WO2018193611A1 - 繊維強化樹脂製部品の接続構造および繊維強化樹脂製部品の製造方法 - Google Patents

繊維強化樹脂製部品の接続構造および繊維強化樹脂製部品の製造方法 Download PDF

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Publication number
WO2018193611A1
WO2018193611A1 PCT/JP2017/016000 JP2017016000W WO2018193611A1 WO 2018193611 A1 WO2018193611 A1 WO 2018193611A1 JP 2017016000 W JP2017016000 W JP 2017016000W WO 2018193611 A1 WO2018193611 A1 WO 2018193611A1
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WIPO (PCT)
Prior art keywords
fiber
component
layer
reinforced resin
resin
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PCT/JP2017/016000
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English (en)
French (fr)
Inventor
翔平 倉井
大久保　洋志
Original Assignee
日産自動車株式会社
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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 CN201780089827.6A priority Critical patent/CN110545989B/zh
Priority to PCT/JP2017/016000 priority patent/WO2018193611A1/ja
Priority to JP2019513190A priority patent/JP6844695B2/ja
Priority to EP17906336.7A priority patent/EP3613565B1/en
Priority to US16/500,132 priority patent/US11390043B2/en
Publication of WO2018193611A1 publication Critical patent/WO2018193611A1/ja

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    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/48—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
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    • 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
    • B32B7/05—Interconnection of layers the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection
    • 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
    • B32B7/08—Interconnection of layers by mechanical means
    • B32B7/09—Interconnection of layers by mechanical means by stitching, needling or sewing
    • 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
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3055—Cars
    • 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
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B32B2262/0269—Aromatic polyamide 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
    • B32B2262/101—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
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars

Definitions

  • the present invention relates to a connection structure for fiber-reinforced resin parts and a method for manufacturing fiber-reinforced resin parts.
  • Patent Document 1 a structure for attaching a second part to a first part made of fiber reinforced resin is known (see, for example, Patent Document 1).
  • Patent Document 1 describes a bonded structure of a carbon fiber reinforced resin material in which a carbon fiber reinforced resin material and a member to be bonded are bonded by a bonding means.
  • the carbon fiber reinforced resin material changes the temperature by overlapping the first laminated portion and the second laminated portion that is in the carbon fiber surface direction orthogonal to the carbon fiber surface direction of the first laminated portion. The linear expansion amount in the overlapping direction due to is reduced.
  • the member to be coupled is fastened to the carbon fiber reinforced resin material with bolts and nuts.
  • the present invention provides the first component even when the connection between the first component and the second component (adhesion by the adhesive) is released by inputting a relatively large load to the first component or the second component.
  • An object is to suppress the separation of the component and the second component.
  • a first component made of fiber reinforced resin
  • a second component made of fiber reinforced resin bonded to the first component
  • a connecting fiber connecting the first component and the second component.
  • a connection structure of fiber reinforced resin parts One end of the connecting fiber is sandwiched between the first fiber layers of the first part, and the other end of the connecting fiber is sandwiched between the second fiber layers of the second part.
  • the second aspect of the present invention is a method for manufacturing a fiber-reinforced resin part.
  • this manufacturing method one end of the connecting fiber is sandwiched between the first fiber layers, and the other end of the connecting fiber is sandwiched between the second fiber layers, so that the gap between the one end and the other end of the connecting fiber is increased.
  • the above-described manufacturing method further includes a step of impregnating the first fiber layer and the second fiber layer with the matrix resin without impregnating the intermediate portion of the connecting fiber with the matrix resin.
  • FIG. 1 is a side view showing a connection structure for fiber-reinforced resin parts according to an embodiment of the present invention.
  • FIG. 2 is a schematic cross-sectional view showing a cross section taken along line AA of FIG.
  • FIG. 3 is a partially enlarged side view showing a state before bonding of the connection structure of the fiber-reinforced resin parts according to the embodiment of the present invention.
  • FIG. 4A is an explanatory diagram of a method for manufacturing a fiber-reinforced resin part according to an embodiment of the present invention.
  • Drawing 4B is an explanatory view of the manufacturing method of the part made from fiber reinforced resin concerning the embodiment of the present invention.
  • FIG. 1 is a side view showing a connection structure for fiber-reinforced resin parts according to an embodiment of the present invention.
  • FIG. 2 is a schematic cross-sectional view showing a cross section taken along line AA of FIG.
  • FIG. 3 is a partially enlarged side view showing a state before bonding of the connection structure of
  • FIG. 4C is an explanatory diagram of the method for manufacturing the fiber-reinforced resin part according to the embodiment of the present invention.
  • Drawing 5A is an explanatory view of the manufacturing method of the part made from fiber reinforced resin concerning the embodiment of the present invention.
  • Drawing 5B is an explanatory view of the manufacturing method of the part made from fiber reinforced resin concerning the embodiment of the present invention.
  • Drawing 5C is an explanatory view of the manufacturing method of the part made from fiber reinforced resin concerning the embodiment of the present invention.
  • FIG. 6A is an explanatory diagram of a method for manufacturing a fiber-reinforced resin part according to an embodiment of the present invention.
  • Drawing 6B is an explanatory view of the manufacturing method of the part made from fiber reinforced resin concerning the embodiment of the present invention.
  • FIG. 6C is an explanatory diagram of the method for manufacturing the fiber-reinforced resin part according to the embodiment of the present invention.
  • connection structure of the fiber-reinforced resin part 1 according to the embodiment of the present invention will be described with reference to FIGS.
