WO2024232185A1 - 自動車部品及び自動車部品の製造方法 - Google Patents

自動車部品及び自動車部品の製造方法 Download PDF

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Publication number
WO2024232185A1
WO2024232185A1 PCT/JP2024/013080 JP2024013080W WO2024232185A1 WO 2024232185 A1 WO2024232185 A1 WO 2024232185A1 JP 2024013080 W JP2024013080 W JP 2024013080W WO 2024232185 A1 WO2024232185 A1 WO 2024232185A1
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WIPO (PCT)
Prior art keywords
resin
component
loss factor
automobile
joint
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PCT/JP2024/013080
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English (en)
French (fr)
Japanese (ja)
Inventor
奈沙 島崎
毅 河内
恭兵 狩野
教之 禰宜
由佳 姉川
透 高山
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日本製鉄株式会社
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Priority to JP2025519341A priority Critical patent/JPWO2024232185A1/ja
Publication of WO2024232185A1 publication Critical patent/WO2024232185A1/ja

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/18—Layered products comprising a layer of metal comprising iron or steel
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/20—Floors or bottom sub-units

Definitions

  • This application discloses an automobile part and a method for manufacturing the automobile part.
  • the present application discloses the following aspects as one of the means for solving the above problems.
  • the automotive part according to any one of aspects 1 to 5, one or both of the first component and the second component comprises a steel plate;
  • the steel plate has a plate thickness of 0.3 mm or more and 5.0 mm or less.
  • the first part is a skeleton;
  • the second part is a panel.
  • a method for manufacturing an automobile part including a first part and a second part, Applying a resin composition to one or both of a portion of the first component and a portion of the second component; bonding the first component and the second component via the resin composition; foaming the resin composition; and performing one or both of welding and mechanical joining at an adhesive portion between the first part and the second part.
  • the automotive parts disclosed herein have excellent vibration damping properties.
  • FIG. 1 shows a schematic diagram of an example of a configuration of an automobile part.
  • 1 shows a schematic diagram of an example of an automobile part.
  • 1 shows a schematic diagram of an example of an automobile part.
  • 1 shows a schematic diagram of an example of an automobile part.
  • 2 is a schematic diagram showing an example of a plan view configuration of a joint portion between a first part and a second part in an automobile part;
  • FIG. 4 is a schematic diagram showing a cross section taken along the line IV-IV in FIG. 3.
  • FIG. 4 is a schematic diagram showing an example of a cross section of a joint between a first part and a second part in an automobile part, in which a foamed resin is present around a welded part.
  • FIG. 4 is a schematic diagram showing a cross section taken along the line IV-IV in FIG. 3.
  • FIG. 4 is a schematic diagram showing an example of a cross section of a joint between a first part and a second part in an automobile part, in which no foamed resin is present around the welded part.
  • FIG. 3 is a schematic diagram showing a cross-sectional configuration taken along the line V-V in FIG. 2.
  • FIG. 3 is a schematic diagram showing an example of a cross-sectional configuration of a portion of a joint between a first part and a second part in an automobile part that is not welded or mechanically joined (a portion away from a weld or a mechanical joint). 1 shows an example of a manufacturing process for an automobile part.
  • 1 shows an example of a manufacturing process for an automobile part.
  • the structure of the sandwich steel plate used in the evaluation of the loss factor is shown diagrammatically.
  • the relationship between the air bubble ratio and the loss factor is shown.
  • 1 shows a schematic diagram of the configuration of components used to evaluate the loudness of sound radiated from a panel.
  • the figure shows the relationship between the area ratio of adhesive containing air bubbles and adhesive without air bubbles and the maximum panel radiation sound ratio (relative to the maximum panel radiation sound when 100% adhesive without air bubbles is applied).
  • the figure shows the relationship between the area ratio of adhesive containing air bubbles and adhesive without air bubbles and the average panel radiation sound ratio (relative to the average panel radiation sound when 100% adhesive without air bubbles is applied).
  • an automobile part 100 includes a first part 10, a second part 20, and a joint 30 that joins the first part 10 and the second part 20.
