WO2016132425A1 - 複合材料構造体 - Google Patents

複合材料構造体 Download PDF

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Publication number
WO2016132425A1
WO2016132425A1 PCT/JP2015/054103 JP2015054103W WO2016132425A1 WO 2016132425 A1 WO2016132425 A1 WO 2016132425A1 JP 2015054103 W JP2015054103 W JP 2015054103W WO 2016132425 A1 WO2016132425 A1 WO 2016132425A1
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WO
WIPO (PCT)
Prior art keywords
main surface
metal member
composite material
material structure
thermal expansion
Prior art date
Application number
PCT/JP2015/054103
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English (en)
French (fr)
Inventor
幸宏 濱田
大久保　洋志
Original Assignee
日産自動車株式会社
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 日産自動車株式会社 filed Critical 日産自動車株式会社
Priority to PCT/JP2015/054103 priority Critical patent/WO2016132425A1/ja
Priority to JP2017500490A priority patent/JP6376274B2/ja
Priority to US15/546,022 priority patent/US10065687B2/en
Priority to CN201580075221.8A priority patent/CN107206750B/zh
Priority to EP15882530.7A priority patent/EP3260293B1/en
Publication of WO2016132425A1 publication Critical patent/WO2016132425A1/ja

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/001—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material
    • B62D29/005—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material preformed metal and synthetic material elements being joined together, e.g. by adhesives
    • 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
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
    • B32B15/016—Layered products comprising a layer of metal all layers being exclusively metallic all layers being formed of aluminium or aluminium alloys
    • 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
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal 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
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/14—Layered products comprising a layer of metal next to a fibrous or filamentary layer
    • 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
    • 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
    • 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
    • B32B3/263—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 having non-uniform thickness
    • 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
    • B32B3/266—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 an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
    • 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
    • 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
    • B32B5/028—Net structure, e.g. spaced apart filaments bonded at the crossing points
    • 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
    • B32B5/142—Variation across the area of the layer
    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/20—Floors or bottom sub-units
    • 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
    • B32B2250/03—3 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
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • 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
    • B32B2307/70—Other properties
    • B32B2307/706—Anisotropic
    • 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
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • 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
    • B32B2605/003—Interior finishings
    • 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 composite material structure using a metal and a fiber reinforced resin.
  • Patent Document 1 In order to efficiently absorb the input load from the outside, a technique of sticking carbon fiber reinforced plastic (CFRP) to a light metal load receiving component such as aluminum, aluminum alloy, magnesium, magnesium alloy or the like is disclosed (Patent Document 1). reference).
  • CFRP carbon fiber reinforced plastic
  • Patent Document 1 since the technique described in Patent Document 1 has a different coefficient of thermal expansion between light metal and CFRP, a special adhesive is required to absorb the difference in the amount of deformation due to heat after bonding. Or it may be difficult to mold a light metal with a CFRP matrix resin.
  • an object of the present invention is to provide a composite material structure capable of reducing the influence due to the difference in thermal expansion coefficient between a metal and a fiber reinforced resin.
  • the composite material structure includes a metal member and a resin member.
  • the metal member is made of metal and is formed in a flat plate shape so that the coefficient of thermal expansion in the first direction along the main surface is larger than the coefficient of thermal expansion in the second direction perpendicular to the first direction along the main surface.
  • the resin member is made of a fiber reinforced resin, and is affixed to the main surface of the metal member so that the amount of fibers along the second direction is larger than the amount of fibers along the first direction.
  • FIG. 1 is a perspective view for explaining a floor panel of an automobile provided with a composite material structure according to an embodiment of the present invention.
  • FIG. 2 is a partial cross-sectional view as seen from the AA direction of FIG.
