WO2019013239A1

WO2019013239A1 - Vehicle wheel

Info

Publication number: WO2019013239A1
Application number: PCT/JP2018/026129
Authority: WO
Inventors: 佐竹　弘之; 房郎北條; 正浩三宅; 亮吉沢; 祐典望月; 孝一小宅; 義正藤井
Original assignee: 日立金属株式会社
Priority date: 2017-07-11
Filing date: 2018-07-11
Publication date: 2019-01-17

Abstract

The objective of the present invention is to provide a vehicle wheel which has a laminated structure with a fiber layer thickness and fiber orientation that are appropriate with respect to a load acting on the vehicle wheel, and which has good strength. This vehicle wheel includes a rim portion 300 comprising a resin reinforced using fibers, characterized in that the rim portion 300 has a structure in which a plurality of layers of substantially cylindrically shaped fiber layers a to g are laminated together, and at least one of the fiber layers a to g is configured with an orientation pattern that is different from at least one other fiber layer.

Description

Vehicle wheel

The present invention relates to a vehicle wheel. In particular, the present invention relates to a vehicle wheel having a rim portion made of fiber reinforced resin.

The fiber reinforced resin material is, for example, a material obtained by solidifying a carbon fiber with an epoxy resin or the like, has high strength and high rigidity as compared with a metal material, and only weighs about 1⁄4 of the metal material. Attempts to reduce the weight using resin materials have been made in various fields. For example, in the case of aluminum wheels for vehicles, lightweight wheels partially replaced with fiber reinforced resin materials have been developed and are commercially available.

FIG. 1A is a view for explaining the concept of a lightweight vehicle wheel. In FIG. 1A, the vehicle wheel 100 which has been reduced in weight is constituted by a rim portion 101 in which a portion which used an aluminum material so far is replaced by a fiber reinforced resin material, and spokes 102 made of aluminum. A weight reduction of approximately 20% to 60% is possible. FIG. 1B is a cross-sectional view taken along the line X-X 'of FIG. 1A. As shown in FIG. 1B, the rim portion 101 of the fiber reinforced resin material and the spokes 102 made of aluminum are joined by an adhesive or a bolt at the connection portion 103 to form a lightweight vehicle wheel 100.

By the way, although a fiber reinforced resin material shows high intensity and rigidity, when a load direction and a fiber direction correspond, when a load direction and a fiber direction differ, there is a property to which strength is remarkably lost. Therefore, when a part of the industrial product is replaced with the fiber reinforced resin material, it is necessary to set the thickness of the fiber reinforced resin material and the orientation of the fibers in accordance with the direction of load.

FIG. 2 is a view for explaining the difference in the strength of the fiber-reinforced resin material depending on the fiber direction and the load direction, using a commercially available Toray T800S / # 3900-2B fiber-reinforced resin material as the fiber-reinforced resin material. The graph shows the relationship between the load direction applied to 200 and the strength of the fiber-reinforced resin material 200.

As shown in the graph of FIG. 2, when a tensile load in the same direction as the fiber direction H is applied (load in the 0 ° direction), the tensile strength of the fiber reinforced resin material 200 is as high as 3000 MPa while the fiber direction H When a tensile load is applied to the fiber-reinforced resin material 200 along the direction deviated from the direction 45 ° (load in the direction 45 °), the tensile strength of the fiber-reinforced resin material 200 decreases significantly, and the direction deviated 90 ° from the fiber direction H When a tensile load is applied to it (a load in the direction of 90 °), the effect of fiber reinforcement is not obtained, and the tensile strength becomes a small value of 70 MPa. As described above, in order to apply the fiber reinforced resin material, it is necessary to match the fiber direction with the load direction in consideration of the direction of the load acting on the fiber reinforced resin material.

A sheet winding method is known as a prior art of manufacturing a rim portion of a vehicle wheel by applying a fiber reinforced resin material. The sheet winding method is a method of laminating and molding a thin sheet-like material for a fiber-reinforced resin many times around a mold and manufacturing it. In this method, a thin sheet-like fiber-reinforced resin material is wound on a mold, and the sheet is covered with a cut so as to form a pseudo-continuous cylindrical shape while covering the cut of the sheet with the next sheet. In this case, the strength is lowered, and the uneven thickness due to the step is a cause of vibration and breakage. In order to solve this problem, in the method for manufacturing a rim of a wheel described in Patent Document 1, a continuous fiber reinforced resin material (corresponding to a material for fiber reinforced resin in the present application) is applied to the outer peripheral surface of a rim forming mold. By laying in parallel in the axial direction and further winding a constraining material around the axis, it is precisely laminated on the rim type of the concave wheel. In this method, since the continuous fiber reinforced resin material is covered on the outer peripheral surface of the rim forming mold, there are no fiber cuts, the problems caused by the cuts are resolved, and a seamless cylindrical shape can be formed.

JP, 2016-150614, A

However, according to the method of manufacturing a rim of a vehicle wheel disclosed in Patent Document 1, only homogeneous fiber layers having the same fiber orientation are used because they are laid in parallel in the axial direction on the outer peripheral surface of the rim forming mold. I can not build. Loads act on the rim from multiple directions, so the stress generated differs from part to part. However, the manufacturing method of Patent Document 1 is based on the thickness of the fiber layer against the load acting from such multiple directions. Number) and the orientation direction of the fibers, it is not a method to obtain a rim portion made of a fiber reinforced resin material in which a fiber layer is appropriately disposed, so a rim portion having sufficient strength to cope with different stress for each portion It can not be built.

Therefore, the present invention provides a wheel for a vehicle having a rim portion made of a fiber reinforced resin material, and the strength appropriately set so as to withstand different stresses for each portion against a load acting on the rim portion from multiple directions. It is an object of the present invention to provide a vehicle wheel having a rim portion having the following.

In order to solve the above problems, a vehicle wheel according to the present invention is a vehicle wheel having a rim portion made of a fiber-reinforced resin, and the rim portion is formed by laminating a plurality of substantially cylindrical fiber layers. It is characterized in that it has a structure and at least one of the fiber layers is configured with an orientation pattern different from at least one other fiber layer.
The present specification includes the disclosure content of Japanese Patent Application No. 2017-135698 on which the priority of the present application is based.