  • the joint 30 includes one or both of a welded part 31 and a mechanical joint (not shown), as well as a foamed resin 32 that bonds the first part 10 and the second part 20.
  • the automobile part 100 includes a first part 10 and a second part 20.
  • the first part 10 and the second part 20 may be different parts from each other.
  • the first part 10 may be, for example, a framework, a panel, or a part other than these.
  • the second part may be, for example, a framework, a panel, or a part other than these.
  • the first component 10 may be a skeleton
  • the second component 20 may be a panel.
  • the skeleton and the panel can be firmly joined via a joint 30 described below, and the presence of foamed resin 32 can enhance vibration damping between the skeleton and the panel. In other words, the transmission of vibration from the skeleton to the panel and from the panel to the skeleton can be suppressed.
  • the first component 10 may be a skeleton
  • the second component 20 may be a skeleton different from the first component 10.
  • the first skeleton and the other skeleton can be firmly joined via a joint 30 described below, and the presence of the foamed resin 32 can increase the vibration damping between the first skeleton and the other skeleton. In other words, the transmission of vibration from the first skeleton to the other skeleton can be suppressed.
  • the first component 10 may be a panel
  • the second component 20 may be a panel different from the first component 10.
  • the first panel and the other panel can be firmly joined via a joint 30 described below, and the presence of the foamed resin 32 can increase the vibration damping between the first panel and the other panel. In other words, the transmission of vibration from the first panel to the other panel can be suppressed.
  • the skeleton may be any type of structure that is suitable for use in an automobile, and there are no particular limitations on the specific type.
  • the skeleton may be, for example, a floor member, a side member, a cross member, or other member; a pillar, such as an A-pillar, a B-pillar, or a C-pillar; a sill, such as a side sill; or a floor cross.
  • the panel may be any automobile panel, and its specific type is not particularly limited.
  • the panel may be, for example, a floor panel, roof panel, inner panel, back panel, door, bonnet hood, wheel house, or cowl portion.
  • Figures 2A to 2D show specific examples of combinations of a first part 10 and a second part 20.
  • Figure 2A shows an automobile part having an A-pillar as the first member 10 and a roof panel as the second member 20.
  • Figure 2B shows an automobile part having an inner panel of a wheel house as the first member 10 and an outer panel of the wheel house as the second member 20.
  • Figure 2C shows an automobile part having a side sill as the first member 10 and a floor panel as the second member 20.
  • Figure 2D shows an automobile part having a front side member as the first member 10 and a floor cross as the second member 20.
  • the technology disclosed herein can be applied to various automobile parts.
  • the material and shape of the first part 10 and the second part 20 may be any material that allows welding and/or mechanical joining.
  • the material of the first part 10 and the second part 20 may be at least one material selected from, for example, metal materials, plastic materials, rubber materials, fiber reinforced plastic materials (FRP), etc.
  • the first part 10 and the second part 20 may be made of the same material or different materials. In particular, when the material of one or both of the first part 10 and the second part 20 is a metal material, excellent strength is easily ensured. Also, when the material of one or both of the first part 10 and the second part 20 is a fiber reinforced plastic material, excellent strength is easily ensured.
  • the type of metal material is not particularly limited, and may be at least one selected from iron, titanium, aluminum, magnesium, and alloys thereof.
  • alloys include iron-based alloys (including stainless steel), Ti-based alloys, Al-based alloys, and Mg alloys.
  • one or both of the first part 10 and the second part 20 may be made of steel.
  • the steel is not particularly limited, and may be one that is standardized by the Japanese Industrial Standards (JIS), for example. Specific examples include carbon steel, alloy steel, and high-tensile steel used for general structures and machine structures.
  • JIS Japanese Industrial Standards
  • the components of the steel are not particularly limited, and may contain one or more of Mn, Si, P, Al, N, Cr, Mo, Ni, Cu, Ca, Mg, Ce, Hf, La, Zr, and Sb in addition to Fe and C.
  • the steel may have a component that contains C, Si, Mn, P, S, Al, and N, with the balance being Fe and impurities.
  • Fiber reinforced resin material is a matrix resin reinforced with a fiber material.