  • FIG. 3 is a cross-sectional view illustrating a composite material structure according to an embodiment of the present invention.
  • FIG. 4 is a plan view illustrating a resin material included in the composite material structure according to the embodiment of the present invention.
  • FIG. 5 is a cross-sectional view illustrating a state in which the metal material included in the composite material structure according to the embodiment of the present invention has undergone thermal expansion.
  • FIG. 6 is a cross-sectional view illustrating a modification of the composite material structure according to the embodiment of the present invention.
  • FIG. 7 is a cross-sectional view illustrating a composite material structure according to another embodiment of the present invention.
  • the composite material structure 1 is applied as a floor panel 11 provided in a vehicle body front portion 10 of an automobile, for example, as shown in FIGS. 1 and 2.
  • the composite material structure 1 may be applied to a dash panel, a roof panel, or the like of a vehicle body, or may be applied to a side shell 12, a floor tunnel 13, a cross member 14, or the like included in the vehicle body front portion 10.
  • the composite material structure 1 is made of a metal, a metal member 2 formed in a flat plate shape, and a fiber-reinforced resin, and is a sheet-like resin stuck on both main surfaces of the metal member 2.
  • a member 4 The metal member 2 is made of a light metal such as aluminum, an aluminum alloy, magnesium, or a magnesium alloy.
  • the resin member 4 is made of a fiber reinforced resin having a smaller coefficient of thermal expansion than the material of the metal member 2, and is made of, for example, carbon fiber reinforced plastic (CFRP).
  • CFRP carbon fiber reinforced plastic
  • the metal member 2 has a thermal expansion coefficient in the first direction (X-axis direction) along the main surface that is larger than the thermal expansion coefficient in the second direction (Y-axis direction) perpendicular to the first direction along the main surface. Formed as follows.
  • the metal member 2 is formed by, for example, extrusion molding in which the first direction is the metal extrusion direction.
  • the metal member 2 may be formed by other processing methods such as bending and casting.
  • the metal member 2 is formed so that the cross-sectional shape seen from the first direction is constant.
  • the metal member 2 is bent at a plurality of main surface portions 21 whose outer surfaces form the main surface of the metal member 2 and the respective end portions 22 in the second direction of the main surface portion 21, whereby the main surface portion 21 on the other surface side is bent.
  • a plurality of connecting portions 23 connected to each end portion 22.
  • the main surface portion 21 and the connecting portion 23 are each flat.
  • the main surface portion 21 and the connecting portion 23 are connected so as to be bent at the end portion 22, thereby improving the strength of the metal member 2 in the third direction (Z-axis direction) orthogonal to the first direction and the second direction. be able to.
  • a plurality of main surface portions 21 are arranged on both surface sides of the metal member 2 in the third direction so that the end portions 22 and the end portions 22 of the other adjacent main surface portions 21 have a gap portion 20 therebetween. Is done. That is, the metal member 2 is formed such that each main surface is continuous in the first direction and discontinuous in the second direction.
  • the adhesive 3 has a thin portion 31 formed with a thickness thinner than other portions.
  • the thin portion 31 is formed on the outer surface of the main surface portion 21 and is formed by the thick portion 24 having a thickness thicker than other portions.
  • the thick part 24 and the thin part 31 are periodically located in the second direction.
  • the thick part 24 is located in the center part in the 2nd direction of each main surface part 21, for example.
  • the adhesive 3 has an anchor portion 32 that protrudes inwardly and is formed by entering a gap 20 sandwiched between two opposing end portions 22.
  • the adhesive 3 has an anchor portion 32 sandwiched between two opposing end portions 22, thereby generating an anchor effect and improving the adhesive force to the metal member 2.
  • the resin member 4 is formed such that the amount of fibers 42 along the second direction is larger than the amount of fibers 41 along the first direction. That is, the resin member 4 is formed so that the thermal expansion coefficient in the second direction is smaller than the thermal expansion coefficient in the first direction.
  • the metal member 2 undergoes thermal expansion as shown in FIG. In FIG. 5, the metal member 2 before thermal expansion is indicated by a two-dot chain line, and the metal member 2 after thermal expansion is indicated by a solid line.
  • the main surface portion 21 is thermally expanded, the gap portion 20 that extends in the second direction and is sandwiched between the two opposing end portions 22 becomes narrower.
  • the gap portion 20 functions as a margin for thermal expansion, the metal member 2 has a thermal expansion coefficient in the second direction smaller than that in the first direction.