According to the present invention, according to the load acting on the rim from multiple directions, at least one of the plurality of fiber layers constituting the rim has an orientation pattern different from that of at least one other fiber layer. In this way, it is possible to construct a laminated structure in which the thickness of the fiber layer (the number of laminations) and the orientation direction of the fibers are adjusted according to the strength required for each part of the rim part. It is possible to provide a vehicle wheel having various strengths. In addition, the subject except having mentioned above, a structure, and an effect are clarified by description of the following embodiment.

It is a perspective view showing a wheel for vehicles. It is a X-X 'sectional view of Drawing 1A. It is a figure for demonstrating the difference in the intensity | strength of the fiber reinforced resin material by a fiber direction and a load direction. It is a sectional view of a rim portion of a wheel for vehicles concerning a 1st embodiment. It is a contour figure which shows an example of the load which acts on the wheel for vehicles. It is a conceptual diagram for demonstrating the method to manufacture the rim part of the wheel for vehicles. It is a figure which shows the prototype for forming a rim part. FIG. 5B is a cross-sectional view taken along line Y-Y 'of FIG. 5B. It is a figure which shows the embodiment of the raw material for fiber reinforced resin used for constructing | assembling laminated structure L. FIG. It is sectional drawing of the rim part of the wheel for vehicles which concerns on 2nd Embodiment. It is an expanded sectional view of a rim part of a wheel for vehicles concerning a 3rd embodiment. It is a figure which shows the raw material for fiber reinforced resin used for manufacture of the rim part of FIG. FIG. 9 is a view for explaining a process of manufacturing a rim portion of a vehicle wheel by turning back the cylindrical fiber-reinforced resin material shown in FIG. 8. FIG. 9 is a view for explaining a process of manufacturing a rim portion of a vehicle wheel by turning back the cylindrical fiber-reinforced resin material shown in FIG. 8. It is an enlarged view of the return part in FIG. It is a figure which shows the metal mold | die used when manufacturing a vehicle wheel. FIG. 2 is a side view of an apparatus for laying a continuous fiber bundle on the outer peripheral surface of a mold of a vehicle wheel. FIG. 1 is a front view of an apparatus for laying a continuous fiber bundle on an outer peripheral surface of a mold of a vehicle wheel. It is a figure explaining the lamination structure data used by a control part. It is a figure explaining shape data used by a control part. It is a figure which shows the operation | movement content of the laying apparatus for every advancing direction of drive shaft, and an orientation pattern. It is a figure explaining the operation example of the apparatus which covers a fiber bundle on the outer peripheral surface of the metal mold | die of a vehicle wheel. It is a figure explaining an analysis model at the time of performing simulation of a 13 ° impact test. It is a figure which shows the analysis result about the wheel for vehicles which concerns on an Example and a comparative example.

Hereinafter, based on the embodiment, a vehicle wheel according to the present invention will be described in detail. In each embodiment below, the same numerals may be used for the component which has the same function, and explanation for the second time may be omitted.

First Embodiment
First, a first embodiment of the present invention will be described based on FIG. 3 and FIGS. 5A to 5D. FIG. 3 is a cross-sectional view of the rim portion 300 of the vehicle wheel according to the present embodiment. The rim portion 300 is manufactured using a fiber reinforced resin material for the purpose of weight reduction.

Here, in the fiber reinforced resin material, it is important that the fiber direction matches the load direction. FIG. 4 shows an example of a load acting on an aluminum vehicle wheel. The load distribution shown in FIG. 4 is measured with a strain gauge or the like, for example, by measuring the load applied to the rim based on a rotating bending fatigue test, a radial load endurance test, and an impact test defined by a vehicle light alloy wheel test conference. The load can be synthesized and created. The load distribution shown in FIG. 4 can also be created by simulation using commercially available structural analysis software such as structural analysis software Abaqus manufactured by Dassault Systès. The magnitude of the load generated on the vehicle wheel differs depending on the place, and the acting direction is also different.

Thus, as shown in FIG. 3, the rim portion 300 made of the fiber reinforced resin material in the vehicle wheel according to the present embodiment has fiber layers a to g as shown in FIG. Has a laminated structure, and at least one of the plurality of fiber layers a to g (for example, fiber layers a and b, g: fiber layers having an orientation pattern in the fiber direction of + 45 ° and −45 °) are It is configured with an orientation pattern different from at least one other fiber layer (for example, a fiber layer c, a fiber layer having an orientation pattern of fiber orientation of f: 0 ° and 90 °). And, in the vehicle wheel according to the present embodiment, in order to appropriately cover and manufacture each of the plurality of fiber reinforced resin materials including the fiber layers a to g, at the boundary where the load acting on the rim portion changes The area in which the material for fiber reinforced resin is laid is divided, and by setting the fiber orientation direction and the number of layers (thickness) for each divided area, good strength is obtained for each part of the divided area. Is realized.

In the rim portion 300 in FIG. 3, the region is divided into seven parts at the boundary where the load changes, based on the load acting on the aluminum vehicle wheel in FIG. Here, in consideration of easiness of fabrication, it is devised so that the shape that can be divided into a simple cylindrical shape. That is, in FIG. 3, the rim portion 300 is used with a plane perpendicular to the central axis I, with the boundary at which the load changes as a standard, the

regions

301A, 301B, 301C, 301C, 301D, 301E, 301F , And divided into seven areas of area 301G.

Next, the laminated structure of the fiber reinforced resin material including the fiber layers different in the number of laminations and the fiber direction for each region was calculated from the maximum load for each region and the strength of the fiber reinforced resin material according to the failure judgment criterion formula. For this calculation, a commercially available strength calculation software HyperSizer manufactured by Coreia Research Inc. was used. It was assumed that T800S / # 3900-2B having a thickness of 0.2 mm, which is a commercially available prepreg manufactured by Toray Industries, Inc., is used as the fiber reinforced resin material.

In FIG. 3, the laminated structure L indicates the number of laminated fiber layers and the fiber orientation in the lower cross-sectional portion 302 of the rim portion 300. The laminated structure L is composed of seven layers of fiber reinforced resin materials from the fiber layer a to the fiber layer g. That is, when the direction of the central axis I is 0 °, the fiber layer a which is the innermost layer has an orientation pattern of + 45 ° fiber direction and −45 ° fiber direction, and a fiber reinforced resin having the fiber layer a The material is cylindrically laid on the area 301C.

