WO2023149083A1 - Structure de véhicule comprenant un panneau de résine et élément de fixation métallique ayant une partie d'insertion de boulon - Google Patents

Structure de véhicule comprenant un panneau de résine et élément de fixation métallique ayant une partie d'insertion de boulon Download PDF

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Publication number
WO2023149083A1
WO2023149083A1 PCT/JP2022/045569 JP2022045569W WO2023149083A1 WO 2023149083 A1 WO2023149083 A1 WO 2023149083A1 JP 2022045569 W JP2022045569 W JP 2022045569W WO 2023149083 A1 WO2023149083 A1 WO 2023149083A1
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Prior art keywords
resin member
reinforced resin
fiber
fiber reinforced
vehicle structure
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PCT/JP2022/045569
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English (en)
Japanese (ja)
Inventor
恵造 横山
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帝人株式会社
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Publication of WO2023149083A1 publication Critical patent/WO2023149083A1/fr

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/18—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length in the form of a mat, e.g. sheet moulding compound [SMC]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60J—WINDOWS, WINDSCREENS, NON-FIXED ROOFS, DOORS, OR SIMILAR DEVICES FOR VEHICLES; REMOVABLE EXTERNAL PROTECTIVE COVERINGS SPECIALLY ADAPTED FOR VEHICLES
    • B60J5/00—Doors
    • B60J5/10—Doors arranged at the vehicle rear

Definitions

  • the present invention relates to a vehicle structure including a metal fastener having a bolt insertion portion and a resin panel, and a manufacturing method thereof.
  • Patent Literature 1 describes a vehicle resin back door structure in which the rear glass can be replaced while the load from the damper is removed when the rear glass is replaced.
  • Patent Document 2 describes a resin molded product in which a metal plate is used as an insert member and the metal plate is embedded and integrated, and a method of insert molding the molded product.
  • US Pat. No. 5,300,009 describes a hybrid tailgate or rear door for vehicles, particularly automobiles, such as passenger cars, comprising a thermoplastic internal structure and composite stiffeners.
  • Patent Document 4 a heat-shrinkable container (nut), a fiber-reinforced plastic surrounding the container, and a fiber-reinforced plastic disposed between the container and the fiber-reinforced plastic due to the heat shrinkage of the container.
  • a fiber-reinforced plastic molding is described that has a relief layer that relieves the tensile stress acting on the fiber.
  • the relaxation layer is formed by evenly applying acrylic-modified silicone resin to the nut and curing the resin.
  • Patent Literature 5 describes an SMC (sheet molding compound) molded product having a uniform thickness and having a plate-like reinforcing member integrally formed on one side thereof.
  • This molded product has a uniform thickness space corresponding to the thickness of this mold and the plate-shaped molded product by disposing the plate-shaped reinforcing member in a recess corresponding to the thickness of the plate-shaped reinforcing member formed in one of the molds.
  • the sheet-shaped molding material is molded under heat and pressure using another mold designed to form a plate-shaped molded article and a plate-shaped reinforcing member.
  • An object of the present invention is to provide a vehicle structure that can reduce manufacturing man-hours by embedding a metal fastener having a bolt insertion part in a resin panel by insert molding when attaching a resin panel and other parts such as a damper stay. It is to provide the body.
  • the present invention provides the following means.
  • a vehicle structure comprising a metal fastener having a bolt insertion portion and a resin panel, The metal fastener is embedded in the resin panel by insert molding, The vehicle structure, wherein the resin panel is provided with a hole at a position corresponding to the bolt insertion portion.
  • the resin panel is a fiber-reinforced resin member A containing reinforcing fibers a having a weight-average fiber length of less than 3 mm; a fiber-reinforced resin member B containing reinforcing fibers b having a weight average fiber length of 3 mm or more;
  • ⁇ 3> The vehicle structure according to ⁇ 2>, wherein the fiber-reinforced resin member A has the hole.
  • ⁇ 4> The vehicle structure according to ⁇ 2> or ⁇ 3>, wherein the metal fastener is covered with the fiber-reinforced resin member A.
  • ⁇ 5> The vehicle structure according to any one of ⁇ 2> to ⁇ 4>, wherein the fiber reinforced resin member B is in contact with the fiber reinforced resin member A.
  • ⁇ 6> The vehicle structure according to ⁇ 4> or ⁇ 5>, wherein the fiber-reinforced resin member B is not in contact with the metal fastener.
  • the resin contained in the fiber-reinforced resin member A is a thermoplastic resin or a thermosetting resin
  • the fiber reinforced resin member A is a glass fiber reinforced resin member A GF containing glass fibers having a weight average fiber length of less than 3 mm
  • the fiber reinforced resin member B is a carbon fiber reinforced resin member B CF containing carbon fibers having a weight average fiber length of 3 mm or more, or a glass fiber reinforced resin member B GF containing glass fibers having a weight average fiber length of 3 mm or more.
  • the reinforced fiber resin member B includes a carbon fiber reinforced resin member B CF containing carbon fibers having a weight average fiber length of 3 mm or more, and a glass fiber reinforced resin member B GF containing glass fibers having a weight average fiber length of 3 mm or more, The metal fastener is covered with a glass fiber reinforced resin member AGF containing glass fibers having a weight average fiber length of less than 3 mm, The vehicle structure according to ⁇ 7>, wherein the glass fiber reinforced resin member AGF is in contact with the carbon fiber reinforced resin member BCF .