  • the adhesive 3 firmly bonds the metal member 2 and the resin member 4 at the thin portion 31.
  • the metal member 2 has a larger coefficient of thermal expansion than the resin member 4, so that the adhesive 3 in the region excluding the thinly formed thin portion 31 has the main surface portion 21 and the resin member 4.
  • the shear deformation larger than that of the thin-walled portion 31 occurs between the two.
  • the adhesive 3 functions as a buffer layer that absorbs a difference in displacement due to thermal expansion between the metal member 2 and the resin member 4 by causing shear deformation. Since the thin portion 31 is located at the center of each main surface portion 21 in the second direction, the shear deformation is small and the damage is small.
  • the gap 20 is formed to have such a width that the adhesive 3 and the matrix resin 40 (see FIG. 4) of the resin member 4 do not enter the region beyond the main surface portion 21 of the metal member 2 (region sandwiched by the connecting portion 23). Is done.
  • the width of the gap 20 is, for example, about several mm, and can be about 1 to 2 mm when the width of each main surface portion 21 in the second direction is about 20 to 30 mm.
  • the gap portion 20 prevents the matrix resin 40 from flowing inwardly of the metal member 2 when molding the matrix resin 40 on the metal member 2 on which the fibers 41 and 42 are arranged.
  • the metal member 2 and the resin member 4 are affixed so that the highly oriented fibers 42 are along the direction in which the thermal expansion coefficient of the metal member 2 is small. Therefore, the influence by the difference of the thermal expansion coefficient between a metal and fiber reinforced resin can be reduced. Therefore, when an adhesive is used, a special adhesive is not required, and it is easy to mold the matrix resin 40 on the metal member 2 (resin transfer molding: RTM).
  • the metal member 2 since the main surface of the metal member 2 is formed so as to be continuous in the first direction and discontinuous in the second direction, the metal member having a small coefficient of thermal expansion in the second direction. 2 can be easily formed by extrusion molding or the like.
  • the adhesive 3 since the adhesive 3 has the thin portion 31, the metal member 2 and the resin member 4 can be firmly bonded in the thin portion 31. Furthermore, the thin part 31 functions periodically as an anchor when the adhesive 3 is hardened by being periodically positioned in the second direction, and the warpage of the composite material structure 1 can be reduced.
  • the composite material structure 1A according to the modification of the embodiment of the present invention is connected to both sides in the third direction by connecting portions 23A that are connected at locations separated from the end portion 22A of the main surface portion 21A.
  • a metal member 2A that connects the main surface portions 21A to each other is provided.
  • a plurality of main surface portions 21A are arranged on both sides of the metal member 2A in the third direction so that the end portions 22A and the end portions 22A of other adjacent main surface portions 21A are spaced apart from each other with a gap portion 20A. Is done.
  • the connecting portion 23A is formed along the third direction.
  • the metal member 2A is formed so that the thermal expansion coefficient in the first direction is larger than the thermal expansion coefficient in the second direction.
  • the metal member 2A is formed so that the cross-sectional shape viewed from the first direction is constant.
  • FIG. 6 illustrates the case where the connecting portions 23 are along the third direction, but are exemplary, and each connecting portion 23 may have an inclination with respect to the third direction. In this case, as in FIG. 3 and the like, it is desirable that the directions of inclination of the connecting portions 23 are staggered in the second direction.
  • the thick portion 24 may be arranged so as to be shifted from the central portion of each main surface portion 21 in the second direction, as shown in FIG. Moreover, as shown in FIG. 7, the period (pitch) arrange
  • positioned in the 2nd direction of the thick part 24 and the thin part 31 does not necessarily need to correspond with the period of the main surface part 21, and is periodic in a 2nd direction. As long as it is located in
  • the present invention includes various embodiments that are not described here, such as a configuration in which the above-described configurations are applied to each other. Therefore, the technical scope of the present invention is defined only by the invention specifying matters according to the scope of claims reasonable from the above description.
  • the influence of the difference in the thermal expansion coefficient between the metal and the fiber reinforced resin is achieved by preferentially orienting the fibers of the fiber reinforced resin so that the thermal expansion coefficient of the metal member is along the direction of small Can be provided.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Mechanical Engineering (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)
  • Body Structure For Vehicles (AREA)