  • the fiber reinforced resin part 1 can be applied to a vehicle component such as a hood (bonnet), a door panel, a bumper, a trunk lid, a rear gate, a fender panel, a side body panel, and a roof panel.
  • a vehicle component such as a hood (bonnet), a door panel, a bumper, a trunk lid, a rear gate, a fender panel, a side body panel, and a roof panel.
  • the fiber reinforced resin part 1 is not limited to the structural member for vehicles, but can be applied to various structural members.
  • the fiber-reinforced resin part 1 is mainly composed of a first part 2, a second part 3, and a connection fiber 4.
  • the first component 2 is a component made of fiber reinforced resin having a plurality of first fiber layers 5 and a matrix resin (first resin) 6 impregnated in the first fiber layer 5 ( (See FIG. 4C).
  • the first component 2 of the present embodiment is a vehicle outer panel (fender panel) (not shown).
  • the first component 2 includes a component main body (panel main body) 2a and a first component-side adhesive portion 2b to which the second component 3 is attached.
  • the fibers constituting the first fiber layer 5 are not particularly limited, and various fibers such as carbon fibers, aramid fibers, and glass fibers can be used.
  • the matrix resin 6 is not specifically limited, For example, various thermosetting resins, such as an epoxy resin, a phenol resin, and a polyamide resin, can be used.
  • the matrix resin 6 is not limited to a thermosetting resin, and various thermoplastic resins can be used.
  • the second component 3 is a component made of a fiber reinforced resin including a plurality of second fiber layers 7 and a matrix resin (second resin) 8 impregnated in the second fiber layer 7 ( (See FIG. 4C).
  • the second component 3 is bonded to the first component 2 via the adhesive layer 9 (see FIG. 2). That is, in the present embodiment, the connection between the first component 2 and the second component 3 is not performed using a bolt and a nut, but is performed using an adhesive.
  • the second component 3 of the present embodiment is a bracket for attaching the vehicle outer panel (first component 2) to a vehicle body (not shown).
  • the second component 3 includes a second component-side adhesive portion 3a attached to the first component 2 and attached thereto, a vehicle body attachment portion 3b attached to the vehicle body of the vehicle, a second component-side adhesive portion 3a, and a vehicle body attachment portion 3b. And a connecting portion 3c disposed between the two.
  • the fibers constituting the second fiber layer 7 are not particularly limited, and various fibers such as carbon fibers, aramid fibers, and glass fibers can be used. Further, as the second fiber layer 7, for example, NCF (Non Crimp Fabric), woven fabric (woven fabric), or non-woven fabric (nonwoven fabric) can be used. Further, the matrix resin 8 is not particularly limited, and various thermosetting resins such as an epoxy resin, a phenol resin, and a polyamide resin can be used. The matrix resin 8 is not limited to a thermosetting resin, and various thermoplastic resins can also be used.
  • the adhesive constituting the adhesive layer 9 is not particularly limited as long as sufficient adhesive strength can be obtained.
  • an epoxy resin adhesive and a urethane resin adhesive can be used.
  • the adhesive may be a thermosetting adhesive or a thermoplastic adhesive.
  • the connecting fiber 4 connects the first part 2 and the second part 3. Specifically, one end portion 4a of the connecting fiber 4 (a portion hatched in FIG. 3) is sandwiched between the first fiber layers 5 of the first component 2, and the other end portion 4b of the connecting fiber 4 is placed. (Locations with point hatching in FIG. 3) are sandwiched between the second fiber layers 7 of the second component 3. And the intermediate part 4c between the one end part 4a and the other end part 4b in the connecting fiber 4 is exposed from the first fiber layer 5 of the first part 2 and the second fiber layer 7 of the second part 3. The intermediate resin 4c of the connecting fiber 4 is not impregnated with the matrix resins 6 and 8.
  • one end portion (first component connecting portion) 4a of the connecting fiber 4 is disposed in the intermediate layer (the middle layer in the thickness direction) of the first fiber layer 5, and the other end of the connecting fiber 4 is used.
  • the portion (second component connecting portion) 4b is disposed in the intermediate layer (the middle layer in the thickness direction) of the second fiber layer 7 (see FIG. 4A).
  • the first component connecting portion 4a of the connecting fiber 4 is disposed on the outer layer outside the intermediate layer in the first fiber layer 5, and the second component connecting portion 4b of the connecting fiber 4 is the second fiber. You may arrange
  • the first component connecting portion 4a of the connecting fiber 4 is not arranged on the entire first component 2, but only on a part of the first component 2 (first component-side adhesive portion 2b). Is arranged (see FIG. 3).
  • the second component connecting portion 4b of the connecting fiber 4 is not disposed on the entire second component 3, but is disposed only on a part of the second component 3 (second component side bonding portion 3a). (See FIG. 3).
  • the intermediate portion 4c of the connecting fiber 4 is not disposed in the entire width direction region of the first component connecting portion 4a and the second component connecting portion 4b, and the first component connecting portion 4a and the second component connecting portion are not arranged. It is arranged only in a partial region in the width direction of the portion 4b (both end regions in the width direction).
  • connection fiber 4 is embedded in the adhesive layer 9.
  • the connecting fiber 4 may be arranged around the adhesive layer 9 in a state where the first component 2 and the second component 3 are bonded via the adhesive layer 9.