The fiber layer b laminated on the outside of the fiber layer a has an orientation pattern of + 45 ° fiber direction and −45 ° fiber direction with respect to the direction of the central axis I, and a fiber reinforced resin material having the fiber layer b Are laid over the area 301B and the area 301C.

The fiber layer c laminated on the outer side of the fiber layer b has an orientation pattern of the fiber direction of 0 ° and the fiber direction of 90 °, and the fiber reinforced resin material having the fiber layer c is a region 301 B, a region 301 C, a region It is covered for 301D.

The fiber layer d laminated on the outside of the fiber layer c has a fiber direction of + 45 ° and -45 ° with respect to the

regions

301A and 301B, and a fiber direction of 0 ° and 90 ° with respect to the region 301C, with respect to the region 301D. Is composed of three partial fiber layers d1, d2 and d3 each having an orientation pattern of fiber directions of + 45 ° and -45 ° again, and the fiber reinforced resin material having the fiber layer d corresponds to the regions 301A-D. It has been laid down.

The fiber layer e laminated on the outside of the fiber layer d has an orientation pattern of + 45 ° and −45 ° in the fiber direction from the region 301A to the region 301D and an orientation pattern of 0 ° and 90 ° in the fiber direction from the region 301E to the region 301G The fiber reinforced resin material having the fiber layer e is covered in the regions 301A to G.

The fiber layer f laminated on the outside of the fiber layer e has an orientation pattern in the fiber direction of 0 ° and 90 °, and the fiber reinforced resin material having the fiber layer f covers the entire area of the area 301A to the area 301G. It is packed. Similarly, the fiber layer g laminated on the outer side of the fiber layer f has an orientation pattern of + 45 ° and -45 ° in the fiber direction from the region 301A to the entire region 301G, and a fiber reinforced resin material having the fiber layer g Are spread over the entire area of the area 301A to the area 301G. And among the fiber layers a to g, the fiber layers a to d are disposed only in a partial region in the direction along the central axis I of the vehicle wheel, and the fiber layers are laminated in the partial region The number is greater than the number of fiber layers in the other regions. For example, the number of stacked layers (five layers) in the region 301D is larger than the number of stacked layers (three layers) in the region 301E.

As described above, since each of the regions 301A to 301G set in the rim portion 300 is configured by the number of laminated fiber layers corresponding to the load and the orientation pattern in the fiber direction, a vehicle wheel having appropriate strength is obtained be able to. In particular, by including two or more partial fiber layers (partial fiber layers d1, d2 and d3 and partial fiber layers e1 and e2 respectively) having different orientation patterns in the fiber direction, as in the fiber layers d and e. And a vehicle wheel having more appropriate strength can be obtained. As in the fiber layers d and e, in the case where a certain fiber layer includes two or more partial fiber layers having mutually different orientation patterns in the fiber direction, the specific fiber layer “Consisting of a fiber layer and an orientation pattern different from each other” means that each of two or more partial fiber layers contained in a specific fiber layer is different from at least one other fiber layer (other at least one fiber layer is When two or more partial fiber layers whose orientation patterns in the fiber direction are different from each other are included, it means that they are configured in an orientation pattern different from any one of the partial fiber layers). For example, a partial fiber layer e1 having an orientation pattern of fiber directions of + 45 ° and -45 ° in the fiber layer e is a fiber having an orientation pattern of 0 ° and 90 ° fiber directions, which is at least one other fiber layer. It is comprised by the orientation pattern different from the layer f. In addition, the partial fiber layer e2 having an orientation pattern of 0 ° and 90 ° in the fiber direction is different from the fiber layer g having an orientation pattern of fiber directions of + 45 ° and −45 °, which is at least one other fiber layer. It is composed of different alignment patterns.

FIG. 5A is a conceptual diagram for illustrating a method of manufacturing a rim portion 300 of a vehicle wheel having the laminated structure L of FIG. 3 using a fiber-reinforced resin material. In order to manufacture the rim portion 300, as shown in FIG. 5A, first, based on the laminated structure L, a cylindrical fiber reinforced resin material (prepreg) made of a woven fabric of fiber bundles (fibers) impregnated with resin. Prepare 303a to 303g for each fiber layer. That is, the cylindrical fiber reinforced resin material 303 a in FIG. 5A is a material for forming a fiber reinforced resin material including the fiber layer a of the laminated structure L shown in FIG. 3, and in the fiber direction of + 45 ° and −45 °. It has an orientation pattern and is shaped to cover the region 301C. Thereafter, cylindrical fiber reinforced resin materials 303b to 303g having alignment patterns in the fiber direction including the fiber layers b to g are similarly prepared. At this time, since the fiber layer a to the fiber layer g are sequentially laminated on the outer side, the diameter of the cylindrical fiber reinforced resin material is formed so as to gradually increase in consideration of the thickness which has been laminated on the inner side. There is. Thus, the rim portion having the laminated structure L of FIG. 3 is formed by overlapping the cylindrical fiber reinforced resin materials 303 a to 303 g in order from the inside to the outside in the order of the fiber layers a to g. An original mold (laminate of fiber-reinforced resin materials 303 a to 303 g before curing the resin) is obtained. FIG. 5B is a view showing an outline of a rim 304 having a laminated structure L. As shown in FIG. 5C is a cross-sectional view taken along the line Y-Y 'of FIG. 5B, and cylindrical fiber reinforced resin materials 303a to 303g are sequentially laminated to constitute the laminated structure L of FIG. Thereafter, the original mold 304 of the rim portion of FIG. 5B is placed in a mold shown in FIG. 11 described later, the sheet is covered, and the interior is vacuumed to carry out a curing process. The rim portion 300 of the wheel can be obtained. In the cross-sectional view of the prototype 304 in FIG. 5C, a gap is provided between adjacent fiber-reinforced resin materials in order to make it easy to understand the laminated state of the fiber-reinforced resin materials, but in the actual prototype 304, There is almost no gap between adjacent fiber reinforced resin materials, and each fiber reinforced resin material is in close contact. 5C is a cross-sectional view of the rim 304, but the rim 300 formed by curing the arch 304 has the same configuration.

