characteristics is proposed.
  • the fiber-reinforced resin member may have a fifth feature in which the cross section of the fiber-reinforced resin member is point-symmetrical. Is proposed.
  • a layer in which the layer disposed on the inner side is disposed on the outer side at an axial end of the fiber reinforced resin member A fiber-reinforced resin member is proposed, which has a sixth feature of projecting more axially.
  • the first flat portion 12 and the second flat portion 14 of the embodiment correspond to the flat portion of the present invention
  • the first corner portion 13 of the embodiment corresponds to the corner portion of the present invention
  • the first layer 17 corresponds to the layer laminated to the outside of the present invention
  • the second layer 18 of the embodiment corresponds to the layer laminated to the inside of the present invention.
  • the fiber-reinforced resin layer in which continuous fibers are reinforced with a synthetic resin has a corner portion in a cross section orthogonal to the axial direction.
  • the continuous fiber comprises an axially oriented axial fiber and an orthogonally oriented fiber, and the density of the perpendicularly oriented fiber at the outside of the corner portion is Since the density is higher than the density of the fibers, when the axial load is input and the fiber reinforced resin member breaks, the fibers in the direction perpendicular to the axis arranged at high density in the outer layer of the corner portion are positively stretched. By breaking, a large energy absorption effect can be exhibited.
  • the fiber reinforced resin member has a simple structure in which the density of fibers in the direction perpendicular to the axis is changed, the increase in the manufacturing cost can be minimized.
  • the influence of the resin on the energy absorption characteristics is small, stable energy absorption characteristics can be obtained regardless of environmental factors such as temperature change.
  • the fiber reinforced resin layer is composed of a plurality of laminated layers, and the synthetic resin of the layer disposed inside the corner portion is a thermoplastic resin which has high compressive strength and is difficult to expand.
  • the synthetic resin of the layer placed outside the corner is a thermoplastic resin with low compressive strength and easy to expand
  • the strength of the fiber reinforced resin member is usually in the layer inside the corner with high compressive strength. Breaking and expanding the outer layer of the corner portion with low compressive strength for the input of the axial load while securing it, and breaking the axially orthogonal fibers arranged there to efficiently exhibit the energy absorption effect Can.
  • the fiber reinforced resin layer has a flat portion continuous with the corner portion, when an axial load is input, the corner portion of the fiber in the flat portion is first separated. In the direction perpendicular to the axis of the fiber, it becomes a trigger to break and the break in the direction perpendicular to the axis can be promoted.
  • the axial fibers are disposed adjacent to the bent portion of the axially perpendicular fibers, the axial load is input and the axial orthogonal fibers are When breaking, the axial movement of the fibers in the direction perpendicular to the axis can be prevented by the axial fibers to enable reliable breaking of the fibers in the direction perpendicular to the axis.
  • the cross section of the fiber reinforced resin member is point-symmetrical in shape, the fiber reinforced resin member is prevented from being inclined with respect to the axis when an axial load is input.
  • the reinforced resin member can be broken along a long distance in the axial direction to enhance the energy absorption effect.
  • the layer disposed on the inner side protrudes in the axial direction more than the layer disposed on the outer side.
  • the inner layer breaks first, and then the outer layer breaks, allowing the energy absorption to be incrementally enabled to allow stable energy absorption.
  • FIG. 1 is a perspective view of a fiber reinforced resin member.
  • First Embodiment FIG. 2 is an enlarged view of part 2 of FIG.
  • First Embodiment FIG. 3 is an explanatory view of the deformation of the cross section of the corner portion when an axial load is input.
  • First Embodiment FIG. 4 is an explanatory view of delamination of a flat portion when an axial load is input.
  • First Embodiment FIG. 5 is an explanatory view of the expansion direction of the first corner portion and the second corner portion.
  • First Embodiment FIG. 6 is a cross-sectional view of a fiber reinforced resin member.
  • Second Embodiment FIG. 7 is a perspective view of a fiber reinforced resin member.
  • Third Embodiment FIG. 2 is an enlarged view of part 2 of FIG.
  • First Embodiment FIG. 3 is an explanatory view of the deformation of the cross section of the corner portion when an axial load is input.
  • First Embodiment FIG. 4 is
  • FIGS. 1 to 5 a first embodiment of the present invention will be described based on FIGS. 1 to 5.