  • the type of resin and fiber material is not particularly limited. FRP may be composed of only a matrix resin and a fiber material. Alternatively, FRP may contain various additives such as conductive particles, inorganic fillers, rubber materials, pigments, colorants, antioxidants, and flame retardants for the purpose of imparting functionality. FRP may be single-layered or multi-layered, and the number of layers may be selected according to the application.
  • the matrix resin contained in the fiber reinforced resin material (FRP) is not particularly limited, and may be a thermoplastic resin, a thermosetting resin, or a combination of these. In particular, thermoplastic resins have good bending strength and excellent processability.
  • thermoplastic resin per 100 parts by mass of the resin component.
  • the matrix resin may be only a thermoplastic resin.
  • thermoplastic resin that can be used for the matrix resin is not particularly limited, and may be, for example, one or more selected from polyolefins and their acid-modified products; polypropylene; polystyrene; polymethyl methacrylate; AS resin; ABS resin; thermoplastic aromatic polyesters such as polyethylene terephthalate and polybutylene terephthalate; polycarbonate; thermoplastic epoxy resins; polyimides; polyamides; polyamideimides; polyetherimides; polyethersulfones; polyphenylene ethers and their modified products; polyphenylene sulfide; polyoxymethylene; polyarylates; polyether ketones; polyether ether ketones; polyether ketone ketones; and nylons.
  • the thermosetting resin that can be used for the matrix resin is not particularly limited, and may be, for example, one or more selected from epoxy resins, vinyl ester resins, phenolic resins, and urethane resins.
  • the fiber material contained in the fiber reinforced resin material (FRP) is not particularly limited, and may be, for example, at least one selected from carbon fibers, boron fibers, silicon carbide fibers, glass fibers, aramid fibers, and the like.
  • the fiber material may be long or short fiber.
  • FRP containing carbon fiber has excellent strength.
  • the type of carbon fiber may be, for example, PAN-based or pitch-based, and may be selected according to the purpose and use.
  • the fiber material may be only one of the above-mentioned fibers, or a combination of multiple types.
  • the reinforcing fiber substrate (prepreg) that serves as the substrate of the above-mentioned fiber material include a nonwoven substrate using chopped fiber, a cloth material using continuous fiber, and a unidirectional reinforcing fiber substrate (UD material). From the viewpoint of reinforcing effect, it is preferable to use a cloth material or a UD material as the reinforcing fiber substrate.
  • the volume content Vf of the fiber material in the FRP is not particularly limited, but is preferably 20% by volume or more and 70% by volume or less from the viewpoint of strength and processability.
  • the Vf of the fiber material in the FRP is more preferably 25% by volume or more or 30% by volume or more, and more preferably 65% by volume or less or 60% by volume or less.
  • the measurement of Vf can be performed by a method known to those skilled in the art.
  • the shapes of the first part 10 and the second part 20 may be determined according to the application.
  • one or both of the first part 10 and the second part 20 may be a steel plate.
  • the steel plate may be optionally surface-treated.
  • the surface treatment may be at least one selected from various plating treatments such as zinc plating (hot-dip galvanizing, electrolytic zinc plating, etc.) and aluminum plating, chemical conversion treatments such as chromate treatment and non-chromate treatment, and physical surface roughening treatments such as sandblasting or chemical surface roughening treatments such as chemical etching, but is not limited to these.
  • the steel plate may be subjected to alloy plating or multiple types of surface treatments.
  • the surface treatment of the steel plate preferably includes at least a treatment aimed at imparting rust resistance.
  • one or both of the first part 10 and the second part 20 may comprise a steel plate, and the steel plate may have a thickness of 0.3 mm or more and 5.0 mm or less.
  • the thickness of the steel plate may be 0.5 mm or more and 3.0 mm or less, or 1.0 mm or more and 3.0 mm or less.
  • the term "steel plate” is a concept that includes a molded product in which a bend or unevenness is imparted to a steel plate.
  • one or both of the first part 10 and the second part 20 may comprise a steel plate, and the steel plate may have a tensile strength of 250 MPa or more and 2500 MPa or less, and may have the above-mentioned plate thickness.