  • the resin panel has a fiber reinforced resin member B,
  • the fiber reinforced resin member B is Reinforcing fiber b having a weight average fiber length of 3 mm or more, and a thermoplastic resin,
  • the reinforced resin member B includes a glass fiber reinforced resin member B GF ,
  • the glass fiber reinforced resin member B GF is Glass fiber with a weight average fiber length of 3 mm or more, and a thermoplastic resin,
  • the resin panel has a fiber reinforced resin member B,
  • the fiber reinforced resin member B includes a glass fiber reinforced resin member B GF containing glass fibers having a weight average fiber length of 3 mm or more,
  • the fiber reinforced resin member B includes a carbon fiber reinforced resin member B CF containing carbon fibers having a weight average fiber length of 3 mm or more, and a glass fiber reinforced resin member B GF containing glass fibers having a weight average fiber length of 3 mm or more,
  • the carbon fiber reinforced resin member BCF is formed by molding a sheet molding compound,
  • ⁇ 18> The vehicle structure according to any one of ⁇ 1> to ⁇ 17>, wherein the metal fastener is L-shaped or I-shaped.
  • the resin panel is a door panel constituting a vehicle back door, and the vehicle structure is a vehicle resin back door structure.
  • the vehicle back door includes a damper stay, The door panel and the damper stay are fastened and fixed by a bolt inserted into the bolt insertion portion, The vehicle structure according to ⁇ 19>.
  • ⁇ 21> The vehicle structure according to ⁇ 19> or ⁇ 20>, wherein the door panel includes a rear glass.
  • ⁇ 22> The vehicle structure according to any one of ⁇ 2> to ⁇ 21>, wherein the resin panel has a rib within 30 mm from the metal fastener.
  • ⁇ 25> The method of manufacturing a vehicle structure according to ⁇ 24>, wherein the hole is provided by secondary processing after integrally molding the fiber-reinforced resin member A, the fiber-reinforced resin member B, and the metal fastener.
  • ⁇ 26> The method for manufacturing a vehicle structure according to ⁇ 24>, wherein the holes are provided at the same time when the fiber-reinforced resin member A, the fiber-reinforced resin member B, and the metal fastener are integrally molded.
  • FIG. 2 is a schematic diagram showing a resin back door structure for a vehicle in which a reinforcing bracket is fastened to a resin back door panel
  • FIG. 2 is a schematic diagram showing a resin back door structure for a vehicle in which a reinforcing bracket is fastened to a resin back door panel
  • FIG. 5 is a schematic diagram showing the location of the AA cross section for explaining the damper stay mounting position in FIG. 4
  • FIG. 4 is a cross-sectional view taken along the line AA in FIG. 3
  • 1 is a cross-sectional view showing an embodiment of a vehicle structure
  • FIG. 2 is a schematic diagram of a vehicle structure in which a metal fastener is embedded in a resin panel by insert molding, before bolts are attached;
  • 1 is a cross-sectional view showing an embodiment of a vehicle structure;
  • FIG. FIG. 4 is a schematic diagram of a vehicle structure in which a metal fastener is embedded in a resin panel by insert molding, after bolts are attached.
  • 1 is a schematic diagram of a vehicle structure of the present invention comprising metal fasteners with bolt inserts and resin panels;
  • FIG. The metal fastener is embedded in the resin panel by insert molding, and the resin panel is provided with a hole h1 (601) at a position corresponding to the bolt insertion portion. Before the bolt is inserted.
  • FIG. 4 is a schematic diagram showing part of the side frame to which the damper stay is attached; 11 is a cross-sectional view taken along line XI-XI of FIG. 10; FIG. FIG. 4 is a cross-sectional view of a side frame using a metal fastener 20B having an L-shaped cross section; It is a schematic diagram which shows the manufacturing method of a vehicle structure. It is a schematic diagram which shows the manufacturing method of a vehicle structure.
  • the present invention provides a vehicle structure including a metal fastener having a bolt insertion portion and a resin panel, wherein the metal fastener is embedded in the resin panel by insert molding, and is inserted into the resin panel.
  • the resin panel has a fiber-reinforced resin member A and a fiber-reinforced resin member B.
  • the reinforcing fiber is preferably at least one selected from the group consisting of carbon fiber, aramid fiber and glass fiber. More preferably, the reinforcing fibers are carbon fibers or glass fibers. More specifically, when the fiber-reinforced resin member A is used, the reinforcing fibers contained therein are preferably carbon fibers or glass fibers. When the fiber-reinforced resin member B is used, the reinforcing fibers contained therein are preferably carbon fibers or glass fibers.
  • Carbon fibers in general Carbon fibers used in the present invention generally include polyacrylonitrile (PAN)-based carbon fibers, petroleum/coal pitch-based carbon fibers, rayon-based carbon fibers, cellulose-based carbon fibers, lignin-based carbon fibers, and phenol-based carbon fibers. Carbon fibers and the like are known, and any of these carbon fibers can be suitably used in the present invention. Among them, polyacrylonitrile (PAN)-based carbon fibers are preferably used in the present invention because of their excellent tensile strength. As the PAN-based carbon fiber, for example, carbon fiber “Tenax” (registered trademark) STS40-24KS (average fiber diameter 7 ⁇ m) manufactured by Teijin Limited can be used.