  • a fiber reinforced resin member 11 used for a frame or the like of an automobile includes a first flat portion 12 and a pair of first corner portions 13 and 13 bent at a right angle from the first flat portion 12 And a pair of second flat portions 14 and 14 connected to the first corner portions 13 and 13 and a pair of flange portions 16 and 16 bent at a right angle in the reverse direction from the pair of second flat portions 14 and 14 in the axial direction Have a constant hat-like cross section.
  • FIG. 2 is an enlarged cross-sectional view of the first corner portion 13 of the fiber reinforced resin member 11.
  • the fiber reinforced resin layer of the fiber reinforced resin member 11 is a first layer 17 outside the bending direction of the first corner portion 13;
  • the second layer 18 on the inner side in the bending direction of the one corner portion 13 is stacked to form two layers.
  • the outer first layer 17 of the first corner portion 13 has a layer of axially extending fibers 19 which are arranged parallel to each other and extend in the axial direction, and an axis of two layers which are laminated on both sides and extend in the direction perpendicular to the axis It is composed of right angle direction fibers 20.
  • the axial fibers 19 and the right-angled fibers 20 are continuous fibers of glass or carbon, and the matrix resin is polypropylene which is easily expanded in volume when crushed because of its relatively low compressive strength.
  • the inner second layer 18 of the first corner portion 13 is a layer of axially extending fibers 19 arranged in parallel with each other in parallel and an axis of one layer laminated on one side thereof and extending in a direction perpendicular to the axis It is composed of right angle direction fibers 20.
  • the axial fibers 19 and the axially right fibers 20 are continuous fibers of glass or carbon, and the matrix resin is nylon which is difficult to expand in volume when crushed because of its relatively high compressive strength.
  • the density of the fibers 20 in the direction perpendicular to the axis in the bending direction outer portion increases, and the direction of the fibers 20 in the direction perpendicular to the axis in the bending direction inner portion (the second layer 18) The density is lower.
  • the fiber reinforced resin member 11 has a two-layer structure of the first layer 17 and the second layer 18, but the number of layers to be stacked is not limited to two, and is arbitrarily set It is possible. Further, the number of layers of axial fibers 19... And axially orthogonal fibers 20... Inside the first layer 17 and the second layer 18 is also arbitrary. The axial fibers 19 and the right-angled fibers 20 may be mutually woven or may be simply superposed.
  • FIG. 3 schematically shows the expansion of the cross section of the first corner portion 13.
  • the energy perpendicular to the axis-perpendicular direction of the outer first layer 17 is strongly drawn and broken to absorb the collision energy.
  • the fibers 20 in the direction perpendicular to the axis of the first layer 17 are arranged in the second layer 18 at a density higher than the fibers 20 in the direction perpendicular to the axis, the number of fibers 20 in the direction perpendicular to the axis breaks is increased. Energy absorption performance can be enhanced.
  • the stretched axial-perpendicular direction fibers 20 By preventing the axial fibers 19 from moving inward in the bending direction with the axial fibers 19 ..., it is possible to accelerate the breakage of the axially perpendicular fibers 20.
  • the matrix resin of the first layer 17 is polypropylene which is relatively low in compressive strength and easily expands in volume when crushed, and the matrix resin of the second layer 18 is relatively high in compressive strength and is crushed Since the first layer 17 is largely expanded at the time of input of an axial load, the fibers 20... Can be effectively broken to further enhance the energy absorbing performance. In addition, since the second layer 18 that does not actively contribute to energy absorption has high strength, the strength of the fiber reinforced resin member 11 can be secured at normal times, not at the time of vehicle collision.
  • the first flat portion 12 and the second flat portion 14 sandwiching the first corner portion 13 delaminate at the boundary between the first layer 17 and the second layer 18 when an axial load is input. As a result, the crush of the first corner portion 13 is promoted and the energy absorption is further improved.
  • the 2nd corner part 15 also exhibits energy absorption performance by the same operation.
  • the reinforcing resin member 11 having a hat-shaped cross section includes the first corner portion 13 and the second corner portion 15 whose expansion directions are opposite to each other, the fiber in the direction perpendicular to the axis is input when an axial load is input.
  • the tension of 20 ... can be increased efficiently to enhance the energy absorption performance.