  • the tensile strength of the steel plate may be 300 MPa or more, 350 MPa or more, 400 MPa or more, 450 MPa or more, 500 MPa or more, 550 MPa or more, 600 MPa or more, 650 MPa or more, 700 MPa or more, 750 MPa or more, 780 MPa or more, 800 MPa or more, 850 MPa or more, 900 MPa or more, 950 MPa or more, 980 MPa or more, 1000 MPa or more, 1050 MPa or more, 1100 MPa or more, or 1200 MPa or more.
  • "tensile strength" is in accordance with JIS Z 2241:2011.
  • the joint 30 includes one or both of a welded portion 31 that joins the first component 10 and the second component 20 by welding, and a mechanical joint (not shown) that mechanically joins the first component 10 and the second component 20.
  • the joint 30 includes a foamed resin 32 that bonds the first component 10 and the second component 20 together.
  • the first part 10 and the second part 20 are firmly joined by one or both of the welded part 31 and the mechanical joint.
  • a spot welded part is exemplified as the welded part 31 in Figs. 3, 4A, and 4B, the type of the welded part 31 is not limited thereto.
  • the welded part 31 may be at least one type selected from, for example, a spot welded part, a resistance welded part, a seam welded part, a laser welded part, and an element welded part.
  • the mechanical joint may be at least one type selected from, for example, a riveted joint, a hemmed joint, a drill screw joint, a bolted joint, and a friction stir welded part.
  • the joint 30 may include at least one selected from a spot weld, a projection weld, an arc spot weld, a laser weld (linear, spot, O-shaped or C-shaped), a hemmed portion, a blind rivet joint, a self-piercing rivet joint, a resistance element weld, an element arc weld, and a friction stir spot weld. As shown in Figs.
  • a portion in which the metal components are melted and solidified is formed in the portion pressurized by the electrode, and a corona bond in which the metal components are joined without melting can be formed around the nugget 31a.
  • the "corona bond” refers to the portion where the first part and the second part are pressed together around the nugget.
  • the shape, size, number, and interval of the welded portion 31 and the mechanical joint portion are not particularly limited as long as they can join the first part 10 and the second part 20.
  • Appropriate welded portions 31 and mechanical joint portions may be adopted according to the thickness and material of the first part 10 and the second part 20, and according to the target joining strength.
  • the welded portion 31 and the mechanical joint portion may be present around the welded portion 31 and the mechanical joint portion between the first part 10 and the second part 20.
  • the welded portion 31 and the mechanical joint portion may be formed so as to penetrate the foamed resin 32.
  • the foamed resin 32 may not be present around the welded portion 31 and the mechanical joint portion between the first part 10 and the second part 20.
  • the foamed resin 32 may be disposed in a portion of the joint portion 30 away from the welded portion 31 and the mechanical joint portion (for example, between one welded portion 31 and another welded portion 31).
  • the first part 10 and the second part 20 are bonded by the foamed resin 32.
  • the foamed resin 32 By combining the foamed resin 32 with the above-mentioned welded part 31 and/or mechanical joint part in the joint 30, excellent vibration damping properties can be exhibited between the first part 10 and the second part 20. That is, the vibration in the first part 10 is attenuated by the foamed resin 32 and is less likely to propagate to the second part 20. In addition, the vibration in the second part 20 is attenuated by the foamed resin 32 and is less likely to propagate to the first part 10.
  • the automobile part 100 has excellent vibration damping properties.
  • the foamed resin 32 has resin 32a and air bubbles (voids) 32b.
  • resin 32a There are no particular limitations on the type of resin 32a, as long as it is capable of bonding the first component 10 and the second component 20.
  • the resin 32a exerts vibration damping properties by shear deformation, and the presence of air bubbles (voids) 32b together with the resin 32a induces shear deformation, further enhancing the vibration damping effect.
  • the foamed resin 32 contains the air bubbles 32b together with the resin 32a, so that the foamed resin 32 has a high loss factor.
  • the loss factor of the foamed resin 32 containing the air bubbles 32b is likely to be higher than the loss factor of the resin 32a alone.
  • the resin 32a (cured resin) constituting the foamed resin 32 has a loss factor above a certain level and below a certain level, the effect of increasing the loss factor by introducing the air bubbles 32b is high.