  • PAN polyacrylonitrile
  • STS40-24KS average fiber diameter 7 ⁇ m
  • the carbon fiber used in the present invention may have a sizing agent attached to its surface.
  • the type of the sizing agent is appropriately selected according to the type of carbon fiber and the type of thermoplastic resin used for the fiber-reinforced resin member B or the fiber-reinforced resin member A. It can be done, and is not particularly limited.
  • the fiber diameter of the carbon fiber single yarn (generally, the single yarn is sometimes called a filament) used in the present invention may be appropriately determined according to the type of carbon fiber, and is particularly limited. not to be
  • the average fiber diameter is generally preferably in the range of 3 ⁇ m to 50 ⁇ m, more preferably in the range of 4 ⁇ m to 12 ⁇ m, even more preferably in the range of 5 ⁇ m to 8 ⁇ m.
  • the carbon fiber is in the form of a fiber bundle, it refers to the diameter of the carbon fiber (single filament) forming the fiber bundle, not the diameter of the fiber bundle.
  • the average fiber diameter of carbon fibers can be measured, for example, by the method described in JIS R7607:2000.
  • Glass fiber A case where the reinforcing fibers used in the present invention are glass fibers will be described.
  • the glass fiber used in the present invention may be any glass fiber generally called glass fiber.
  • the glass composition of A glass, C glass, E glass and the like is not particularly limited, and may contain components such as TiO 2 , SO 3 and P 2 O 5 depending on the case.
  • As the glass fiber for example, glass fiber E-glass RS240QR-483 (count: 2400 g/1000 m) manufactured by Nitto Boseki Co., Ltd. can be used.
  • the glass fiber used in the present invention may have a sizing agent attached to its surface.
  • the type of the sizing agent can be appropriately selected according to the type of glass fiber and the type of resin contained in the resin panel, and is not particularly limited. not something.
  • Glass fibers pretreated with conventionally known coupling agents such as organic silane-based compounds, organic titanium-based compounds, organic borane-based compounds and epoxy-based compounds can preferably be used.
  • the average fiber diameter of the glass fiber is preferably 1 ⁇ m to 50 ⁇ m, more preferably 5 ⁇ m to 20 ⁇ m. If the average fiber diameter is too small, it becomes difficult to impregnate the fibers with the thermoplastic resin, and if it is too large, moldability and workability are adversely affected.
  • the weight-average fiber length of the reinforcing fibers a contained in the fiber-reinforced resin member A is preferably less than 3 mm. More preferably, the weight-average fiber length of the reinforcing fibers contained in the fiber-reinforced resin member A is 0.01 mm or more and less than 3 mm.
  • the weight-average fiber length Lwa of the reinforcing fibers a is not particularly limited, but the lower limit is preferably 0.01 mm or longer, more preferably 0.05 mm or longer, and even more preferably 0.1 mm or longer.
  • the weight average fiber length Lwa of the reinforcing fibers a is 0.01 mm or more, the mechanical strength is ensured.
  • the upper limit of the weight average fiber length Lwa of the reinforcing fibers a is preferably less than 3 mm, more preferably less than 2 mm, and even more preferably less than 1 mm. If Lwa is 1.0 mm or less, it is easy to manufacture the fiber-reinforced resin member A by injection. In the case of injection, a kneading process is included, and carbon fibers that have undergone a sufficient kneading process generally have a weight-average fiber length of less than 1 mm.
  • the weight-average fiber length Lwa of the reinforcing fibers a is obtained by the formulas (1) and (2) described below.
  • the weight average fiber length of the reinforcing fibers a is preferably shorter than the weight average fiber length of the reinforcing fibers b.
  • the weight-average fiber length of the reinforcing fibers b contained in the fiber-reinforced resin member B is preferably 3 mm or more. More preferably, the weight-average fiber length of the reinforcing fibers b contained in the fiber-reinforced resin member B is 3 mm or more and 100 mm or less. The weight average fiber length of the reinforcing fibers b is preferably longer than the weight average fiber length of the reinforcing fibers a. Reinforcing fibers b having different fiber lengths may be used together.
  • the reinforcing fiber b used in the present invention may have a single peak in the weight-average fiber length distribution, or may have a plurality of peaks.
  • the weight average fiber length Lwb of the reinforcing fibers b is more preferably 3 mm or more and 80 mm or less, and even more preferably 5 mm or more and 60 mm or less. If Lwb is 100 mm or less, the fluidity of the material is less likely to decrease when the fiber-reinforced resin member B is manufactured by press molding, and the fiber-reinforced resin member B can be easily formed into a desired shape.
  • the mechanical strength of the resulting fiber-reinforced resin member is less likely to decrease, which is preferable.
  • the weight average fiber length and number average fiber length of the reinforcing fibers b can be measured in the same manner as in formulas (1) and (2) described below.
  • I indicates the number of reinforcing fibers measured.
  • the number average fiber length and the weight average fiber length have the same value.
  • Reinforcing fibers can be extracted from a resin panel by, for example, performing heat treatment at 500° C. for about 1 hour and removing the resin in a furnace.