  • the fiber reinforced resin member 11 has a simple structure in which the density of the fibers 20 in the direction perpendicular to the axis is changed, the increase in manufacturing cost can be minimized.
  • the influence of the resin on the energy absorption characteristics is small, stable energy absorption characteristics can be obtained regardless of environmental factors such as temperature change.
  • the fiber-reinforced resin member 11 according to the first embodiment has a hat-like cross-sectional shape that is not point-symmetrical, but the fiber-reinforced resin member 11 according to the second embodiment is point-symmetrical with respect to the axial center L It has an approximately S-shaped cross-sectional shape.
  • the cross-sectional shape of the fiber reinforced resin member 11 point-symmetrical, it is possible to prevent the fiber reinforced resin member 11 from being inclined with respect to the axial center L when an axial load is input. Can be reliably crushed over a long stroke to enhance energy absorption performance.
  • the first corner portion 13 exerts the same energy absorbing effect as that of the first embodiment when the fiber reinforced resin members 11 and 21 are crushed by the axial load.
  • the second layer 18 exposed at the axial end is crushed first, and then both the second layer 18 and the first layer 17 are crushed simultaneously, thereby gradually increasing the energy absorption amount and stabilizing it. Energy absorption can be made possible.
  • the fiber reinforced resin layer of the fiber reinforced resin member 11 does not necessarily need to be divided into a plurality of layers, and may be a single layer.
  • vertical direction fiber 20 ... should just be higher than the inner side of a corner part in the outer side of a corner part.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Textile Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Medicinal Chemistry (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Composite Materials (AREA)