  • connection fibers 4 are not particularly limited, and various fibers such as carbon fibers and aramid fibers can be used. Further, as the connection fiber 4, NCF (Non Crimp Fabric) or woven fabric (woven fabric) can be used. For this reason, the first component connecting portion 4a is sandwiched between the first fiber layers 5 of the first component 2 by sandwiching the first component connecting portion 4a of the connecting fiber 4 so that the first component connecting portion 4a is a common fabric layer with the first fiber layer 5. (That is, a part of the first fiber layer 5).
  • the second component connecting portion 4b is a fabric common to the second fiber layer 7 by sandwiching the second component connecting portion 4b of the connecting fiber 4 between the second fiber layers 7 of the second component 3. Constituting a layer (that is, a part of the second fiber layer 7).
  • RTM Resin® Transfer® Molding
  • the laminated first fiber layer 5, second fiber layer 7, and connection fiber 4 are placed in a molding die 10 for molding.
  • a plurality of first fiber layers 5 may be stacked, and a plurality of second fiber layers 7 may be stacked.
  • matrix resins 6 and 8 are injected into the mold 10 from a resin injection port (not shown), the first fiber layer 5 is impregnated with the matrix resin (first resin) 6, and the second The fiber layer 7 is impregnated with a matrix resin (second resin) 8. Then, in a state where the first fiber layer 5 and the second fiber layer 7 are impregnated with the matrix resins 6 and 8, the matrix resins 6 and 8 are cured (solidified).
  • a sealing resin 11 such as packing is provided in the intermediate portion 4c of the connecting fiber 4 so that the matrix resin is provided in the intermediate portion 4c of the connecting fiber 4.
  • the matrix resins 6 and 8 are prevented from flowing into the portion of the mold 10 where the intermediate portion 4c of the connecting fiber 4 is disposed.
  • the intermediate portion 4c of the connecting fiber 4 is covered with the brittle resin 12 such as acrylic resin, so that the intermediate resin 4c of the connecting fiber 4 is not impregnated with the matrix resins 6 and 8. You may do it. That is, by covering the intermediate portion 4c of the connecting fiber 4 with the brittle resin 12 in advance, the matrix resins 6 and 8 do not flow into the portion of the mold 10 where the intermediate portion 4c of the connecting fiber 4 is disposed. To. In this case, the brittle resin 12 is removed from the intermediate portion 4c of the connection fiber 4 after the matrix resins 6 and 8 are cured (after solidification).
  • the matrix resins 6 and 8 are cured (after solidification).
  • the intermediate portion 4c of the connecting fiber 4 is covered with a soft resin 13 such as polyurethane or polyethylene, so that the intermediate portion 4c of the connecting fiber 4 is impregnated with matrix resins 6 and 8. It may not be allowed to. That is, by covering the intermediate portion 4c of the connecting fiber 4 with the soft resin 13 in advance, the matrix resins 6 and 8 do not flow into the portion of the mold 10 where the intermediate portion 4c of the connecting fiber 4 is disposed. To. In this case, since the soft resin 13 is flexible after curing, it is left without being removed from the intermediate portion 4c of the connecting fiber 4 after the matrix resins 6 and 8 are cured (after solidification). Also good.
  • a soft resin 13 such as polyurethane or polyethylene
  • the first part 2, the second part 3, and the connection fibers 4 are taken out from the mold 10.
  • the intermediate portion 4c of the connecting fiber 4 is in a state that can be freely deformed.
  • the first component 2 and the second component 3 are bonded using an adhesive, whereby an adhesive layer 9 is formed between the first component 2 and the second component 3.
  • an adhesive layer 9 is formed between the first component 2 and the second component 3.
  • connection structure of the fiber reinforced resin component 1 includes a first component 2 having a plurality of first fiber layers 5 and a matrix resin 6 impregnated in the first fiber layer 5, and a first component 2.
  • a second component 3 that is bonded to the component 2 via an adhesive layer 9.
  • This connection structure further includes a connection fiber 4 that connects the first component 2 and the second component 3.
  • the second component 3 includes a plurality of second fiber layers 7 and a matrix resin 8 that is impregnated in the second fiber layers 7.
  • One end 4 a of the connecting fiber 4 is sandwiched between the first fiber layers 5, and the other end 4 b of the connecting fiber 4 is sandwiched between the second fiber layers 7.
  • connection structure of the fiber reinforced resin parts 1 the first part 2 and the second part 3 are connected by connecting fibers 4, and a matrix is provided in an intermediate portion 4 c of the connecting fibers 4. Resins 6 and 8 are not impregnated. For this reason, even if the connection (adhesion by the adhesive) between the first component 2 and the second component 3 is released by the input of a relatively large load to the first component 2 or the second component 3, the connection The connection between the first component 2 and the second component 3 (connection by the connection fiber 4) is maintained by the use fiber 4. Therefore, according to the connection structure of the fiber reinforced resin component 1 according to the present embodiment, it is possible to suppress the first component 2 and the second component 3 from being separated.
  • the connecting fibers 4 are connected to the first component 2.
  • the second component 3 can be held relatively firmly.
  • One end 4 a of the connecting fiber 4 is arranged in the intermediate layer of the first fiber layer 5, and the other end 4 b of the connecting fiber 4 is arranged in the intermediate layer of the second fiber layer 7.
  • One end portion 4a of the connecting fiber 4 is arranged in the intermediate layer of the first fiber layer 5, and the other end portion 4b of the connecting fiber 4 is arranged in the intermediate layer of the second fiber layer 7, whereby the connecting fiber 4 Can be held more firmly against the first component 2 and the second component 3.