FIG. 5D is a conceptual diagram for describing an embodiment of a fiber-reinforced resin material used to construct a laminated structure L. The fiber-reinforced resin material is a fiber-reinforced resin material, and in the fibers, fiber bundles composed of a large number of single fibers are usually arranged with directionality and configured in various orientation patterns. As shown in FIG. 5D, the fiber-reinforced resin material of (a) or (b) having a woven fabric configuration in which a horizontally oriented fiber bundle and a longitudinally oriented fiber bundle are knitted is called a plain weave material, and a reference direction Assuming that the direction of the central axis I of the rim portion is 0 °, the plain weave material of (a) corresponds to a material for fiber reinforced resin knitted with fiber bundles of 0 ° and 90 °, and the plain weave material of (b) Is equivalent to a fiber reinforced resin material knitted with + 45 ° and -45 ° fiber bundles. On the other hand, a tape material (one-way material) 305A consisting of a plurality of fiber bundles in the 90 ° direction and a tape material 305B (one-way material) consisting of a plurality of fiber bundles in the 0 ° direction Since the composite material (c) has the same directional characteristics of fibers as the plain weave material (a), the plain weave material (a) may be substituted by the composite material (c). Similarly, a tape material (one direction material) 305C made of a plurality of fiber bundles in the 45 ° direction and a tape material (one direction material) 305D made of a plurality of fiber bundles in the −45 ° direction are overlapped with respect to the reference direction of 0 °. The synthetic material of (d) configured as described above has the same fiber directional characteristics as the plain weave material of (b), so the plain weave material of (b) may be substituted with the synthetic material of (d).

The plain weave materials of (a) and (b) are easy to handle as a sheet material without fear of unraveling of the fibers because the fibers are knitted. On the other hand, the composites of (c) and (d) in which unidirectional materials are combined are not restrained between fibers because the fibers are not knitted, but are easily released. However, a rim using an apparatus described later in FIGS. 12A and 12B. In the production of the part, fibers are laid on a mold to sequentially build a laminated structure, so the fiber configuration of the synthetic material of (c) and (d) is easier to construct a laminated structure. The fibers to be used are not particularly limited, and various fibers such as synthetic fibers and glass fibers can be used. However, in order to obtain a vehicle wheel having high mechanical strength and light weight, carbon fibers are used. Although it is desirable to use various carbon fibers such as PAN-based and pitch-based carbon fibers as carbon fibers, it is preferable to use long fibers, preferably continuous fibers. A vehicle wheel to which continuous fibers are applied will be described in detail in a third embodiment described below.

As described above, the rim portion 300 of the present embodiment has a structure in which each of the fiber reinforced resin materials 303 a to 303 g having the fiber layers a to g is laminated as shown in FIG. At least one of a to g is configured with an orientation pattern different from that of at least one other fiber layer, as shown in FIG. Then, in the present embodiment, the load applied to the rim portion 300 is checked by structural analysis or the like, and the rim portion 300 is divided into a plurality of regions at the boundary where the load changes, and each divided region, that is, for each portion of the rim portion 300 The layered structure L is designed by setting the number of laminated fiber layers and the fiber orientation in accordance with the respective loads. According to this laminated structure L, by laminating a plurality of substantially cylindrical fiber layers of different orientation patterns in the direction intersecting with the central axis of the vehicle wheel, it corresponds to the load acting from multiple directions, and for each part It is possible to produce a vehicle wheel with good strength set appropriately.

Second Embodiment
Subsequently, a second embodiment of the present invention will be described based on FIG. FIG. 6 is a cross-sectional view of the rim portion 400 of the vehicle wheel according to the present embodiment, which corresponds to FIG. 3 of the first embodiment. The rim portion 400 in the present embodiment has a structure in which the fiber layers a to g are laminated as in the first embodiment described above, and at least one of the plurality of fiber layers a to g (for example, the fiber layer a , B, g: fiber layers having an orientation pattern of fiber directions of + 45 ° and -45 °, and at least one other fiber layer (eg, fiber layer c, f: orientation of fiber directions of f: 0 ° and 90 °) The fiber layer having a pattern is composed of different orientation patterns. Then, at the boundary where the load acting on the rim changes, the area in which the fiber reinforced resin material is placed is divided into seven areas, and the direction of the fibers is set for each of the divided areas, so that the area is appropriately set. It has achieved good strength.

Specifically, the laminated structure L in the present embodiment is formed of seven layers of fiber reinforced resin materials from the fiber layer a to the fiber layer g, and the fiber layer a which is the innermost layer has a direction of the central axis I of 0 °. When it is assumed that the fiber reinforced resin material having the fiber direction of + 45 ° and the fiber direction of -45 ° and having the fiber layer a is spread from the area 301A to the entire area of the area 301G. Similarly, the fiber layer b laminated on the outer side of the fiber layer a also has an orientation pattern of + 45 ° fiber direction and −45 ° fiber direction with respect to the direction of the central axis I, and a fiber having the fiber layer b The reinforced resin material is covered from the area 301A to the entire area of the area 301G.

The fiber layer c laminated on the outer side of the fiber layer b has an orientation pattern of the fiber direction of 0 ° and the fiber direction of 90 °, and the fiber reinforced resin material having the fiber layer c has all the regions 301A to 301G The area is covered.

The fiber layer d laminated on the outer side of the fiber layer c is a partial fiber layer d1 having a fiber direction of + 45 ° and -45 ° with respect to the

regions

301A and 301B, and a fiber direction of 0 ° and 90 ° with respect to the region 301C. Partial fiber layer d2 having a fiber direction of + 45 ° and -45 ° again for the region 301D, and a portion having a fiber direction of 0 ° and 90 ° again for the region 301E-G The fiber reinforced resin material having the fiber layer d4 and four partial fiber layers d1 to d4 each having a different orientation pattern, and having the fiber layer d, is covered from the area 301A to the entire area of the area 301G. . The fiber layers e to g sequentially laminated on the outer side of the fiber layer d have the same configuration as the fiber layers e to g in the first embodiment.