  • Body Structure For Vehicles (AREA)
  • Laminated Bodies (AREA)
  • Vibration Dampers (AREA)
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Abstract

繊維強化樹脂部材（１１）の連続繊維は、軸方向に配向された軸方向繊維（１９）と軸直角方向に配向された軸直角方向繊維（２０）とからなり、コーナー部（１３）の外側の第１層（１７）における軸直角方向繊維（２０）の密度を、コーナー部（１３）の内側の第２層（１８）における軸直角方向繊維（２０）の密度よりも高くしたので、軸方向荷重が入力して繊維強化樹脂部材（１１）が破壊するときに、コーナー部（１３）の外側の第１層（１７）に高密度で配置された軸直角方向繊維（２０）が積極的に引き伸ばされて破断することで、大きなエネルギー吸収効果を発揮することができる。しかも繊維強化樹脂部材（１１）は、その内部の軸直角方向繊維（２０）の密度を変化させただけの簡単な構造であるため、製造コストの増加を最小限に抑えることができる。

Description

繊維強化樹脂部材
　本発明は、連続繊維を合成樹脂で補強した繊維強化樹脂層が、その軸方向に対して直交する軸直角方向の横断面にコーナー部を有する繊維強化樹脂部材に関する。
　連続繊維の繊維束をマトリクス樹脂に埋設した複数の繊維強化樹脂部材を、連続繊維の配向方向が交互に交差するように積層するとともに、それら複数の繊維強化樹脂部材の層を拘束糸で厚さ方向に貫通するように縫製したエネルギー吸収体が、下記特許文献１により公知である。このエネルギー吸収体は、圧縮荷重の入力時に、拘束糸を破断しながら厚さ方向の中央部で二層に分かれるように破壊することで、エネルギー吸収効果を発揮するものである。
日本特許第４１３３８４０号公報
　しかしながら、上記従来のものは、連続繊維が三次元織物を構成するので製造コストが嵩むだけでなく、拘束糸が破断することでエネルギー吸収効果を発揮するため、エネルギー吸収効果を高めるには拘束糸の数を増やす必要があり、縫製工数が増加して製造コストが更に嵩む問題がある。しかも拘束糸の数を増やすと、圧縮荷重の入力時に拘束糸が破断し難くなって厚さ方向中央部で二層に分かれるように破壊する際のエネルギー吸収量が増加するが、相互に交差するように配向した連続繊維の量が減少してエネルギー吸収体の強度自体が低下する懸念がある。また厚さ方向中央部で二層に分かれることでエネルギー吸収するので、樹脂によるエネルギー吸収特性の影響が大きく、温度変化等の環境要素によりエネルギー吸収特性が安定しない可能性がある。
　本発明は前述の事情に鑑みてなされたもので、簡単な構造でありながら、軸方向の圧縮荷重の入力時に大きなエネルギー吸収効果を発揮する繊維強化樹脂部材を提供することを目的とする。
　上記目的を達成するために、本発明によれば、連続繊維を合成樹脂で補強した繊維強化樹脂層が、その軸方向に対して直交する軸直角方向の横断面にコーナー部を有する繊維強化樹脂部材であって、前記連続繊維は、軸方向に配向された軸方向繊維と軸直角方向に配向された軸直角方向繊維とからなり、前記コーナー部の外側における前記軸直角方向繊維の密度を、前記コーナー部の内側における前記軸直角方向繊維の密度よりも高くしたことを第１の特徴とする繊維強化樹脂部材が提案される。
　また本発明によれば、前記第１の特徴に加えて、前記繊維強化樹脂層は積層された複数の層からなり、前記コーナー部の内側に配置される層の前記合成樹脂は圧縮強度が高く膨張し難い熱可塑性樹脂であり、前記コーナー部の外側に配置される層の前記合成樹脂は圧縮強度が低く膨張し易い熱可塑性樹脂であることを第２の特徴とする繊維強化樹脂部材が提案される。
　また本発明によれば、前記第２の特徴に加えて、前記繊維強化樹脂層は前記コーナー部に連続する平坦部を有することを第３の特徴とする繊維強化樹脂部材が提案される。
　また本発明によれば、前記第１～第３の何れか１つの特徴に加えて、前記繊維強化樹脂層は、前記軸直角方向繊維の屈曲部に隣接して前記軸方向繊維が配置されることを第４の特徴とする繊維強化樹脂部材が提案される。
　また本発明によれば、前記第１～第４の何れか１つの特徴に加えて、前記繊維強化樹脂部材の横断面は点対称な形状であることを第５の特徴とする繊維強化樹脂部材が提案される。
　また本発明によれば、前記第１～第５の何れか１つの特徴に加えて、前記繊維強化樹脂部材の軸方向端部において、前記内側に配置される層が前記外側に配置される層よりも軸方向に突出することを第６の特徴とする繊維強化樹脂部材が提案される。