  • the connecting fiber 4 is embedded in the adhesive layer 9.
  • the connecting fiber 4 is embedded in the adhesive layer 9, the connecting fiber 4 (intermediate portion 4 c) is not exposed in a state where the first component 2 and the second component 3 are bonded via the adhesive layer 9. Can be.
  • the connecting fiber 4 may be arranged around the adhesive layer 9.
  • the connecting fiber 4 By disposing the connecting fiber 4 so as to bypass the adhesive layer 9, the connecting fiber 4 (intermediate portion 4 c) can be prevented from interfering with the adhesion between the first component 2 and the second component 3. .
  • the first component 2 is a vehicle outer panel
  • the second component 3 is a bracket for attaching the outer panel to the vehicle body.
  • the one end 4a of the connection fiber 4 is sandwiched between the first fiber layers 5, and the other end 4b of the connection fiber 4 is the second fiber.
  • a step of exposing the intermediate portion 4c of the connecting fiber 4 by being sandwiched between the layers 7 is provided.
  • the first fiber layer 5 and the second fiber layer 7 are impregnated with the matrix resins 6 and 8 without impregnating the matrix resin 6 and 8 into the intermediate portion 4c of the connecting fiber 4, and the matrix A step of solidifying the resins 6 and 8.
  • the fiber reinforced resin part 1 can be efficiently manufactured.
  • one end 4 a of the connecting fiber 4 is sandwiched between the first fiber layers 5, and the other end 4 b of the connecting fiber 4 is sandwiched between the second fiber layers 7.
  • the component 2 and the second component 3 can be held relatively firmly.
  • the first fiber layer 5 and the second fiber layer 7 are impregnated with the matrix resins 6 and 8, while the intermediate portion 4c of the connecting fiber 4 is not impregnated with the matrix resins 6 and 8. Is possible.
  • the intermediate portion 4c of the connecting fiber 4 may not be impregnated with the matrix resins 6 and 8.
  • first fiber layer 5 and the second fiber layer 7 are impregnated with the matrix resins 6 and 8, while the intermediate portion 4 c of the connecting fiber 4 is not impregnated with the matrix resins 6 and 8. It is possible to
  • first fiber layer 5 and the second fiber layer 7 are impregnated with the matrix resins 6 and 8, while the intermediate portion 4 c of the connecting fiber 4 is not impregnated with the matrix resins 6 and 8. It is possible to

Abstract