In this embodiment, as in the first embodiment, the fiber layer (fiber layers a to d in the first embodiment) disposed only in a partial region in the direction along the central axis I of the vehicle wheel is not provided. , All of the fiber layers ag are disposed throughout the regions 301A-G. Thus, in the second embodiment, a laminated structure is constructed in which the orientation of the fibers is adjusted in accordance with the load applied to the vehicle wheel, and all layers of the fiber layer are at the central axis I of the vehicle wheel. Although the overall weight is increased by the area of the fiber layers a to d as compared with the vehicle wheel of the first embodiment, since it is disposed over the entire region in the direction along the vehicle wheel, it is for the vehicle of the first embodiment It is possible to obtain a vehicle wheel having excellent strength as well as the wheel. Also, in a region divided in the direction along the central axis I of the rim 400, as in the fiber layer d composed of the partial fiber layers d1 to d4 and the fiber layer e composed of the partial fiber layers e1 and e2. Correspondingly, by providing a plurality of partial fiber layers having different orientation patterns in the fiber direction in one fiber layer, it is possible to cope with different loads for each area generated by loads acting from multiple directions, and for each part The rim portion 400 having a sufficient strength set appropriately can be realized.

Third Embodiment
Subsequently, a third embodiment of the present invention will be described based on FIGS. 7 to 10. FIG. 7 is a cross-sectional view of the rim portion of the vehicle wheel according to the present embodiment. As shown in FIG. 7, the rim portion 600 in the vehicle wheel according to the present embodiment is a fiber reinforced resin material formed by laminating fiber reinforced resin materials 603 a to 603 g each having a plurality of fiber layers a to g. As in the first and second embodiments, at least one of the plurality of fiber layers a to g is configured in an orientation pattern different from at least one other fiber layer. This laminated structure corresponds to the laminated structure L of FIG. In the cross-sectional view of the rim portion 600 in FIG. 7, a gap is provided between adjacent fiber reinforced resin materials in order to facilitate understanding of the laminated state of the fiber reinforced resin material. There is almost no gap between adjacent fiber reinforced resin materials, and each fiber reinforced resin material is in close contact.

The rim portion 600 of FIG. 7 includes two adjacent fiber layers (for example, the fiber layer a contained in the fiber-reinforced resin material 603a and the fiber layer b contained in the fiber-reinforced resin material 603b). The laminated fiber layers a to g are formed by continuous fiber bundles (continuous fibers). Thus, the rim portion having the laminated structure L of FIG. 3 can be constructed by continuously twisting the fiber reinforced resin material (fiber layer).

Next, a method for manufacturing the rim portion shown in FIG. 7 will be described. The fiber reinforced resin material used for the vehicle wheel is a resin material reinforced with fibers, and there are two methods depending on the time of resin impregnation (injection) to the fibers. Specifically, a method of laminating a fiber reinforced resin material (prepreg) impregnated with uncured resin in advance on a fiber layer formed using fiber bundles, and a plurality of fiber layers formed using only fiber bundles There is a method in which uncured resin is injected (impregnated) into a fiber layer which is laminated and later laminated using a mold or the like. In either case, a rim portion made of a fiber reinforced resin material can be obtained by curing treatment of the resin. First, the case where the rim portion is manufactured using the former prepreg will be described.

FIG. 8 is a view showing a material for fiber reinforced resin (prepreg) impregnated with uncured resin, which is used for manufacturing a rim portion of a vehicle wheel according to the present embodiment. In FIG. 8, the fiber-reinforced resin material 603 used for manufacturing the rim portion is cylindrical and has a plurality of orientation patterns. The cylindrical fiber reinforced resin material 603 can be produced by producing an orientation pattern using continuous fibers by a blading method. By twisting and folding this cylindrical fiber-reinforced resin material 603, a laminated structure L shown in FIG. 3 can be realized.

In FIG. 8, a cylindrical fiber reinforced resin material 603 is composed of fiber reinforced resin materials 603 a to 603 g having a predetermined orientation pattern and folded parts 610 a to 610 f. The orientation patterns of the fiber reinforced resin materials 603a to 603g are determined for each of the fiber layers a to g based on the laminated structure L of FIG. That is, the fiber layer a having the fiber orientation orientation pattern of + 45 ° and -45 ° in FIG. 3 is included in the fiber-reinforced resin material 603a of FIG. Sequentially, the fiber layer b forms three fiber layers d1 to d3 which are different from each other in the fiber orientation direction pattern in the fiber direction. The fiber layer e is made of two

parts

611d and 611e which form partial fiber layers e1 and e2 having different orientation patterns in the fiber direction to the fiber reinforced resin material 603d consisting of the

parts

611a, 611b and 611c In the material 603e, the fiber layer f is contained in the material for fiber reinforced resin 603f, and the fiber layer g is contained in the material for fiber reinforced resin 603g. Between the adjacent materials for the fiber reinforced resin, folded portions are interposed so as to be easily folded back, respectively: folded portions 610a, folded portions 610b, folded portions 610c, folded portions 610d, folded portions 610e, The folded back portion 610f connects between the fiber reinforced resin materials 603a to 603g. In this embodiment, using the cylindrical fiber reinforced resin material 603 shown in FIG. 8, the material is reinforced by folding back (bellows weave) sequentially by folding back at the folded portions 610a to 610f. By laminating 603a to 603g, a prototype 604 of the rim portion of FIG. 7 having the laminated structure L of FIG. 3 is constructed.

FIGS. 9A and 9B are conceptual diagrams illustrating a process of manufacturing a rim portion of a vehicle wheel having the laminated structure L of FIG. 3 by turning back the cylindrical fiber reinforced resin material 603 shown in FIG.

In step 1 of FIG. 9A, the cylindrical fiber-reinforced resin material 603 is valley-folded at the folded portion 610a and mountain-folded at the folded portion 610b, so that the fiber-reinforced resin material 603a and the fiber-reinforced resin material 603b are fibers. The inside of the reinforced resin material 603c is serpentine (bellows fold), and a laminated structure of the fiber layer a, the fiber layer b, and the fiber layer c is obtained from the inside. In the same manner, in step 2, valley fold at the fold back portion 610c and mountain fold at the fold back portion 610d to obtain a laminated structure in which the inside is serpentine (bellows fold) is obtained, and further at step 3, the fold back portion 610e By performing valley folding and mountain folding at the folded back portion 610f, a mold 604 of the rim portion in which the respective fiber layers are folded in a serpentine manner (belly fold) can be obtained. FIG. 9B shows a process in which the material for fiber reinforced resin is folded at the position of the turn-back portion in step 1 of FIG. 9A. That is, the fiber-reinforced resin material 603a and the fiber-reinforced resin material 603b are sequentially folded inside the fiber-reinforced resin material 603 by being valley-folded by the fold-back portion 610a and mountain-folded by the fold-back portion 610b. A laminated structure of a, b and c is constructed. Thereafter, the original mold 604 is placed in a mold shown in FIG. 11 described later, the sheet is covered, and the inside is vacuumed to carry out a curing process, whereby the rim portion 600 of the target vehicle wheel can be obtained.