Abstract

複合材料構造体（１）は、金属からなり、主面に沿う第１方向（Ｘ）における熱膨張率が、主面に沿い、第１方向（Ｘ）に直交する第２方向（Ｙ）における熱膨張率よりも大きくなるように平板状に形成された金属部材（２）と、繊維強化樹脂からなり、金属部材（２）の主面に貼付され、第２方向（Ｙ）に沿う繊維の量が、第１方向（Ｘ）に沿う繊維の量よりも多くなるように形成された樹脂部材（４）とを備える。

Description

複合材料構造体
　本発明は、金属と繊維強化樹脂とを用いた複合材料構造体に関する。
　外部からの入力荷重を効率よく吸収するために、アルミニウム、アルミニウム合金、マグネシウム、マグネシウム合金等の軽金属の荷重受け部品に炭素繊維強化プラスチック（ＣＦＲＰ）を貼り付ける技術が開示されている（特許文献１参照）。
国際公開第９９／１０１６８号
　しかしながら、特許文献１に記載の技術は、軽金属とＣＦＲＰとの間で熱膨張率が異なるため、貼り付けた後の熱による伸び変形量の差を吸収するために特別な接着剤が必要であったり、軽金属をＣＦＲＰのマトリクス樹脂でモールディングすることが困難であったりする。
　本発明は、上記問題点を鑑み、金属と繊維強化樹脂との間の熱膨張率の差による影響を低減可能な複合材料構造体を提供することを目的とする。
　複合材料構造体は、金属部材と、樹脂部材とを備える。金属部材は、金属からなり、主面に沿う第１方向における熱膨張率が、主面に沿い、第１方向に直交する第２方向における熱膨張率よりも大きくなるように平板状に形成される。樹脂部材は、繊維強化樹脂からなり、金属部材の主面に貼付され、第２方向に沿う繊維の量が、第１方向に沿う繊維の量よりも多くなるように形成される。
図１は、本発明の実施の形態に係る複合材料構造体を備える自動車のフロアパネルを説明する斜視図である。 図２は、図１のＡ－Ａ方向から見た部分断面図である。 図３は、本発明の実施の形態に係る複合材料構造体を説明する断面図である。 図４は、本発明の実施の形態に係る複合材料構造体が備える樹脂材料を説明する平面図である。 図５は、本発明の実施の形態に係る複合材料構造体が備える金属材料が熱膨張を生じた状態を説明する断面図である。 図６は、本発明の実施の形態に係る複合材料構造体の変形例を説明する断面図である。 図７は、本発明の他の実施の形態に係る複合材料構造体を説明する断面図である。
　図面を参照して、本発明の実施の形態を説明する。図面の記載において、同一又は類似の部分には同一又は類似の符号を付し、重複する説明を省略する。なお、図面は模式的なものであり、各寸法の関係や比率などは実際のものとは異なる場合がある。
（複合材料構造体）
　本発明の実施の形態に係る複合材料構造体１は、例えば、図１及び図２に示すように、自動車の車体前部１０が備えるフロアパネル１１として適用される。複合材料構造体１は、その他、車体のダッシュパネル、ルーフパネル等に適用されてもよく、車体前部１０が備えるサイドシェル１２、フロアトンネル１３、クロスメンバ１４等に適用されてもよい。
　複合材料構造体１は、図３に示すように、金属からなり、平板状に形成された金属部材２と、繊維強化樹脂からなり、金属部材２の両主面に貼付されたシート状の樹脂部材４とを備える。金属部材２は、例えば、アルミニウム、アルミニウム合金、マグネシウム、マグネシウム合金等の軽金属からなる。樹脂部材４は、金属部材２の材料より熱膨張率の小さな繊維強化樹脂からなり、例えば炭素繊維強化プラスチック（ＣＦＲＰ）からなる。
　金属部材２は、主面に沿う第１方向（Ｘ軸方向）における熱膨張率が、主面に沿い、第１方向に直交する第２方向（Ｙ軸方向）における熱膨張率よりも大きくなるように形成される。金属部材２は、例えば、第１方向を金属の押し出し方向とする押出成形により形成される。金属部材２は、曲げ加工、鋳造等の他の加工法により形成されてもよい。
　金属部材２は、第１方向から見た断面形状が一定となるように形成される。金属部材２は、外側の表面が金属部材２の主面をなす複数の主面部２１と、主面部２１の第２方向における各端部２２において屈曲することにより、他面側の主面部２１の各端部２２に連結する複数の連結部２３とを有する。主面部２１及び連結部２３は、それぞれ平板状である。主面部２１及び連結部２３は、端部２２において屈曲されるように連結することにより、第１方向及び第２方向に直交する第３方向（Ｚ軸方向）における金属部材２の強度を向上することができる。
　主面部２１は、端部２２と、隣接する他の主面部２１の端部２２とが、間隙部２０を有して離間するように、第３方向における金属部材２の両面側にそれぞれ複数配置される。すなわち、金属部材２は、各主面が、第１方向において連続、第２方向において不連続となるように形成される。
　金属部材２の両主面と樹脂部材４とは、接着剤３により互いに貼付される。接着剤３は、厚さが他所より薄く形成された薄肉部３１を有する。薄肉部３１は、主面部２１の外側の表面に形成され、厚さが他所より厚く形成された厚肉部２４により形成される。厚肉部２４及び薄肉部３１は、第２方向において周期的に位置する。厚肉部２４は、例えば、各主面部２１の第２方向における中央部に位置する。
　接着剤３は、対向する２つの端部２２に挟まれた間隙部２０に進入することにより形成された、内側方向に突出するアンカー部３２を有する。接着剤３は、対向する２つの端部２２に挟まれたアンカー部３２を有することによりアンカー効果を生じ、金属部材２に対する接着力を向上することができる。