繊維強化樹脂製部品（１）の接続構造は、複数層の第１繊維層（５）および第１繊維層（５）に含浸されるマトリックス樹脂（６）を有する第１部品（２）と、第１部品（２）に接着層（９）を介して接着される第２部品（３）と、を備える。繊維強化樹脂製部品（１）の接続構造は、第１部品（２）と第２部品（３）とを接続する接続用繊維（４）をさらに備える。第２部品（３）は、複数層の第２繊維層（７）および第２繊維層（７）に含浸されるマトリックス樹脂（８）を有する。接続用繊維（４）の一端部（４ａ）が第１繊維層（５）間に挟持され、接続用繊維（４）の他端部（４ｂ）が第２繊維層（７）間に挟持される。

Description

繊維強化樹脂製部品の接続構造および繊維強化樹脂製部品の製造方法
　本発明は、繊維強化樹脂製部品の接続構造および繊維強化樹脂製部品の製造方法に関する。
　従来から、繊維強化樹脂製の第１部品に、第２部品を取り付けるための構造が公知である（例えば、特許文献１参照）。
　特許文献１には、炭素繊維強化樹脂材と被結合部材とを結合手段によって結合した炭素繊維強化樹脂材の結合構造が記載されている。この結合構造では、炭素繊維強化樹脂材は、第１積層部と、第１積層部の炭素繊維面方向と直交する炭素繊維面方向とされた第２積層部と、を重ねることで、温度変化による重ね合わせ方向の線膨張量を小さくする。また、特許文献１に記載の繊維強化樹脂材の結合構造では、被結合部材は炭素繊維強化樹脂材にボルトおよびナットで締結される。
特開２００７－２９２１０６号公報
　前述の構造では、第１部品と第２部品とがボルトおよびナットにより締結されるので、第１部品または第２部品への比較的大きな荷重の入力により第１部品と第２部品との接続（ボルトおよびナットによる締結）が解除される可能性は低い。ボルトおよびナットによる締結は、作業性が低く、コスト上昇の要因となり得るため、ボルトおよびナットによる締結から接着剤による接着への変更が検討される。しかしながら、第１部品と第２部品とを接着剤により接着するだけでは、第１部品または第２部品への比較的大きな荷重の入力により第１部品と第２部品との接続（接着剤による接着）が解除され、第１部品と第２部品とが分離することが懸念される。
　そこで、本発明は、第１部品または第２部品への比較的大きな荷重の入力により第１部品と第２部品との接続（接着剤による接着）が解除された場合であっても、第１部品と第２部品とが分離してしまうことを抑制することを目的とする。
　本発明の第１の態様は、繊維強化樹脂製の第１部品と、第１部品に接着される繊維強化樹脂製の第２部品と、第１部品と第２部品とを接続する接続用繊維と、を備える繊維強化樹脂製部品の接続構造である。接続用繊維の一端部が第１部品の第１繊維層間に挟持され、接続用繊維の他端部が第２部品の第２繊維層間に挟持される。
　本発明の第２の態様は、繊維強化樹脂製部品の製造方法である。この製造方法は、接続用繊維の一端部を第１繊維層間に挟み込み、接続用繊維の他端部を第２繊維層間に挟み込むことにより、接続用繊維における一端部と他端部との間の中間部を第１繊維層および第２繊維層から露出させる工程を備える。また、前述の製造方法は、接続用繊維の中間部にはマトリックス樹脂を含浸させずに、第１繊維層および第２繊維層にマトリックス樹脂を含浸させる工程をさらに備える。
　本発明によれば、第１部品または第２部品への比較的大きな荷重の入力により第１部品と第２部品との接続（接着剤による接着）が解除された場合であっても、第１部品と第２部品とが分離してしまうことを抑制することができる。
図１は、本発明の実施形態に係る繊維強化樹脂製部品の接続構造を示す側面図である。 図２は、図１のＡ－Ａ線断面を示す概略的な断面図である。 図３は、本発明の実施形態に係る繊維強化樹脂製部品の接続構造の接着前の状態を示す部分拡大側面図である。 図４Ａは、本発明の実施形態に係る繊維強化樹脂製部品の製造方法の説明図である。 図４Ｂは、本発明の実施形態に係る繊維強化樹脂製部品の製造方法の説明図である。 図４Ｃは、本発明の実施形態に係る繊維強化樹脂製部品の製造方法の説明図である。 図５Ａは、本発明の実施形態に係る繊維強化樹脂製部品の製造方法の説明図である。 図５Ｂは、本発明の実施形態に係る繊維強化樹脂製部品の製造方法の説明図である。 図５Ｃは、本発明の実施形態に係る繊維強化樹脂製部品の製造方法の説明図である。 図６Ａは、本発明の実施形態に係る繊維強化樹脂製部品の製造方法の説明図である。 図６Ｂは、本発明の実施形態に係る繊維強化樹脂製部品の製造方法の説明図である。 図６Ｃは、本発明の実施形態に係る繊維強化樹脂製部品の製造方法の説明図である。
　以下、本発明の実施形態を図面と共に詳述する。
　本発明の実施形態に係る繊維強化樹脂製部品１の接続構造を図１から図３に基づいて説明する。
　繊維強化樹脂製部品１は、例えば、フード（ボンネット）、ドアパネル、バンパー、トランクリッド、リアゲート、フェンダパネル、サイドボディパネル、ルーフパネルなど車両用構成部材に適用することができる。また、繊維強化樹脂製部品１は、車両用構成部材に限定されず、各種構成部材に適用することが可能である。
　図１から図３に示すように、繊維強化樹脂製部品１は、第１部品２と、第２部品３と、接続用繊維４と、から主に構成されている。
　第１部品２は、複数層の第１繊維層５と、第１繊維層５に含浸されるマトリックス樹脂（第１樹脂）６とを有して構成される繊維強化樹脂製の部品である（図４Ｃ参照）。本実施形態の第１部品２は、図示しない車両の外板パネル（フェンダパネル）である。第１部品２は、部品本体部（パネル本体部）２ａと、第２部品３が接着して取り付けられる第１部品側接着部２ｂとを有して構成されている。