A sheet winding method in which a thin sheet of fiber reinforced resin material as in the prior art is laminated and formed around a mold in layers, or a continuous fiber reinforced resin material is applied to the outer peripheral surface of a rim forming mold In the vehicle wheel of this embodiment, a cylindrical fiber reinforced resin material having a plurality of orientation patterns is prepared as opposed to the method of laying in parallel in the axial direction and further winding the constraining material around the axis. By twisting and folding this, it is possible to efficiently manufacture a vehicle wheel in which strength is taken into consideration in order to obtain a desired laminated structure.

FIG. 10 is an enlarged view of the folded back portion 610a in FIG. 7 and is a view for explaining an outline of the folded back portion. As shown in FIG. 10, the folded back portion 610a preferably includes, at the folded back position, a constrained fiber bundle 612 wound in the circumferential direction of the rim portion. The same applies to the other folded portions 610b to 610f. The restraining fiber bundle 612 is wound in the circumferential direction of the rim portion 600 to restrain the fiber bundle 613. After being restrained by the restraining fiber bundle 612, the fiber bundle 613 reverses the traveling direction and advances the fiber bundle 613 in the reverse direction. At this time, it is preferable to invert the fiber bundle 613 itself while giving a moderate curvature so as not to be applied with a bending stress at the folding position. Since the folding position is fixed by the restraining fiber bundle 612, even if tension is applied to the fiber bundle 613 in the reverse direction by folding, the folding position does not shift, and a highly accurate laminated structure can be constructed.

FIG. 11 illustrates an outline of a mold used when manufacturing a vehicle wheel. A mold is used in the case of impregnating a fiber bundle with a resin, or in a curing process, and is indispensable for forming a rim portion. As shown in FIG. 11, a mold 1000 used in the manufacture of a vehicle wheel is composed of a mold left 1001 and a mold right 1002, and the mold left 1001 and the mold right 1002 are fitted at the connection position 1003. It is combined. Since the

cylindrical rim prototypes

304 and 604 having the laminated structure described in FIGS. 5B and 9A are curved outward toward both ends, first, they are installed on the mold left 1001, and then the mold right By fitting 1002, the

rim molds

304 and 604 can be installed in the mold.

In the case where the rim parts of the

master

304 and 604 are manufactured using a fiber bundle impregnated with resin, such as a prepreg, a sealing sheet is covered and the inside is vacuumed and then cured by an autoclave to obtain gold. The mold 1000 is divided into a mold left 1001 and a mold right 1002 and demolded to obtain

rim parts

300 and 600 of a desired lightweight vehicle wheel.

Next, referring to FIGS. 12A and 12B, a method of laminating a plurality of fiber layers formed using only fiber bundles, and injecting (impregnating) uncured resin to the laminated fiber layers is applied. A method of manufacturing a rim portion of a vehicle wheel according to a third embodiment will be described. 12A and 12B show a schematic configuration of an apparatus for laying a continuous fiber bundle on the outer peripheral surface of a mold of a vehicle wheel, FIG. 12A is a side view of the apparatus, and FIG. 12B is a front view. FIG. As shown to FIG. 12A, this apparatus is roughly comprised from the control part 1101, the drive part 1102, and the fiber laying part 1103. The control unit 1101 is connected to the drive unit 1102 and the fiber laying unit 1103 by a connection line 1104 indicating an interface, and controls the drive unit 1102 and the fiber laying unit 1103 based on layered structure data and shape data described later, Spread the fiber bundle. The drive unit 1102 includes a drive shaft 1105, and a mold 1000 is connected to the drive shaft 1105. The drive unit 1102 adjusts the position of the mold 1000 by moving the drive shaft 1105 back and forth along the center line J of the shaft according to a command from the control unit 1101, and determines the position at which the fiber bundle is to be spread. The fiber laying unit 1103 has four types of laying

devices

1106a, 1106b, 1106c, and 1106d. A plurality of nozzles 1107 are disposed in each device, and a fiber bundle is supplied to the nozzles 1107 and laid in a mold. Do.

As shown in FIG. 12B, the fiber bundle is wound around the reel 1108, and the fiber bundle is supplied to the nozzles 1107 of the respective laying devices of the fiber laying portion 1103.

FIG. 13 is a conceptual diagram for explaining layered structure data used in the control unit 1101. The laminated structure data in FIG. 13 is created based on the laminated structure L in which the number of laminated layers of fibers and the orientation direction are set according to the load described in FIG. In FIG. 13, the layered structure data includes area identifiers A to G for identifying the areas 301A to 301G (see FIG. 3) divided at the boundary where the load changes, and fiber bundles corresponding to the fiber layers a to g. Expressed by a matrix consisting of the fiber layer identification symbols a to g of the fiber layers a to g indicating the stacking order at the time of packing, in the column corresponding to the area and the stacking order in the matrix, , And the end symbol, the turn back indication symbol. In the matrix of FIG. 13, the start symbol is S, the end symbol is E, the turn back indication symbols are A, and the fold is B. If these symbols are described on the left side, they mean the left side in FIG. 12A, and if they are described on the right side, they mean the right side in FIG. 12A. For example, since the start symbol S is described on the left side, it means to start from the left side of the area 301C, and the end symbol E is described on the right side, so it means to end on the right side of the area 301G.

FIG. 14 is a conceptual diagram for explaining shape data used by the control unit 1101. In FIG. 14, the shape data is composed of data indicating the shape of the laminated structure and data indicating the shape of the mold. The shape data of the laminated structure has information on the divided area and the thickness of the laminate, the shape data of the mold has information on the connection element position, and indicates the appropriate position to the drive unit 1102 and the fiber laying unit 1103. The shape data is three-dimensional shape data created by commercially available CAD software, for example, Solidworks manufactured by Dassault Systèmes.