  • the amount of components that are not incorporated into the cross-linked structure of the cured resin increases, the cross-linking density of the cured resin decreases, and the elastic modulus decreases.
  • the decrease in the elastic modulus of the cured resin increases the density of the strain energy concentrated at the interface between the voids caused by the air bubbles 32b and the resin 32a, thereby improving the loss factor and further enhancing the vibration damping effect.
  • the elastic modulus will decrease excessively, making it difficult to maintain the shape and making it impossible to introduce air bubbles into the cured resin.
  • the amount of resin components will decrease due to the air bubbles 32b escaping to the outside of the part together with the resin components, and the loss factor may decrease.
  • the loss factor of the resin 32a alone is 0.02 or more and 0.25 or less
  • the loss factor of the foamed resin 32 containing the air bubbles 32b is likely to be larger than the loss factor of the resin 32a alone that does not contain the air bubbles 32b.
  • the foamed resin 32 may be obtained, for example, by forming a resin composition layer containing a resin component (A), a hardener (B), and a foaming agent (C) between the first part 10 and the second part 20, and then obtaining the above-mentioned resin 32a as a cured resin by a reaction between the resin component (A) and the hardener (B), and generating bubbles 32b by the foaming agent (C).
  • the foamed resin 32 may contain components derived from the resin component (A) and the hardener (B), and components obtained after foaming of the foaming agent (C).
  • the components contained in the foamed resin 32 can be identified by various analytical devices.
  • the types and amounts of "components derived from the resin component (A) and the hardener (B)” and “components after foaming of the foaming agent (C)” can be identified, and the types and amounts of the resin component (A) and the hardener (B) can be identified from the types and amounts of "components derived from the resin component (A) and the hardener (B)", and the type and amount of the foaming agent (C) can be identified from the types and amounts of "components after foaming of the foaming agent (C)".
  • the components contained in the foamed resin 32 can be identified by using a known method.
  • a small amount of foamed resin can be directly and instantaneously thermally decomposed at high temperature by pyrolysis GC-MS (Gas Chromatography-Mass Spectrometry) measurement, and the generated gas components can be introduced into the GC-MS to analyze the components contained in the foamed resin.
  • GC-MS Gas Chromatography-Mass Spectrometry
  • the resin component (A) may be at least one selected from, for example, vinyl chloride resin, vinyl acetate resin, polyvinyl alcohol, polycarbonate, polyvinyl butyral, polystyrene, ABS resin, polymethyl methacrylate (methacrylic resin), polyphenylene oxide, polyurethane, ionomer resin, cellulose-based plastic, polyethylene, polypropylene, polyamide (nylon), polyacetal (polyoxymethylene), polyphenylene sulfide, vinylidene chloride resin, polyethylene terephthalate, fluororesin, phenolic resin, urea resin, melamine resin, unsaturated polyester resin, diallyl phthalate resin, epoxy resin, silicon resin, alkyd resin, polyimide, polyamino bismaleimide, casein resin, furan resin, and urethane resin.
  • vinyl chloride resin vinyl acetate resin
  • polyvinyl alcohol polycarbonate
  • polyvinyl butyral polystyrene
  • the curing agent (B) may be any agent that promotes the curing of the resin component (A).
  • the curing agent (B) may be one or both of an amine-based curing agent and an acid anhydride curing agent, and when the resin component (A) is a urethane resin, the curing agent (B) may be a polyisocyanate compound, etc.
  • the foaming agent (C) may be, for example, at least one selected from azodicarbonamide (ADCA), N,N'-dinitrosopentamethylenetetramine (DPT), 4,4'-oxybis(benzenesulfonylhydrazide) (OBSH), hydrazodicarbonamide (HDCA), barium azodicarboxylate, sodium hydrocarbyl, etc.
  • the foaming agent (C) may be combined with a foaming assistant (D) as necessary.
  • the foaming assistant (D) may be, for example, at least one selected from a urea-based assistant, a vulcanization accelerator, salicylic acid, zinc oxide, etc.