　第１繊維層５を構成する繊維は、特に限定されず、炭素繊維、アラミド繊維、ガラス繊維など、種々の繊維を用いることができる。また、第１繊維層５としては、例えば、ＮＣＦ（Non Crimp Fabric）、織物（織布）、不織物（不織布）を用いることができる。さらに、マトリックス樹脂６は、特に限定されず、例えば、エポキシ樹脂、フェノール樹脂、ポリアミド樹脂など、種々の熱硬化性樹脂を用いることができる。なお、マトリックス樹脂６としては、熱硬化性樹脂に限定されず、種々の熱可塑性樹脂を用いることも可能である。
　第２部品３は、複数層の第２繊維層７と、第２繊維層７に含浸されるマトリックス樹脂（第２樹脂）８とを有して構成される繊維強化樹脂製の部品である（図４Ｃ参照）。第２部品３は、第１部品２に接着層９を介して接着される（図２参照）。すなわち、本実施形態においては、第１部品２と第２部品３との接続には、ボルトおよびナットによる結合は用いられずに、接着剤による接着が用いられる。本実施形態の第２部品３は、車両の外板パネル（第１部品２）を図示しない車両の車体に取り付けるためのブラケットである。第２部品３は、第１部品２に接着して取り付けられる第２部品側接着部３ａと、車両の車体に取り付けられる車体取付部３ｂと、第２部品側接着部３ａと車体取付部３ｂとの間に配設される連結部３ｃとを有して構成されている。
　第２繊維層７を構成する繊維は、特に限定されず、炭素繊維、アラミド繊維、ガラス繊維など、種々の繊維を用いることができる。また、第２繊維層７としては、例えば、ＮＣＦ（Non Crimp Fabric）、織物（織布）、不織物（不織布）を用いることができる。さらに、マトリックス樹脂８は、特に限定されず、例えば、エポキシ樹脂、フェノール樹脂、ポリアミド樹脂など、種々の熱硬化性樹脂を用いることができる。なお、マトリックス樹脂８としては、熱硬化性樹脂に限定されず、種々の熱可塑性樹脂を用いることも可能である。
　接着層９を構成する接着剤は、十分な接着強度が得られるものであればよく、例えば、エポキシ樹脂系接着剤、ウレタン樹脂系接着剤を用いることができる。また、この接着剤は、熱硬化性の接着剤であってもよく、熱可塑性の接着剤であってもよい。
　接続用繊維４は、第１部品２と第２部品３とを接続するものである。具体的には、接続用繊維４の一端部４ａ（図３中に点ハッチングを付した箇所）が第１部品２の第１繊維層５間に挟持され、接続用繊維４の他端部４ｂ（図３中に点ハッチングを付した箇所）が第２部品３の第２繊維層７間に挟持される。そして、接続用繊維４における一端部４ａと他端部４ｂとの間の中間部４ｃは、第１部品２の第１繊維層５および第２部品３の第２繊維層７から露出しており、接続用繊維４の中間部４ｃには、マトリックス樹脂６，８は含浸されてはいない。
　本実施形態においては、接続用繊維４の一端部（第１部品接続部）４ａが第１繊維層５の中間層（厚さ方向の真ん中の層）に配置され、接続用繊維４の他端部（第２部品接続部）４ｂが第２繊維層７の中間層（厚さ方向の真ん中の層）に配置される（図４Ａ参照）。これに限定されず、接続用繊維４の第１部品接続部４ａが第１繊維層５における中間層よりも外側の外層に配置され、接続用繊維４の第２部品接続部４ｂが第２繊維層７における中間層よりも外側の外層に配置されてもよい。
　本実施形態においては、接続用繊維４の第１部品接続部４ａは、第１部品２の全体には配置されておらず、第１部品２の一部分（第１部品側接着部２ｂ）のみに配置されている（図３参照）。また、接続用繊維４の第２部品接続部４ｂは、第２部品３の全体には配置されておらず、第２部品３の一部分（第２部品側接着部３ａ）のみに配置されている（図３参照）。さらに、接続用繊維４の中間部４ｃは、第１部品接続部４ａおよび第２部品接続部４ｂの幅方向の全領域には配置されておらず、第１部品接続部４ａおよび第２部品接続部４ｂの幅方向の一部領域（幅方向の両端領域）のみに配置されている。
　第１部品２と第２部品３とを接着層９を介して接着した状態において、例えば、接続用繊維４は、接着層９に埋め込まれる。これに限定されず、第１部品２と第２部品３とを接着層９を介して接着した状態において、接続用繊維４は、接着層９を迂回して配置されてもよい。
　接続用繊維４を構成する繊維は、特に限定されず、炭素繊維、アラミド繊維など、種々の繊維を用いることができる。また、接続用繊維４としては、ＮＣＦ（Non Crimp Fabric）、織物（織布）を用いることができる。このため、接続用繊維４の第１部品接続部４ａを第１部品２の第１繊維層５間に挟持させることにより、第１部品接続部４ａは、第１繊維層５と共通のファブリック層（すなわち、第１繊維層５の一部）を構成する。その一方で、接続用繊維４の第２部品接続部４ｂを第２部品３の第２繊維層７間に挟持させることにより、第２部品接続部４ｂは、第２繊維層７と共通のファブリック層（すなわち、第２繊維層７の一部）を構成する。
　次に、本実施形態に係る繊維強化樹脂製部品１の製造方法の一例を説明する。
　繊維強化樹脂製部品１を製造する方法には、例えばＲＴＭ（Resin Transfer Molding）成形を用いることができる。
　［ＲＴＭ成形の場合］
　１．積層
　まず、図４Ａに示すように、複数層の第１繊維層５を積層すると共に、複数層の第２繊維層７を積層する。この際に、接続用繊維４の第１部品接続部４ａを第１繊維層５間に挟み込み、接続用繊維４の第２部品接続部４ｂを第２繊維層７間に挟み込む。このようにすることにより、接続用繊維４における第１部品接続部４ａと第２部品接続部４ｂとの間の中間部４ｃを第１繊維層５および第２繊維層７から露出させる。
　２．マトリックス樹脂の含浸
　次いで、図４Ｂに示すように、積層した第１繊維層５、第２繊維層７および接続用繊維４を成形用の成形型１０内に入れる。なお、成形型１０内において、複数層の第１繊維層５を積層すると共に、複数層の第２繊維層７を積層するようにしてもよい。