Next, the laying devices 1106 a to 1106 d of the fiber laying unit 1103 will be described. Each of the laying devices 1106 a to 1106 d is driven by an instruction of the control unit 1101 and coats the fiber bundle on the mold 1000 in conjunction with the operation of the drive unit 1102. In the side view of FIG. 12A, when the drive shaft 1105 moves to the right and reverses, the folded portion can be on the left side, and when the drive shaft 1105 moves to the left and reverses, the folded portion can be on the right. Therefore, the laying devices 1106a to 1106d have different roles depending on the direction in which the drive shaft 1105 is moving.

FIG. 15 shows the operation contents of the laying devices 1106 a to 1106 d for each traveling direction and orientation pattern of the drive shaft 1105.

In FIG. 15, when the traveling direction of the drive shaft 1105 is the right direction in FIG. 12A and the orientation pattern is ± 45 °, the laying device 1106 b is interlocked with the drive unit 1102 and the center line J The laying device 1106 c rotates the fiber bundle in the + 45 ° direction counterclockwise with respect to the center line J and lays the fiber bundle in the −45 ° direction on the mold 1000. In addition, the laying device 1106 d lays the constrained fiber bundle in the circumferential direction of the mold 1000 at the turn-back portion. Similarly, in the case where the advancing direction of the drive shaft 1105 is the left direction and the orientation pattern is ± 45 °, the laying device 1106 b rotates clockwise with respect to the center line J in conjunction with the drive unit 1102 The laying device 1106 c rotates the fiber bundle in the + 45 ° direction counterclockwise with respect to the center line J and lays the fiber bundle in the −45 ° direction in the mold 1000. Also, the laying device 1106 a lays the restraining fiber bundle in the circumferential direction of the mold 1000 at the turning portion. When the advancing direction of the drive shaft 1105 is rightward and the orientation pattern is 0 ° / 90 °, the laying device 1106b lays fiber bundles in the circumferential direction of the mold 1000 in conjunction with the drive unit 1102 Thus, the preceding laying device 1106c lays the fiber bundle in the 90 ° direction in the mold 1000 by supplying the fiber bundle without rotating it. In addition, the laying device 1106 d lays the constrained fiber bundle in the circumferential direction of the mold 1000 at the turn-back portion. When the advancing direction of the drive shaft 1105 is the left direction and the orientation pattern is 0 ° / 90 °, the laying device 1106 c lays the fiber bundle in the circumferential direction of the mold in conjunction with the drive unit 1102 The preceding laying device 1106b lays the fiber bundle in the 90 ° direction in the mold in the 0 ° direction, which supplies the fiber bundle without rotating. Also, the laying device 1106 a lays the restraining fiber bundle in the circumferential direction of the mold 1000 at the turning portion.

FIG. 16 is a conceptual diagram for explaining an operation example of the apparatus for laying the fiber bundle on the outer peripheral surface of the mold of the vehicle wheel described with reference to FIGS. 12A and 12B.

In step 1, the apparatus first performs an operation for start on the left side of the area 301C shown in FIG. 3 in accordance with the S symbol of the information in the fiber layer identification symbol a and the area identifier C in FIG. This is because the drive shaft 1105 is sent to the right from the position of the corresponding mold 1000, and the fiber bundles L1 and L2 are covered by the

laying devices

1106b and 1106c, and the restrained fiber bundles are circumferentially placed thereon by the laying device 1106d. The fiber bundle is restrained to the mold 1000. Then, by performing turning back, the start processing is finished, and the preparation for constructing a laminated structure is completed.

In step 2, the apparatus carries out the processing of +/- 45 ° in the fiber layer identification symbol a and the area identifier C in FIG. 13 and sends the drive shaft 1105 to the left side, and the fiber direction is obtained by the

laying devices

1106b and 1106c. The fiber bundle of +/− 45 ° is supplied to form a fiber layer a, and the constraining fiber bundle is circumferentially placed by the laying device 1106 a according to the folding symbol A in the fiber layer identification symbol a and the region identifier C in FIG. The fiber bundle is tightened to form a folded back portion 614a. A resin material is injected into the formed fiber layer a and the folded portion 614a and cured to form the fiber reinforced resin material 603a and the folded portion 610a shown in FIG. The same applies to the department).

Likewise, in step 3, in the fiber layer identification symbol b of FIG. 13, the process is performed in the order of the area identifier C and the area identifier B to form the fiber layer b (fiber-reinforced resin material 603b after curing), A folded portion 614 b (folded portion 610 b after curing) is formed at the left end of the region 301 B.

In step 4, in the fiber layer identification symbol c of FIG. 13, the process is performed in the order of the area identifier B, the area identifier C, and the area identifier D to form a fiber layer c (fiber-reinforced resin material 603c after curing). A folded back portion 614 c (folded back portion 610 c after curing) is formed at the right end of 301 D.

In step 5, in the fiber layer identification symbol d of FIG. 13, the process is performed in the order of the area identifier D, the area identifier C, the area identifier B, and the area identifier A, and the fiber layer d (fiber reinforced resin material 603d after curing) The folded portion 614 d (the folded portion 610 d after curing) is formed at the left end of the region 301 A.

Here, since the orientation patterns are different between the

regions

301D and 301C, and the

regions

301C and 301B, the

laying devices

1106b and 1106d follow the operation of the respective orientation patterns in the case of advancing in the left direction described in FIG. Stack on the mold 1000.

In step 6, in the fiber layer identification code e of FIG. 13, processing is performed in the order of the area identifiers A to G to form the fiber layer e (the fiber reinforced resin material 603e after curing), and the folded portion at the right end of the area 301G. 614 e (turned portion 610 e after curing) is formed. Also here, since the orientation patterns are different between the region 301D and the region 301E, the

laying devices

1106b and 1106c follow the operation of each orientation pattern when advancing in the right direction described in FIG. Let's stack.

In step 7, in the fiber layer identification symbol f of FIG. 13, the process is performed in the order of the area identifiers G to A to form the fiber layer f (the fiber reinforced resin material 603f after curing) and turn back at the left end of the area 301A. 614 f (folded portion 610 f after curing) is formed.

In step 8, in the fiber layer identification code g of FIG. 13, the process is performed in the order of the area identifiers A to G to form the fiber layer g (the fiber reinforced resin material 603 g after curing), and the end process is performed on the right of the area 301G. Is completed, and fabrication of the rim part prototype using fiber bundles not impregnated with resin is completed.