　尚、実施の形態の第１平坦部１２および第２平坦部１４は本発明の平坦部に対応し、実施の形態の第１コーナー部１３は本発明のコーナー部に対応し、実施の形態の第１層１７は本発明の外側に積層される層に対応し、実施の形態の第２層１８は本発明の内側に積層される層に対応する。
　本発明の第１の特徴によれば、繊維強化樹脂部材は、連続繊維を合成樹脂で補強した繊維強化樹脂層が、その軸方向に対して直交する軸直角方向の横断面にコーナー部を有する。連続繊維は、軸方向に配向された軸方向繊維と軸直角方向に配向された軸直角方向繊維とからなり、コーナー部の外側における軸直角方向繊維の密度を、コーナー部の内側における軸直角方向繊維の密度よりも高くしたので、軸方向荷重が入力して繊維強化樹脂部材が破壊するときに、コーナー部の外側の層に高密度で配置された軸直角方向繊維が積極的に引き伸ばされて破断することで、大きなエネルギー吸収効果を発揮することができる。しかも繊維強化樹脂部材は、その内部の軸直角方向繊維の密度を変化させただけの簡単な構造であるため、製造コストの増加を最小限に抑えることができる。また樹脂によるエネルギー吸収特性への影響が少ないため、温度変化等の環境要素に関わらずに安定したエネルギー吸収特性を得ることができる。
　また本発明の第２の特徴によれば、繊維強化樹脂層は積層された複数の層からなり、コーナー部の内側に配置される層の合成樹脂は圧縮強度が高く膨張し難い熱可塑性樹脂であり、コーナー部の外側に配置される層の合成樹脂は圧縮強度が低く膨張し易い熱可塑性樹脂であるので、通常時は圧縮強度が高いコーナー部の内側の層で繊維強化樹脂部材の強度を確保しながら、軸方向荷重の入力に圧縮強度が低いコーナー部の外側の層を破壊して膨張させ、そこに配置された軸直角方向繊維を破断してエネルギー吸収効果を効率的に発揮させることができる。
　また本発明の第３の特徴によれば、繊維強化樹脂層はコーナー部に連続する平坦部を有するので、軸方向荷重に入力時に、先ず平坦部の軸方向繊維が層間剥離することでコーナー部の軸直角方向繊維が破断するトリガーとなり、軸直角方向繊維の破断を促進することができる。
　また本発明の第４の特徴によれば、繊維強化樹脂層は、軸直角方向繊維の屈曲部に隣接して軸方向繊維が配置されるので、軸方向荷重が入力して軸直角方向繊維が破断するときに、その軸直角方向繊維の横方向への移動を軸方向繊維で阻止することで、軸直角方向繊維の確実な破断を可能にすることができる。
　また本発明の第５の特徴によれば、繊維強化樹脂部材の横断面は点対称な形状であるので、軸方向荷重の入力時に繊維強化樹脂部材が軸線に対して傾くのを防止し、繊維強化樹脂部材を軸方向の長い距離に亙って破壊してエネルギー吸収効果を高めることができる。
　また本発明の第６の特徴によれば、繊維強化樹脂部材の軸方向端部において、内側に配置される層が外側に配置される層よりも軸方向に突出するので、軸方向荷重の入力時に先ず内側の層が破壊し、次いで外側の層が破壊することで、エネルギー吸収量を漸増させて安定したエネルギー吸収を可能にすることができる。
図１は繊維強化樹脂部材の斜視図である。（第１の実施の形態） 図２は図１の２部拡大図である。（第１の実施の形態） 図３は軸方向荷重の入力時のコーナー部の断面の変形の説明図である。（第１の実施の形態） 図４は軸方向荷重の入力時の平坦部の層間剥離の説明図である。（第１の実施の形態） 図５は第１コーナー部および第２コーナー部の膨張方向の説明図である。（第１の実施の形態） 図６は繊維強化樹脂部材の横断面図である。（第２の実施の形態） 図７は繊維強化樹脂部材の斜視図である。（第３の実施の形態）
１１　　　　繊維強化樹脂部材
１２　　　　第１平坦部（平坦部）
１３　　　　第１コーナー部（コーナー部）
１４　　　　第２平坦部（平坦部）
１７　　　　第１層（外側に積層される層）
１８　　　　第２層（内側に積層される層）
１９　　　　軸方向繊維
２０　　　　軸直角方向繊維
　以下、図１～図５に基づいて本発明の第１の実施の形態を説明する。
第１の実施の形態
　図１に示すように、自動車のフレーム等に使用される繊維強化樹脂部材１１は、第１平坦部１２と、第１平坦部１２から直角に折れ曲がる一対の第１コーナー部１３，１３と、一対の第１コーナー部１３，１３に連なる一対の第２平坦部１４，１４と、一対の第２平坦部１４，１４から逆方向に直角に折れ曲がる一対のフランジ部１６，１６とからなり、軸方向に一定のハット状断面を有している。