　次いで、図４Ｃに示すように、図示しない樹脂注入口からマトリックス樹脂６，８を成形型１０内に注入し、第１繊維層５にマトリックス樹脂（第１樹脂）６を含浸させると共に、第２繊維層７にマトリックス樹脂（第２樹脂）８を含浸させる。そして、第１繊維層５および第２繊維層７にマトリックス樹脂６，８を含浸させた状態において、マトリックス樹脂６，８を硬化（固化）させる。
　３．マトリックス樹脂の含浸抑制方策
　例えば、図５Ａに示すように、接続用繊維４の中間部４ｃに、パッキンなどのシール部材１１を配設することにより、接続用繊維４の中間部４ｃにはマトリックス樹脂６，８を含浸させないようにする。すなわち、成形型１０内にシール部材１１を配設することにより、成形型１０における接続用繊維４の中間部４ｃが配置された部分にマトリックス樹脂６，８を流入させないようにする。
　また、図５Ｂに示すように、接続用繊維４の中間部４ｃを、アクリル樹脂などの脆性樹脂１２によって被覆することにより、接続用繊維４の中間部４ｃにはマトリックス樹脂６，８を含浸させないようにしてもよい。すなわち、接続用繊維４の中間部４ｃを脆性樹脂１２によって予め被覆しておくことにより、成形型１０における接続用繊維４の中間部４ｃが配置された部分にマトリックス樹脂６，８を流入させないようにする。なお、この場合、脆性樹脂１２は、マトリックス樹脂６，８の硬化後（固化後）に、接続用繊維４の中間部４ｃから取り除くようにする。
　また、図５Ｃに示すように、接続用繊維４の中間部４ｃを、ポリウレタンやポリエチレンなどの軟性樹脂１３によって被覆することにより、接続用繊維４の中間部４ｃにはマトリックス樹脂６，８を含浸させないようにしてもよい。すなわち、接続用繊維４の中間部４ｃを軟性樹脂１３によって予め被覆しておくことにより、成形型１０における接続用繊維４の中間部４ｃが配置された部分にマトリックス樹脂６，８を流入させないようにする。なお、この場合、軟性樹脂１３は、硬化後において可撓性を有するので、マトリックス樹脂６，８の硬化後（固化後）に、接続用繊維４の中間部４ｃから取り除かずに残すようにしてもよい。
　４．マトリックス樹脂の硬化後（固化後）
　図６Ａに示すように、マトリックス樹脂６，８の硬化後（固化後）に、第１部品２、第２部品３および接続用繊維４を成形型１０から取り出す。図６Ａに示すマトリックス樹脂６，８の硬化後（固化後）の状態においては、接続用繊維４の中間部４ｃは、自由に変形が可能な状態である。
　そして、図６Ｂ及び図６Ｃに示すように、第１部品２と第２部品３とを接着剤を用いて接着することにより、第１部品２と第２部品３との間に接着層９を形成する。第１部品２と第２部品３とを接着剤を用いて接着する際には、例えば、接続用繊維４の中間部４ｃを接着層９に埋め込むようにする。また、接続用繊維４が第１部品２と第２部品３との接着の妨げとならないようにするために、接続用繊維４の中間部４ｃを接着層９を迂回して配置するようにしてもよい。
　以下に、本実施形態による作用効果を説明する。
　（１）本実施形態に係る繊維強化樹脂製部品１の接続構造は、複数層の第１繊維層５および第１繊維層５に含浸されるマトリックス樹脂６を有する第１部品２と、第１部品２に接着層９を介して接着される第２部品３と、を備える。この接続構造は、第１部品２と第２部品３とを接続する接続用繊維４をさらに備える。第２部品３は、複数層の第２繊維層７および第２繊維層７に含浸されるマトリックス樹脂８を有する。接続用繊維４の一端部４ａが第１繊維層５間に挟持され、接続用繊維４の他端部４ｂが第２繊維層７間に挟持される。
　本実施形態に係る繊維強化樹脂製部品１の接続構造においては、第１部品２と第２部品３とは接続用繊維４によって接続されており、この接続用繊維４の中間部４ｃにはマトリックス樹脂６，８が含浸されていない。このため、第１部品２または第２部品３への比較的大きな荷重の入力により第１部品２と第２部品３との接続（接着剤による接着）が解除された場合であっても、接続用繊維４により第１部品２と第２部品３との接続（接続用繊維４による接続）が維持される。したがって、本実施形態に係る繊維強化樹脂製部品１の接続構造によれば、第１部品２と第２部品３とが分離してしまうことを抑制することができる。
　接続用繊維４の一端部４ａが第１繊維層５間に挟持され、接続用繊維４の他端部４ｂが第２繊維層７間に挟持されるため、接続用繊維４を第１部品２および第２部品３に対して比較的強固に保持することが可能になる。
　（２）接続用繊維４の一端部４ａが第１繊維層５の中間層に配置され、接続用繊維４の他端部４ｂが第２繊維層７の中間層に配置される。
　接続用繊維４の一端部４ａが第１繊維層５の中間層に配置され、接続用繊維４の他端部４ｂが第２繊維層７の中間層に配置されることにより、接続用繊維４を第１部品２および第２部品３に対してより強固に保持することが可能になる。
　（３）例えば、接続用繊維４は、接着層９に埋め込まれる。
　接続用繊維４が接着層９に埋め込まれることにより、第１部品２と第２部品３とが接着層９を介して接着された状態において、接続用繊維４（中間部４ｃ）が露出しないようにすることができる。
　（４）接続用繊維４は、接着層９を迂回して配置されてもよい。
　接続用繊維４が接着層９を迂回して配置されることにより、接続用繊維４（中間部４ｃ）が第１部品２と第２部品３との接着の妨げとならないようにすることができる。
　（５）例えば、第１部品２は、車両の外板パネルであり、第２部品３は、外板パネルを車両の車体に取り付けるためのブラケットである。
　車両の外板パネルまたはブラケットへの比較的大きな荷重の入力により外板パネルとブラケットとの接続（接着剤による接着）が解除された場合であっても、外板パネルとブラケットとが分離してしまうことを抑制することができる。