  • the number average fiber length Ln and the weight average fiber length Lw can be obtained in the same manner as in the above formulas (1) and (2).
  • the reinforcing fiber volume ratio (Vf) can be obtained by the following formula (3).
  • the reinforcing fiber volume ratio (Vf) is preferably 10 to 60 vol%, more preferably 20 to 50 vol%, and even more preferably 25 to 45 vol%.
  • Reinforcing fiber volume ratio (Vf) 100 ⁇ reinforcing fiber volume / (reinforcing fiber volume + resin volume) Equation (3)
  • the reinforcing fiber volume ratio Vfa of the fiber reinforced resin member A and the carbon fiber volume ratio Vfb of the fiber reinforced resin member B satisfy the relationship Vfb ⁇ Vfa.
  • Vfb a material obtained by crushing offcuts collected from the manufacturing process or product
  • Vfa a thermoplastic resin
  • Vfb>Vfa scraps remaining after cutting out the fiber-reinforced resin member B can be efficiently used, and the product can be easily recycled.
  • Vfb is preferably 20 to 45 Vol%, more preferably 25 to 40 Vol%.
  • Vfa is preferably 1 to 40 Vol%, more preferably 5 to 30 Vol%, still more preferably 10 to 25 Vol%.
  • Vf 100 x reinforcing fiber volume/(reinforcing fiber volume + resin volume)
  • the resin used for the resin panel may be thermosetting or thermoplastic.
  • Thermoplastic Resin 1.1 Overview When the resin used is a thermoplastic resin, the type thereof is not particularly limited, and one having a desired softening point or melting point can be appropriately selected and used. As the thermoplastic resin, one having a softening point in the range of 180° C. to 350° C. is usually used, but the thermoplastic resin is not limited to this.
  • Thermoplastic resins include polyolefin resins, polystyrene resins, polyamide resins, polyester resins, polyacetal resins (polyoxymethylene resins), polycarbonate resins, (meth)acrylic resins, polyarylate resins, polyphenylene ether resins, polyimide resins, and polyether nitriles. Resins, phenoxy resins, polyphenylene sulfide resins, polysulfone resins, polyketone resins, polyetherketone resins, thermoplastic urethane resins, fluorine-based resins, and thermoplastic polybenzimidazole resins can be used.
  • thermoplastic resin used in the resin panel of the present invention may be of only one type, or may be of two or more types.
  • Examples of a mode in which two or more thermoplastic resins are used in combination include, for example, a mode in which thermoplastic resins having different softening points or melting points are used in combination, and a mode in which thermoplastic resins having different average molecular weights are used in combination. is possible, but not limited to this.
  • thermoplastic resin it is more preferable to use a polyolefin resin, and it is even more preferable to use a polypropylene resin.
  • the resin contained in the fiber reinforced resin member A is preferably a thermoplastic resin.
  • the resin contained in the fiber-reinforced resin member B is a thermoplastic resin, it is more preferable that the resins contained in the fiber-reinforced resin members A and B are the same type of thermoplastic resin.
  • Thermosetting Resin The resin contained in the fiber-reinforced resin member B may be a thermosetting resin.
  • the fiber-reinforced resin member B is preferably formed by molding a sheet molding compound (sometimes referred to as SMC) using reinforcing fibers. Due to its high formability, the sheet molding compound can be easily molded even into complex shapes. Sheet molding compounds have higher fluidity and formability than continuous fibers, and can easily form ribs and bosses.
  • material Am the material before molding of the fiber reinforced resin member A used in the vehicle structure
  • material Bm the material before molding of the fiber reinforced resin member B
  • a material containing reinforcing fibers a with a weight average fiber length of less than 3 mm may be called material Am
  • a material containing reinforcing fibers b with a weight average fiber length of 3 mm or more may be called material Bm.
  • the metal fastener used in the present invention is a metal fastener.
  • the shape of the metal fastener used in the present invention is not particularly limited.
  • the cross-sectional shape may be an L-shape or an I-shape.
  • the metal fastener has a bolt insert.
  • FIGS. 5A and 5B An example of the vehicle structure of the present invention is shown in FIGS. 5A and 5B.
  • metal fasteners (503) are embedded in plastic panel 504 by insert molding.
  • bolt 505 fastens metal fastener 503 and bracket 502 .
  • Reference numeral 506 is a nut for fastening the bolt.
  • the bolt 505 is inserted from the outside of the resin panel 504 and fastened to the nut 506 as shown in FIG. 5B.
  • the resin panel 504 may have ribs 501 .
  • Insert molding is a molding method in which resin is injected around a metal fastener inserted into a mold to integrate the metal fastener and the resin. There is no particular limitation on the insert molding method.
  • Insert Molding Using Injection it is preferable to place the material Bm and the metal fastener in advance in the molding die, and then inject the material Am into the molding die to put it into the molding die.
  • the metal fastener is covered with the fiber-reinforced resin member A.
  • the metal fastener is placed in the mold in advance, the material Am is injected into the mold, the metal fastener is covered with the material Am, and the metal fastener is a fiber-reinforced resin member. covered by A.
  • the fiber-reinforced resin member A, the fiber-reinforced resin member B, and the metal fastener are integrally molded.
  • the fiber-reinforced resin member B is not in contact with the metal fastener.