　樹脂部材４は、図４に示すように、第２方向に沿う繊維４２の量が、第１方向に沿う繊維４１の量よりも多くなるように形成される。すなわち、樹脂部材４は、第２方向における熱膨張率が、第１方向における熱膨張率よりも小さくなるように形成される。
　複合材料構造体１が加熱されると、金属部材２は、図５に示すように、熱膨張を生じる。図５において、熱膨張前の金属部材２を二点鎖線、熱膨張後の金属部材２を実線で示す。主面部２１が熱膨張すると、第２方向において伸び、対向する２つの端部２２に挟まれた間隙部２０は狭くなる。間隙部２０が熱膨張時のマージンとして機能することにより、金属部材２は、第２方向における熱膨張率が第１方向の熱膨張率よりも小さくなる。
　接着剤３は、薄肉部３１において金属部材２と樹脂部材４とを強固に接着する。複合材料構造体１が加熱されると、金属部材２は樹脂部材４に比べて熱膨張率が大きいため、厚く形成された薄肉部３１除く領域の接着剤３は、主面部２１と樹脂部材４との間において、薄肉部３１よりも大きなせん断変形を生じる。接着剤３は、せん断変形を生じることにより、金属部材２と樹脂部材４との間の熱膨張による変位量の差を吸収する緩衝層として機能する。薄肉部３１は、第２方向において各主面部２１の中央部に位置するため、せん断変形が小さく、ダメージが小さい。
　間隙部２０は、接着剤３及び樹脂部材４のマトリクス樹脂４０（図４参照）が、金属部材２の主面部２１を越える領域（連結部２３に挟まれる領域）に進入しない程度の幅に形成される。間隙部２０の幅は、例えば数ｍｍ程度であり、第２方向における各主面部２１の幅が２０～３０ｍｍ程度のとき、１～２ｍｍ程度とすることができる。間隙部２０は、繊維４１，４２が配置された金属部材２に対してマトリクス樹脂４０をモールディングする際、金属部材２の内側方向にマトリクス樹脂４０が流入することを防止する。
　本発明の実施の形態に係る複合材料構造体１によれば、多く配向された繊維４２が金属部材２の熱膨張率が小さい方向に沿うように、金属部材２と樹脂部材４とが貼付されているので、金属と繊維強化樹脂との間の熱膨張率の差による影響を低減することができる。よって、接着剤を用いる場合に特殊な接着剤が不要となる他、金属部材２に対してマトリクス樹脂４０をモールディングすること（樹脂トランスファー成形：ＲＴＭ）が容易となる。
　また、複合材料構造体１によれば、金属部材２の主面が第１方向において連続、第２方向において不連続となるように形成されるので、第２方向における熱膨張率が小さい金属部材２を、押出成形等により、容易に形成することができる。
　また、複合材料構造体１によれば、接着剤３が薄肉部３１を有することにより、薄肉部３１において金属部材２と樹脂部材４とを強固に接着することができる。更に、薄肉部３１は、第２方向において周期的に位置することにより、接着剤３が硬化する際のアンカーとして機能し、複合材料構造体１の反りを低減することができる。
（変形例）
　上記の実施の形態において、端部２２において連結部２３により両面側の主面部２１が連結された金属部材２を説明したが、金属部材２の断面形状は、他の形状であっても、複合材料構造体１と同様の作用及び効果を奏することができる。
　本発明の実施の形態の変形例に係る複合材料構造体１Ａは、図６に示すように、主面部２１Ａの端部２２Ａから離間した箇所において連結する連結部２３Ａにより、第３方向における両側の主面部２１Ａを互いに連結する金属部材２Ａを備える。主面部２１Ａは、端部２２Ａと、隣接する他の主面部２１Ａの端部２２Ａとが、間隙部２０Ａを有して離間するように、第３方向における金属部材２Ａの両面側にそれぞれ複数配置される。連結部２３Ａは、例えば、第３方向に沿うように形成される。
　金属部材２と同様に、金属部材２Ａは、第１方向における熱膨張率が、第２方向における熱膨張率よりも大きくなるように形成される。また、金属部材２Ａは、第１方向から見た断面形状が一定となるように形成される。
　図６では、連結部２３が第３方向に沿う場合を図示しているが、例示であり、各連結部２３は、第３方向に対して傾きを有するようにしてもよい。この場合、図３等と同様に、各連結部２３の傾く向きは、第２方向において互い違いとなることが望ましい。
（その他の実施の形態）
　上記のように、本発明を上記の実施の形態によって記載したが、この開示の一部をなす論述及び図面は本発明を限定するものであると理解すべきではない。この開示から当業者には様々な代替実施の形態、実施例及び運用技術が明らかとなろう。
　例えば、既に述べた実施の形態において、厚肉部２４は、図７に示すように、第２方向における各主面部２１の中央部からずれて配置されるようにしてもよい。また、図７に示すように、厚肉部２４及び薄肉部３１の第２方向において配置される周期（ピッチ）は、必ずしも主面部２１の周期と一致する必要ななく、第２方向において周期的に位置していればよい。
　上記の他、上記の各構成を相互に応用した構成等、本発明はここでは記載していない様々な実施の形態等を含むことは勿論である。したがって、本発明の技術的範囲は上記の説明から妥当な特許請求の範囲に係る発明特定事項によってのみ定められるものである。
　本発明によれば、金属部材の熱膨張率が小さい方向に沿うように、繊維強化樹脂の繊維を優先的に配向させることにより、金属と繊維強化樹脂との間の熱膨張率の差による影響を低減可能な複合材料構造体を提供することができる。
　１，１Ａ　複合材料構造体
　２，２Ａ　金属部材
　３　接着剤
　４　樹脂部材
　２０　間隙部
　２１，２１Ａ　主面部（主面）
　３１　薄肉部
　４１，４２　繊維