　（６）本実施形態に係る繊維強化樹脂製部品１の製造方法は、接続用繊維４の一端部４ａを第１繊維層５間に挟み込み、接続用繊維４の他端部４ｂを第２繊維層７間に挟み込むことにより、接続用繊維４の中間部４ｃを露出させる工程を備える。この製造方法は、接続用繊維４の中間部４ｃにはマトリックス樹脂６，８を含浸させずに、第１繊維層５および第２繊維層７にマトリックス樹脂６，８を含浸させる工程と、マトリックス樹脂６，８を固化させる工程と、をさらに備える。
　このようにすることにより、繊維強化樹脂製部品１を効率よく製造することが可能である。特に、接続用繊維４の一端部４ａが第１繊維層５間に挟持され、接続用繊維４の他端部４ｂが第２繊維層７間に挟持されるため、接続用繊維４を第１部品２および第２部品３に対して比較的強固に保持することが可能になる。
　（７）例えば、接続用繊維４の中間部４ｃにシール部材１１を配設することにより、接続用繊維４の中間部４ｃにはマトリックス樹脂６，８を含浸させないようにする。
　このようにすることにより、第１繊維層５および第２繊維層７にマトリックス樹脂６，８を含浸させる一方で、接続用繊維４の中間部４ｃにはマトリックス樹脂６，８を含浸させないようにすることが可能である。
　（８）接続用繊維４の中間部４ｃを脆性樹脂１２によって被覆することにより、接続用繊維４の中間部４ｃにはマトリックス樹脂６，８を含浸させないようにしてもよい。
　このようにすることによっても、第１繊維層５および第２繊維層７にマトリックス樹脂６，８を含浸させる一方で、接続用繊維４の中間部４ｃにはマトリックス樹脂６，８を含浸させないようにすることが可能である。
　（９）接続用繊維４の中間部４ｃを軟性樹脂１３によって被覆することにより、接続用繊維４の中間部４ｃにはマトリックス樹脂６，８を含浸させないようにしてもよい。
　このようにすることによっても、第１繊維層５および第２繊維層７にマトリックス樹脂６，８を含浸させる一方で、接続用繊維４の中間部４ｃにはマトリックス樹脂６，８を含浸させないようにすることが可能である。
　以上、実施例に沿って本発明の内容を説明したが、本発明はこれらの記載に限定されるものではなく、種々の変形および改良が可能であることは、当業者には自明である。
　１　繊維強化樹脂製部品
　２　第１部品
　３　第２部品
　４　接続用繊維
４ａ　一端部（第１部品接続部）
４ｂ　他端部（第２部品接続部）
４ｃ　中間部
　５　第１繊維層
　６　マトリックス樹脂（第１樹脂）
　７　第２繊維層
　８　マトリックス樹脂（第２樹脂）
　９　接着層
１１　シール部材
１２　脆性樹脂
１３　軟性樹脂

Claims (9)

  1. 　複数層の第１繊維層および前記第１繊維層に含浸されるマトリックス樹脂を有する第１部品と、
    　前記第１部品に接着層を介して接着される第２部品と、
    　前記第１部品と前記第２部品とを接続する接続用繊維と、を備え、
    　前記第２部品は、複数層の第２繊維層および前記第２繊維層に含浸されるマトリックス樹脂を有し、
    　前記接続用繊維の一端部が前記第１繊維層間に挟持され、前記接続用繊維の他端部が前記第２繊維層間に挟持される
    　ことを特徴とする繊維強化樹脂製部品の接続構造。
  2. 　前記接続用繊維の前記一端部が前記第１繊維層の中間層に配置され、前記接続用繊維の前記他端部が前記第２繊維層の中間層に配置されることを特徴とする請求項１に記載の繊維強化樹脂製部品の接続構造。
  3. 　前記接続用繊維は、前記接着層に埋め込まれることを特徴とする請求項１または２に記載の繊維強化樹脂製部品の接続構造。
  4. 　前記接続用繊維は、前記接着層を迂回して配置されることを特徴とする請求項１または２に記載の繊維強化樹脂製部品の接続構造。
  5. 　前記第１部品は、車両の外板パネルであり、前記第２部品は、前記外板パネルを前記車両の車体に取り付けるためのブラケットであることを特徴とする請求項１から４のいずれか一項に記載の繊維強化樹脂製部品の接続構造。
  6. 　複数層の第１繊維層および前記第１繊維層に含浸されるマトリックス樹脂を有する第１部品と、複数層の第２繊維層および前記第２繊維層に含浸されるマトリックス樹脂を有する第２部品と、前記第１部品と前記第２部品とを接続する接続用繊維と、を備える繊維強化樹脂製部品を製造する方法において、
    　前記接続用繊維の一端部を前記第１繊維層間に挟み込み、前記接続用繊維の他端部を前記第２繊維層間に挟み込むことにより、前記接続用繊維における前記一端部と前記他端部との間の中間部を前記第１繊維層および前記第２繊維層から露出させる工程と、
    　前記接続用繊維の前記中間部には前記マトリックス樹脂を含浸させずに、前記第１繊維層および前記第２繊維層に前記マトリックス樹脂を含浸させる工程と、
    　前記マトリックス樹脂を固化させる工程と、を備える
    　ことを特徴とする繊維強化樹脂製部品の製造方法。
  7. 　前記接続用繊維の前記中間部にシール部材を配設することにより、前記接続用繊維の前記中間部には前記マトリックス樹脂を含浸させないことを特徴とする請求項６に記載の繊維強化樹脂製部品の製造方法。
  8. 　前記接続用繊維の前記中間部を脆性樹脂によって被覆することにより、前記接続用繊維の前記中間部には前記マトリックス樹脂を含浸させないことを特徴とする請求項６に記載の繊維強化樹脂製部品の製造方法。
  9. 　前記接続用繊維の前記中間部を軟性樹脂によって被覆することにより、前記接続用繊維の前記中間部には前記マトリックス樹脂を含浸させないことを特徴とする請求項６に記載の繊維強化樹脂製部品の製造方法。
PCT/JP2017/016000 2017-04-21 2017-04-21 繊維強化樹脂製部品の接続構造および繊維強化樹脂製部品の製造方法 WO2018193611A1 (ja)

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