  • the material Bm and the metal fastener are placed in advance in the mold without contacting each other, and then the material Am is injected into the mold and put into the mold.
  • the resin of the fiber-reinforced resin member A is a thermoplastic resin, and the metal fastener is covered with the fiber-reinforced resin member A by injecting the material Am.
  • the metal fastener by covering the metal fastener with the fiber-reinforced resin member A and not contacting the fiber-reinforced resin member B, welds caused by contact between the material Am and the material Bm do not exist around the metal fastener. It will be. In other words, it is more preferable that the metal fastener is covered with the fiber-reinforced resin member A and that there is no weld caused by the fiber-reinforced resin member A on the contact surface with the metal fastener. It is preferable that the fiber reinforced resin member B is in contact with the fiber reinforced resin member A when the fiber reinforced resin member B is not in contact with the metal fastener.
  • the fiber reinforced member A is a glass fiber reinforced member AGF containing glass fibers having a weight average fiber length of less than 3 mm
  • the fiber reinforced member B is a carbon fiber reinforced member containing carbon fibers having a weight average fiber length of 3 mm or more. It is preferably B CF or a glass fiber reinforced member B GF containing glass fibers having a weight average fiber length of 3 mm or more. More preferably, the reinforcing fiber member B is a carbon fiber reinforced resin member B CF containing carbon fibers having a weight average fiber length of 3 mm or more, and a glass fiber reinforced resin member B GF containing glass fibers having a weight average fiber length of 3 mm or more.
  • the metal fastener is covered with a glass fiber reinforced resin member AGF containing glass fibers having a weight average fiber length of less than 3 mm, and the glass fiber reinforced resin member AGF is in contact with the carbon fiber reinforced resin member BCF .
  • the carbon fiber reinforced resin member BCF can be partially used.
  • the place where the carbon fiber reinforced resin member BCF is partially used is preferably the periphery of the hole h1, and is preferably used to reinforce the fastening.
  • the resin contained in the fiber-reinforced resin member A is a thermoplastic resin or a thermosetting resin
  • the resin contained in the fiber-reinforced resin member B is a thermoplastic resin or a thermosetting resin.
  • the resin contained in the glass fiber reinforced resin member A GF , the carbon fiber reinforced resin member B CF and the glass fiber reinforced resin member B GF may be a thermoplastic resin. While the glass fiber reinforced resin member AGF is a thermoplastic resin, the carbon fiber reinforced resin member BCF and the glass fiber reinforced resin member BGF may be molded bodies using a sheet molding compound.
  • a sheet molding compound containing carbon fiber may be used as the material Bm, and the metal fastener may be covered at the same time as the material Bm is molded. In this case, it is not always necessary to use the fiber-reinforced resin member A.
  • the resin panel of the vehicle structure has a fiber reinforced resin member B, the fiber reinforced resin member B includes a glass fiber reinforced resin member B GF , and the glass fiber reinforced resin member B GF is formed by molding a sheet molding compound. is preferred. More preferably, the fiber reinforced resin member B includes a carbon fiber reinforced resin member B CF and a glass fiber reinforced resin member B GF , and the carbon fiber reinforced resin member B CF is formed by molding a sheet molding compound, and is a metal fastener. is preferably covered with a glass fiber reinforced resin member BGF or a carbon fiber reinforced resin member BCF . By covering the periphery of the metal fastener with the carbon fiber reinforced resin member BCF and creating the other area with the glass fiber reinforced resin member BGF , the metal fastener and the periphery of the hole h1 can be reinforced.
  • the shape of the resin panel is not particularly limited.
  • the resin panel preferably has at least one plane portion having at least one thickness (plate thickness), and has a cross-sectional shape of T-shape, L-shape, U-shape, hat-shape (hat shape) and these It may have a three-dimensional shape including, and may further have an uneven shape (eg, ribs, bosses, etc.). It is preferable that the resin panel has a shape including a portion having a hat-shaped cross section.
  • the resin panel may include an uneven-thickness portion. That is, the resin panel may include a non-uniform thickness structure.
  • the uneven thickness of the resin panel should be within 30 mm from the metal fastener. Naturally, the uneven thickness portion may exist outside 30 mm from the metal fastener. In other words, the periphery of the metal fastener may have uneven thickness structure.
  • the metal fastener is covered with the fiber reinforced resin member A, it is preferable to provide an uneven thickness structure within 30 mm from the metal fastener by the thickness of the fiber reinforced resin member B and the thickness of the fiber reinforced resin member A. It is more preferable that the uneven thickness of the resin panel is within 20 mm from the metal fastener.
  • the fiber-reinforced resin member A preferably contributes to the uneven thickness structure.
  • the material Bm for producing the fiber-reinforced resin member B is preferably plate-shaped, and the material Am for producing the fiber-reinforced resin member A is preferably an injection material.
  • the material Am it is easy to manufacture a resin panel having an uneven thickness structure. For example, when manufacturing a resin panel having an uneven thickness structure whose thickness gradually increases from 2 mm to 3 mm, when a material Bm having a thickness of 1 mm is placed in a mold, the remaining uneven thickness area of 1 mm to 2 mm is made of material Am. It is preferable to form the fiber reinforced resin member A by throwing it in.