　図２は繊維強化樹脂部材１１の第１コーナー部１３の拡大断面図であり、繊維強化樹脂部材１１の繊維強化樹脂層は、第１コーナー部１３の屈曲方向外側の第１層１７と、第１コーナー部１３の屈曲方向内側の第２層１８とを積層して二層に構成される。
　第１コーナー部１３の外側の第１層１７は、相互に平行に配置されて軸方向に延びる１層の軸方向繊維１９…と、その両側に積層されて軸直角方向に延びる２層の軸直角方向繊維２０…とで構成される。軸方向繊維１９…および軸直角方向繊維２０…はガラスやカーボンの連続繊維であり、マトリクス樹脂は圧縮強度が比較的に低いために圧壊したときに体積が膨張し易いポリプロピレンである。
　第１コーナー部１３の内側の第２層１８は、相互に平行に配置されて軸方向に延びる１層の軸方向繊維１９…と、その片側に積層されて軸直角方向に延びる１層の軸直角方向繊維２０…とで構成される。軸方向繊維１９…および軸直角方向繊維２０…はガラスやカーボンの連続繊維であり、マトリクス樹脂は圧縮強度が比較的に高いために圧壊したときに体積が膨張し難いナイロンである。
　従って、第１コーナー部１３では、屈曲方向外側部分（第１層１７）における軸直角方向繊維２０…の密度が高くなり、屈曲方向内側部分（第２層１８）における軸直角方向繊維２０…の密度が低くなる。
　尚、以上の説明では、繊維強化樹脂部材１１が第１層１７および第２層１８の二層構造になっているが、積層する層数は二層に限定されるものではなく、任意に設定可能である。また第１層１７および第２層１８の内部における軸方向繊維１９…および軸直角方向繊維２０…の層数も任意である。また軸方向繊維１９…および軸直角方向繊維２０…は相互に織られていても良いし、単に重ね合わされていても良い。
　図１から明らかなように、第２コーナー部１５は第１コーナー部１３に対して逆方向に折れ曲がっているため、第１層１７が屈曲方向内側に位置し、第２層１８が屈曲外側に位置することになる、従って、第２コーナー部１５では、第２層１８の軸直角方向繊維２０…の密度を第１層１７に軸直角方向繊維２０…の密度よりも高くする必要がある。第１コーナー部１３および第２コーナー部１５間の軸直角方向繊維２０…の密度の入れ換えは、第１コーナー部１３および第２コーナー部１５に挟まれた第２平坦部１４において強度が急変しないように連続的に行うことが望ましい。
　次に、上記構成を備えた本発明の実施の形態の作用を説明する。
　車両の衝突等により繊維強化樹脂部材１１に軸方向の強い圧縮荷重が入力すると、マトリクス樹脂が座屈により圧壊して粉砕されることで断面が膨張する。図３は第１コーナー部１３の断面の膨張を模式的に示すもので、実線で示す状態から鎖線で示す状態に断面が膨張したとき、第１コーナー部１３の内側の周長は殆ど増加しないのに対し、第１コーナー部１３の外側の周長は大きく増加する。
　その結果、外側の第１層１７の軸直角方向繊維２０…が強く引き延ばされて破断することで衝突のエネルギーが吸収される。このとき、第１層１７の軸直角方向繊維２０…は、第２層１８に軸直角方向繊維２０…よりも高密度で配置されているため、破断する軸直角方向繊維２０…の数を増加させてエネルギー吸収性能を高めることができる。また第１コーナー部１３の第１層１７内で直角に折れ曲がる軸直角方向繊維２０…の折れ曲がり部の内側に軸方向繊維１９…が隣接して配置されるため、引き伸ばされた軸直角方向繊維２０…が屈曲方向内側に移動するのを軸方向繊維１９…で阻止することで、軸直角方向繊維２０…の破断を促進することができる。
　しかも、第１層１７のマトリクス樹脂は圧縮強度が比較的に低くて圧壊したときに体積が膨張し易いポリプロピレンであり、第２層１８のマトリクス樹脂は圧縮強度が比較的に高くて圧壊したときに体積が膨張し難いナイロンであるため、軸方向荷重の入力時に第１層１７を大きく膨張させて軸直角方向繊維２０…を効果的に破断し、エネルギー吸収性能を更に高めることができる。またエネルギー吸収に積極的に寄与しない第２層１８は高強度であるため、車両の衝突時でない通常時に繊維強化樹脂部材１１の強度を確保することができる。
　更に、図４に示すように、軸方向荷重の入力時に、第１コーナー部１３を挟む第１平坦部１２および第２平坦部１４は第１層１７および第２層１８の境界で層間剥離するため、これがトリガーとなって第１コーナー部１３の圧壊が促進され、エネルギー吸収が更に向上する。
　以上、第１コーナー部１３におけるエネルギー吸収について説明したが、第２コーナー部１５も同様の作用でエネルギー吸収性能を発揮する。図５に示すように、ハット状断面の維強化樹脂部材１１は、膨張方向が逆向きである第１コーナー部１３および第２コーナー部１５を備えるので、軸方向荷重の入力時に軸直角方向繊維２０…の張力を効率的に高めてエネルギー吸収性能を高めることができる。そして繊維強化樹脂部材１１は、その内部の軸直角方向繊維２０…の密度を変化させただけの簡単な構造であるため、製造コストの増加を最小限に抑えることができる。また樹脂によるエネルギー吸収特性への影響が少ないため、温度変化等の環境要素に関わらずに安定したエネルギー吸収特性を得ることができる。