In this way, the outer side of the prototype having the fiber layers a to g formed by the continuous fiber bundle and the folded portions 614a to 614f is covered with a sealing sheet or the prototype is placed in a mold for resin injection, By injecting the resin and thereafter performing vacuum heating to cure the resin, a vehicle wheel having the

rim portions

300 and 600 made of the fiber reinforced resin material having the intended laminated structure shown in FIGS. 3 and 7 can be obtained. .

As mentioned above, although the embodiment of the present invention has been described in detail, the specific configuration is not limited to this embodiment, and even if there is a design change or the like without departing from the scope of the present invention, they are It is included in the present invention.

Next, as to the vehicle wheel according to the example of the present invention and the comparative example, a simulation of a 13 ° impact test specified in JIS D 4103 as shown in FIG. 17 was performed. The analysis method and the results will be described below.

In the analysis model, a wheel 1701 shown in FIG. 17 is fixed to a rigid mount M so that the central axis I of the wheel 1701 forms an angle α of 13 ° with the vertical direction V, and an impact force is applied The rigid surface P was brought into contact with the rim flange upper end 1703 of the wheel 1701, and a model was applied in which a static load K corresponding to a case where a weight of 500 kg was dropped from a height of 200 mm was applied to the rigid surface P.

And (a) laying a continuous fiber reinforced resin material as disclosed in the above-mentioned Patent Document 1 (Japanese Patent Laid-Open No. 2016-150614) in parallel in the axial direction with respect to the outer peripheral surface of the rim forming mold, (B) The vehicle wheel of the second embodiment having the laminated structure of the fiber layers a to g shown in FIG. 6 and (c) FIG. 3 With respect to the vehicle wheel of the first embodiment having the laminated structure of the fiber layers a to g, the above analysis model was structurally analyzed with Abaqus, and the strength distribution in each of the vehicle wheels was confirmed. The results are shown in FIG. The conventional vehicle wheel used for analysis and the vehicle wheel of the first and second embodiments all have the same shape. Further, in the vehicle wheel according to the first and second embodiments, for a vehicle formed by T800S / # 3900-2B having a thickness of 0.2 mm including 67% of carbon fiber volume ratio (Vf), which is a prepreg manufactured by Toray Industries, Inc. The analysis was performed on the assumption of the wheel. In the conventional vehicle wheel, the carbon fiber T800S manufactured by Toray Industries, Inc. is formed by laminating seven layers according to the method described in Patent Document 1, and the first embodiment and the second embodiment as a matrix resin The analysis was carried out on the assumption that the vehicle wheel was molded so that the Vf was 67%, using the same epoxy resin as the form prepreg.

FIG. 18 divides the analysis region into finite elements, and when the material strength in the element i is Ti and the stress generated by the static load is σi, the failure judgment value Di of the element i is obtained by the following equation. FIG. 6 is a contour chart in which the magnitude of the destruction determination value Di calculated in each part is color-coded into four colors. The risk of destruction increased as Di was closer to 1, and it was determined that the element was destroyed at an element where Di ≧ 1.
Di = σi / Ti

As apparent from the analysis result of FIG. 18, in the conventional vehicle wheel ((a) of FIG. 18), there is a portion where the strength is insufficient in the rim portion, and the destruction determination value exceeds 1.0. An area appeared. On the other hand, in the vehicle wheel according to the present invention ((b) and (c) in FIG. 18), the fiber layer constituting the rim portion is arranged to have an appropriate strength for each portion. Did not appear, suggesting that it has good strength over the entire rim. Comparing (b) and (c) in FIG. 18, in the wheel for a vehicle in (c), the fiber layers a to g are set for each of the regions 301A to 301G (see FIG. 3) in consideration of the load acting on the rim portion. By optimizing the arrangement, the relative mass was reduced to 0.89 while the destruction judgment value of each part was almost the same as that of the vehicle wheel of (b), and further weight reduction could be achieved.

DESCRIPTION OF SYMBOLS 100 Wheel 100 rim part 102 spoke part 103 connection part 200 fiber reinforced

resin material

300, 400, 600 rim part 301A-301G area 302 cross section part 303a-303g material for fiber reinforced

resin

304, 604 original part 305A-305D of a rim part Material 603 Material for fiber reinforced resin 603a to 603g Material for fiber reinforced resin 610a to 610f Folded portion 611a to 611e Partial fiber layer forming portion 612 Restrained fiber bundle 613 Fiber bundle 614a to 614f Folded portion 1000 Mold 1001 Mold left 1002 Mold right 1003 connection position 1101 control unit 1102 drive unit 1103 fiber laying unit 1104 connection line 1105 drive shaft 1106a to 1106d laying device 1107 nozzle 1108 reel 1701 wheel 1703 rim flange upper end a ~ Fiber layer d1 to d4, e1 to e2 Partial fiber layer H Fiber direction I Central axis J Center line K of laying device Static load L Laminated structure L1 Fiber bundle L2 Fiber bundle M Mounting base P Rigid surface V Vertical direction α angle This specification All publications, patents and patent applications cited in U.S.C. are hereby incorporated by reference in their entirety.

Claims

A vehicle wheel having a rim portion made of fiber reinforced resin, comprising:
The rim portion has a structure in which a plurality of substantially cylindrical fiber layers are laminated, and at least one of the fiber layers is configured in an orientation pattern different from at least one other fiber layer. .
The vehicle wheel according to claim 1, further comprising a folded portion connecting two adjacent fiber layers of the laminated fiber layers on the same end side.
The vehicle wheel according to claim 2, wherein the folded back portion includes a fiber bundle wound in a circumferential direction of the rim portion.
The at least one said fiber layer comprised by a different orientation pattern is arrange | positioned only in the one part area | region in the direction in alignment with the central axis of the said wheel for vehicles. Vehicle wheel.
The wheel for a vehicle according to claim 4, wherein the number of laminated fiber layers in the partial region is larger than the number of laminated fiber layers in the other region.
The vehicle wheel according to any one of claims 1 to 5, wherein the laminated fiber layer is composed of a continuous fiber bundle.
The vehicle wheel according to any one of claims 1 to 6, wherein the at least one fiber layer configured in different orientation patterns includes two or more partial fiber layers having different orientation patterns in the fiber direction.