  • the fiber reinforced resin member B When using insert molding using SMC When using a sheet molding compound containing carbon fiber as the material Bm and covering the metal fastener at the same time as molding the material Bm, the fiber reinforced resin member B has an uneven thickness structure. can contribute.
  • FIG. 6 shows a schematic diagram of the vehicle structure of the present invention, which includes a metal fastener having a bolt insertion portion and a resin panel.
  • the metal fastener 603 is embedded in the resin panel by insert molding, and the resin panel is provided with a hole h1 (601) at a position corresponding to the bolt insertion portion.
  • FIG. 6 is before the bolt is inserted.
  • ribs 602 are provided around metal fasteners 603 .
  • the resin panel is provided with a hole h1 at a position corresponding to the bolt insertion portion.
  • Forming Holes h1 Simultaneously with Molding It is preferable to form holes h1 simultaneously with molding.
  • a hole h1 is formed in the resin panel by forming a hole in the fiber-reinforced resin member A.
  • projections corresponding to the holes h1 to be created are provided in advance on the molding die, when the molding is completed by pouring the material Am , a hole h1 can be created in the fiber-reinforced resin member A.
  • the mold is provided with projections corresponding to the holes h1 to be formed in advance, and holes h0 are formed at positions corresponding to the projections of the mold for the material Bm, A hole h1 can be formed in the fiber-reinforced resin member B by fitting the hole h0 into the projection of the molding die and pressing.
  • the methods described in International Publication No. WO 2017/043186 and JP-A-10-100175 can be referred to. In both cases, since the hole h1 is provided at the same time as the integral molding, the hole h1 can be easily provided. If the hole h1 is provided by integral molding, the manufacturing process can be simplified.
  • hole h1 provided by secondary processing
  • the hole h1 may be provided by secondary processing.
  • the hole h1 may be formed by secondary processing after integral molding, which will be described later.
  • FIG. 7 is a schematic diagram showing a structure in which the resin panel is not involved in the fastening portion as much as possible. That is, the metal fasteners (eg 701 in FIG. 7) embedded in the resin panel by insert molding and the fasteners (eg 704 in FIG. 7) used for connecting to the vehicle body side are in contact with each other. preferable. More preferably, the metal fastener (eg 701 in FIG. 7) embedded in the resin panel by insert molding and the fastener (eg 704 in FIG. 7) used for coupling with the vehicle body side are in surface contact. preferably. A fastener (for example, 704 in FIG.
  • the fastening stability is improved by making surface contact between the metals (701 and 704 in FIG. 7) at the bolt fixing locations where the load is applied.
  • the shape of the hole h1 is defined by the area S1 of the hole h1 viewed from the metal fastener side embedded in the resin panel by insert molding (for example, the area of the hole h1 viewed from the left side in FIG. 7) and the vehicle body side The relationship with the area S2 of the hole h1 viewed from the fastener side (for example, the area of the hole h1 viewed from the right side in FIG.
  • connection with the fastener is preferably S1 ⁇ S2. Since S1 ⁇ S2, it is possible to embed a fastener (for example, 704 in FIG. 7) for connection with the vehicle body side in the resin panel. This stabilizes the fastening strength.
  • FIG. 9 is a schematic diagram showing a vehicle back door 1 to which a vehicle structure according to an embodiment of the present invention is applied.
  • the resin panel is a door panel constituting the vehicle back door 1
  • the vehicle structure is the vehicle resin back door structure.
  • the door panel may have a rear glass 5.
  • the vehicle back door 1 has a side frame 3L on the left side of the rear glass 5 and a side frame 3R on the right side of the rear glass 5. As shown in FIG.
  • FIG. 10 is a schematic diagram showing a part of the side frame 3L to which the damper stay 30 is attached
  • FIG. 11 is a cross-sectional view taken along line XI-XI of FIG.
  • the vehicle backdoor 1 includes a damper stay 30 .
  • the door panel and the damper stay 30 that constitute the side frame 3L are fastened and fixed by inserting the bolt 32 into the bolt insertion portion 20h.
  • bolts are inserted from the inside of the vehicle into the holes 1h provided in the molded body 1A that constitutes the side frame 3L, the bolt insertion portions 20h provided in the metal fasteners 20, and the holes 31 provided in the damper stay 30.
  • the damper stay 30 is fixed to the side frame 3L.
  • the damper stay 30 is a fastener for the damper 35 .
  • the damper 35 is a member that prevents unintentional closing of the back door when the door, lid, or drawer is closed or opened by an orifice structure or a shear structure.
  • the side frame 3L is a vehicle structure including a molding 1A in which a resin panel 10 and metal fasteners 20 are integrally molded.
  • the resin panel 10 has a fiber reinforced resin member 11A containing reinforcing fibers a with a weight average fiber length of less than 3 mm, and a fiber reinforced resin member 12B containing reinforcing fibers b with a weight average fiber length of 3 mm or more.
  • the fiber reinforced resin member 12B is in contact with the fiber reinforced resin member 11A.
  • the metal fastener 20 is embedded in the resin panel 10 by insert molding.
  • the metal fastener 20 is covered with the fiber reinforced resin member 11A. Since the fiber reinforced resin member 11A exists between the metal fastener 20 and the fiber reinforced resin member 12B, the fiber reinforced resin member 12B is not in contact with the metal fastener 20.