　次に、図６に基づいて本発明の第２の実施の形態を説明する。
第２の実施の形態
　第１の実施の形態の繊維強化樹脂部材１１は点対称でないハット状の横断面形状を有しているが、第２の実施の形態の繊維強化樹脂部材１１は軸中心Ｌに対して点対称な概略Ｓ字状の横断面形状を有している。
　このように、繊維強化樹脂部材１１の横断面形状を点対称にすることで、軸方向荷重の入力時に繊維強化樹脂部材１１が軸中心Ｌに対して傾くことを防止し、繊維強化樹脂部材１１を長いストロークに亙って確実に圧壊してエネルギー吸収性能を高めることができる。
　次に、図７に基づいて本発明の第３の実施の形態を説明する。
第３の実施の形態
　第３の実施の形態は、ハット状断面の繊維強化樹脂部材１１の一対のフランジ部１６，１６間に板状の繊維強化樹脂部材２１を結合して閉断面に構成したものである。第２コーナー部１５はフランジ部１６に接続されていて軸直角方向繊維２０…の破断によるエネルギー吸収効果はあまり期待できないため、外側の軸直角方向繊維２０…の密度を内側の軸直角方向繊維２０…の密度よりも高くする構造は、第１コーナー部１３だけに適用される。そして繊維強化樹脂部材１１の軸方向端部において、第１層１７の軸方向端部は、第２層１８の軸方向端部よりも距離ａだけ軸方向に後退している。つまり、繊維強化樹脂部材１１の軸方向端部から距離ａ以内の領域は、第２層１８だけで構成される。
　本実施の形態によれば、繊維強化樹脂部材１１，２１が軸方向荷重により圧壊するとき、第１コーナー部１３が第１の実施の形態と同様のエネルギー吸収効果を発揮するのは勿論であるが、それに加えて、先ず軸方向端部に露出する第２層１８だけが圧壊し、次いで第２層１８および第１層１７の両方が同時に圧壊することで、エネルギー吸収量を漸増させて安定したエネルギー吸収を可能にすることができる。
　以上、本発明の実施の形態を説明したが、本発明はその要旨を逸脱しない範囲で種々の設計変更を行うことが可能である。
　例えば、繊維強化樹脂部材１１の繊維強化樹脂層は必ずしも複数層に分かれている必要はなく、一層であっても良い。要するに、軸直角方向繊維２０…の密度が、コーナー部の外側においてコーナー部の内側よりも高くなっていれば良い。

Claims (6)

  1. 　連続繊維を合成樹脂で補強した繊維強化樹脂層が、その軸方向に対して直交する軸直角方向の横断面にコーナー部（１３）を有する繊維強化樹脂部材であって、
    　前記連続繊維は、軸方向に配向された軸方向繊維（１９）と軸直角方向に配向された軸直角方向繊維（２０）とからなり、前記コーナー部（１３）の外側における前記軸直角方向繊維（２０）の密度を、前記コーナー部（１３）の内側における前記軸直角方向繊維（２０）の密度よりも高くしたことを特徴とする繊維強化樹脂部材。
  2. 　前記繊維強化樹脂層は積層された複数の層（１７，１８）からなり、前記コーナー部（１３）の内側に配置される層（１８）の前記合成樹脂は圧縮強度が高く膨張し難い熱可塑性樹脂であり、前記コーナー部（１３）の外側に配置される層（１７）の前記合成樹脂は圧縮強度が低く膨張し易い熱可塑性樹脂であることを特徴とする、請求項１に記載の繊維強化樹脂部材。
  3. 　前記繊維強化樹脂層は前記コーナー部（１３）に連続する平坦部（１２，１４）を有することを特徴とする、請求項２に記載の繊維強化樹脂部材。
  4. 　前記繊維強化樹脂層は、前記軸直角方向繊維（２０）の屈曲部に隣接して前記軸方向繊維（１９）が配置されることを特徴とする、請求項１～請求項３の何れか１項に記載の繊維強化樹脂部材。
  5. 　前記繊維強化樹脂部材（１１）の横断面は点対称な形状であることを特徴とする、請求項１～請求項４の何れか１項に記載の繊維強化樹脂部材。
  6. 　前記繊維強化樹脂部材（１１）の軸方向端部において、前記内側に配置される層（１８）が前記外側に配置される層（１７）よりも軸方向に突出することを特徴とする、請求項１～請求項５の何れか１項に記載の繊維強化樹脂部材。
PCT/JP2014/065445 2013-06-12 2014-06-11 繊維強化樹脂部材 WO2014200015A1 (ja)

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