Claims (4)

  1. 　金属からなり、主面に沿う第１方向における熱膨張率が、前記主面に沿い、前記第１方向に直交する第２方向における熱膨張率よりも大きくなるように平板状に形成された金属部材と、
    　繊維強化樹脂からなり、前記金属部材の主面に貼付され、前記第２方向に沿う繊維の量が、前記第１方向に沿う繊維の量よりも多くなるように形成された樹脂部材と
    　を備えることを特徴とする複合材料構造体。
  2. 　前記金属部材は、主面が、前記第１方向において連続、前記第２方向において不連続となるように形成されることを特徴とする請求項１に記載の複合材料構造体。
  3. 　前記金属部材の主面と前記樹脂部材とは、接着剤により互いに貼付され、
    　前記接着剤は、厚さが他所より薄く形成された薄肉部を有することを特徴とする請求項１又は２に記載の複合材料構造体。
  4. 　前記薄肉部は、前記第２方向において周期的に位置することを特徴とする請求項３に記載の複合材料構造体。
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WO2019243855A1 (ja) * 2018-06-18 2019-12-26 日産自動車株式会社 接合構造体及びその製造方法
JPWO2019243855A1 (ja) * 2018-06-18 2021-08-12 日産自動車株式会社 接合構造体及びその製造方法
JP7010375B2 (ja) 2018-06-18 2022-02-10 日産自動車株式会社 接合構造体及びその製造方法
US12036746B2 (en) 2018-06-18 2024-07-16 Nissan Motor Co., Ltd. Joined structure and method of manufacturing the same

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JP6376274B2 (ja) 2018-08-22
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US10065687B2 (en) 2018-09-04
EP3260293A4 (en) 2018-05-02
JPWO2016132425A1 (ja) 2017-10-26
CN107206750B (zh) 2019-03-01
CN107206750A (zh) 2017-09-26
EP3260293A1 (en) 2017-12-27

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