  • the fiber-reinforced resin member 11A preferably has a hole 11h at a position corresponding to the bolt insertion portion 20h of the metal fastener 20.
  • the fiber-reinforced resin member 12B preferably has a hole 12h at a position corresponding to the bolt insertion portion 20h of the metal fastener 20. As shown in FIG.
  • the metal fastener 20 has an I-shaped cross section in FIG. 11, the cross-sectional shape of the metal fastener 20 is not limited to this.
  • a metal fastener 20B having an L-shaped cross section may be used, or a molded body 1B in which a resin panel and a metal fastener 20B are integrally molded may be used for a vehicle structure. good.
  • the vehicle structure is preferably manufactured using a cold press.
  • the metal fasteners 20 are preferably fixed to the lower die 101 so as not to move during the pressing process.
  • the metal fastener 20 may be fixed to the lower mold 101 by inserting the slide core 110 provided in the lower mold 101 into the hole 21 of the metal fastener 20 .
  • the metal fastener 20 may be clamped to the lower mold 101 in advance, and the slide core 110 may be used so that the molding (finished product) is removed from the mold at the same time as the molding is completed.
  • a hole Bh may be provided at a position corresponding to the slide core 110 of the material Bm.
  • the step of arranging the material Bm for producing the fiber-reinforced resin member B in the present invention in the mold can be performed using a conventionally known method.
  • the material Bm is preferably placed in the mold in a preheated state.
  • the thermoplastic resin contained in the fiber-reinforced resin member B is crystalline, it is preferably heated to a temperature higher than the melting point and lower than the decomposition temperature.
  • the temperature of the mold (lower mold 101 and upper mold 102) is adjusted to below the melting point when the thermoplastic resin contained in the fiber-reinforced resin member B is crystalline, and below the glass transition temperature when amorphous. It is preferable that By adjusting the temperature of the material Bm and the mold in this way, the cold press can be suitably performed. It should be noted that the material Bm is preferably pre-shaped before starting pressing.
  • the method of injecting the material Am into the mold is not particularly limited, and conventionally known methods can be used.
  • the number of gates 103 for injecting the material Am and the positions of the gates 103 are not particularly limited.
  • Va:Vb is preferably 10:90 to 50:50, more preferably 20:80 to 40:60.
  • Va:Vb is 10:90 to 50:50, for example, the material Bm is used to form the main part of the press-molded body, and only the necessary parts (such as edges and details) have high fluidity. It can be formed using the material Am.
  • the pressure when injecting the material Am is preferably 30-200 kgf/m 2 , more preferably 40-150 kgf/m 2 .
  • the heating temperature of the material Am is not particularly limited, but is preferably 200 to 300° C. when nylon 6 is used as the thermoplastic resin.
  • the resin panel 10 and the metal fastener 20 are integrally formed.
  • Cold pressing can be performed using a conventionally known method.
  • the cold press method is, for example, a fiber-reinforced thermoplastic resin material heated to a first predetermined temperature (material Am when using a thermoplastic resin, material Bm when using a thermoplastic resin as a general term (sometimes referred to as a "fiber-reinforced thermoplastic resin material”) is put into a mold set to a second predetermined temperature, and then pressurized and cooled.
  • the cold press method includes at least the following steps A-1) to A-2).
  • Step A-1) A step of heating a fiber-reinforced thermoplastic resin material to a temperature above the melting point and below the decomposition temperature if the thermoplastic resin is crystalline, and to a temperature above the glass transition temperature and below the decomposition temperature if the thermoplastic resin is amorphous.
  • Step A-2) The temperature of the fiber-reinforced thermoplastic resin material heated in step A-1) is adjusted to below the melting point if the thermoplastic resin is crystalline and below the glass transition temperature if the thermoplastic resin is amorphous.
  • Each of the above steps must be performed in the above order, but other steps may be included between each step.
  • the other step is, for example, prior to step A-2), using a shaping die different from the shaping die used in step A-2) to pre-shape into the shape of the cavity of the shaping die. There is a shaping process, etc.
  • step A-2) is a step of applying pressure to the fiber-reinforced thermoplastic resin material to obtain a molded body having a desired shape. is preferably less than 20 MPa, more preferably 10 MPa or less.
  • various steps may be interposed between the above steps during press molding. For example, vacuum press molding in which press molding is performed while a vacuum is applied may be used.
  • the material Am when the thermoplastic resin is injected into the mold is above the melting point or above the decomposition temperature if the thermoplastic resin is crystalline and below the glass transition temperature if the thermoplastic resin is amorphous. It is common to heat above the temperature and below the decomposition temperature.
  • the material Bm is plate-shaped, and the resin panel 10 is manufactured by flowing and extending the material Am in the in-plane direction of the material Bm.
  • the material Bm and the metal fastener are placed in advance in a mold, the material Am is injected into the mold, and the fiber reinforced resin member A and the fiber Since the reinforced resin member B and the metal fasteners are integrally molded, a resin panel in which the metal fasteners are integrated can be manufactured in a single molding process, resulting in excellent productivity. Moreover, in a preferable manufacturing method, the bonding strength between the fiber reinforced resin member A and the fiber reinforced resin member B is also excellent in the resin panel.
  • the metal fastener 20 is covered with the fiber reinforced resin member 11A, the fiber reinforced resin member 12B is in contact with the fiber reinforced resin member 11A, and the fiber reinforced resin member 12B is in contact with the metal fastener 20.
  • the invention is not limited to this.
  • a molded body 1C in which a metal fastener 20 is covered with a fiber-reinforced resin member 12B may be used for a vehicle structure.
  • the resin panel 10 and the metal fastener 20 are integrally molded in a state where the metal fastener 20 is in contact with the fiber-reinforced resin member 12B and the fiber-reinforced resin member 11A is not in contact with the metal fastener 20.
  • the fiber-reinforced resin member 12B preferably has a hole 12h at a position corresponding to the bolt insertion portion 20h of the metal fastener 20. As shown in FIG.
  • a molded body 1C shown in FIG. 17 can be manufactured, for example, as described below.
  • the metal fastener 20 is fixed to the lower mold 101 as in FIG.
  • the material Bm is placed in the cavity of the lower mold 101 .
  • the mold is closed.
  • the material Am is injected from the gate 103 into the mold.
  • a gate 103 is provided at a portion of the lower mold 101 away from the position where the metal fastener 20 is fixed.
  • press molding is completed so that the material Bm and the metal fastener 20 come into contact with each other before the material Am injected from the gate 103 flows into the space between the material Bm and the metal fastener 20 .
  • FIG. 8 depicts sandwiching and molding a metal fastener 801 using material Bm (sheet molding compound, 802). The metal fastener 801 is supported by the slide core 803 so as not to move by the material Bm or the like. As shown in FIG.
  • a plurality of materials Bm and the metal fasteners 801 are arranged in a mold with the metal fasteners 801 sandwiched between the plurality of materials Bm for making the fiber-reinforced resin member B, By integrally molding the fiber-reinforced resin member B and the metal fastener 801, the vehicle structure can be molded. By arranging them as shown in FIG. 8, it is possible to manufacture a vehicle structure in which the metal fasteners are covered with the glass fiber reinforced resin member BGF or the carbon fiber reinforced resin member BCF .

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Manufacturing & Machinery (AREA)
  • Textile Engineering (AREA)
  • Body Structure For Vehicles (AREA)

Abstract

Lors du montage d'un panneau de résine et d'un autre composant tel qu'un support d'amortisseur, la présente invention réduit le nombre d'étapes de fabrication par incorporation d'un élément de fixation métallique dans le panneau de résine par moulage par insertion. Une structure de véhicule (1) comprend : un élément de fixation métallique (20) ayant une partie d'insertion de boulon (20A) ; et un panneau de résine (10). L'élément de fixation métallique (20) est intégré dans le panneau de résine (10) par moulage par insertion. Le panneau de résine (10) est pourvu d'un trou (10A) formé à une position correspondant à la partie d'insertion de boulon (20A).
PCT/JP2022/045569 2022-02-04 2022-12-09 Structure de véhicule comprenant un panneau de résine et élément de fixation métallique ayant une partie d'insertion de boulon WO2023149083A1 (fr)

Applications Claiming Priority (2)

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JP2022-016724 2022-02-04
JP2022016724 2022-02-04

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WO2023149083A1 true WO2023149083A1 (fr) 2023-08-10

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Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2013257003A (ja) * 2012-06-13 2013-12-26 Advanex Inc インサートナット
JP2014076707A (ja) * 2012-10-09 2014-05-01 Toyota Motor Corp 車両用樹脂バックドア構造
WO2014116151A1 (fr) * 2013-01-24 2014-07-31 Saab Ab Article de revêtement aérien avec trous de fixation renforcés
JP2014528851A (ja) * 2011-07-22 2014-10-30 ザ・ボーイング・カンパニーＴｈｅＢｏｅｉｎｇ Ｃｏｍｐａｎｙ 繊維強化熱可塑性複合材構造物に関する埋込インサート及び方法
JP2016120602A (ja) * 2014-12-24 2016-07-07 トヨタ自動車株式会社 インサート成形品
JP2018039247A (ja) * 2016-09-06 2018-03-15 大成プラス株式会社 Ｃｆｒｔｐと金属の複合体
JP2018187821A (ja) * 2017-05-01 2018-11-29 株式会社チャレンヂ 繊維強化樹脂部品の製造方法

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2014528851A (ja) * 2011-07-22 2014-10-30 ザ・ボーイング・カンパニーＴｈｅＢｏｅｉｎｇ Ｃｏｍｐａｎｙ 繊維強化熱可塑性複合材構造物に関する埋込インサート及び方法
JP2013257003A (ja) * 2012-06-13 2013-12-26 Advanex Inc インサートナット
JP2014076707A (ja) * 2012-10-09 2014-05-01 Toyota Motor Corp 車両用樹脂バックドア構造
WO2014116151A1 (fr) * 2013-01-24 2014-07-31 Saab Ab Article de revêtement aérien avec trous de fixation renforcés
JP2016120602A (ja) * 2014-12-24 2016-07-07 トヨタ自動車株式会社 インサート成形品
JP2018039247A (ja) * 2016-09-06 2018-03-15 大成プラス株式会社 Ｃｆｒｔｐと金属の複合体
JP2018187821A (ja) * 2017-05-01 2018-11-29 株式会社チャレンヂ 繊維強化樹脂部品の製造方法

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