  • An appropriate blending ratio is adopted depending on the amount of bubbles 32b (bubble rate) to be generated in the foamed resin 32. According to the knowledge of the inventor, if the amount of foaming agent (C) is too small, the effect of improving the loss factor is reduced, and if the amount of foaming agent (C) is too large, the foaming rate becomes too high, and the amount of resin 32a in the foamed resin 32 is reduced accordingly, and the effect of improving the loss factor may be reduced.
  • the foamed resin 32 is obtained by foaming 0.1 parts by mass or more and 20 parts by mass or less of the foaming agent (C) with respect to 100 parts by mass of the resin component (A), the effect of improving the loss factor is significantly enhanced, and excellent vibration damping performance is easily ensured.
  • the foamed resin 32 when the foamed resin 32 is obtained by foaming 0.5 parts by mass or more and 5 parts by mass or less of the foaming agent (C) with respect to 100 parts by mass of the resin (A), excellent vibration damping performance is easily ensured.
  • the foaming rate of the foamed resin 32 may be, for example, 1% or more and 70% or less, preferably 3% or more and 50% or less, and more preferably 5% or more and 30% or less. The lower the foaming rate, the smaller the effect of increasing the loss factor. It is considered that the higher the foaming rate, the greater the effect of increasing the loss factor, but if the foaming rate is too high, the amount of the resin 32a becomes relatively small, and the loss factor may actually decrease.
  • the foaming rate can be measured, for example, by an ultrasonic microscope.
  • the bubble ratio of the foamed resin can be measured as follows. That is, a sample (a plate-shaped test piece in which a resin layer is sandwiched between two steel plates) is taken out from an automobile part, and the steel plates are placed in distilled water with the top and bottom facing up. A 10 mm x 10 mm field of view is observed at a portion 1 mm or more away from the edge of the sample (a portion toward the center of the sample) with a reflection-type scanning ultrasonic microscope at an ultrasonic frequency of 50 MHz, and image information of a scanning ultrasonic microscope image of 10 fields of view per sample is collected.
  • the edges of the internal bubbles are binarized so that they can be recognized as circular or elliptical.
  • the area of the binarized circular or elliptical section is regarded as the area of the bubbles observed from above the sample, and the total area ratio of the bubbles is obtained by image analysis, and the average value is obtained for the 10 fields of view, and the average value is regarded as the "bubble ratio".
  • the bubble ratio of the foamed resin may be obtained in the same manner as above. The method for measuring the bubble ratio will be described in more detail in the examples described later.
  • the resin composition of the foamed resin 32 before curing may contain a curing accelerator (E) as an optional component.
  • the curing accelerator (E) may be selected appropriately depending on the type of resin component (A).
  • the amount of the curing accelerator (E) depends on the type of the curing accelerator (E).
  • the foamed resin 32 may also contain other additives.
  • the other additives may be at least one selected from components that contribute to improving vibration damping properties, impact modifiers, adhesion promoters, defoamers, leveling agents, etc. Examples of components that contribute to improving vibration damping properties include rosin-based resins, etc.
  • impact modifiers and adhesion promoters include at least one selected from core-shell type rubber particles, carboxyl-terminated butadiene nitrile rubber (CTBN), thermoplastic elastomers, and acrylic block copolymers, etc.
  • CBN carboxyl-terminated butadiene nitrile rubber
  • the foamed resin 32 includes the bubbles 32b.
  • the loss factor ⁇ 1 of the automobile part 100 can be improved more than when the bubbles 32b are not introduced.
  • the size of the bubbles 32b contained in the foamed resin 32 is 10 ⁇ m or more and 3000 ⁇ m or less
  • the loss factor ⁇ 1 of the automobile part 100 is more easily improved.
  • the size of the bubbles 32b may be 50 ⁇ m or more, 100 ⁇ m or more, 200 ⁇ m or more, or 300 ⁇ m or more, and may be 2500 ⁇ m or less, 2000 ⁇ m or less, or 1500 ⁇ m or less.
  • These lower limit values and upper limit values may be any combination.
  • bubble size refers to the "average circle-equivalent diameter of bubbles" measured by X-ray CT. Specifically, a three-dimensional image of the resin foam is obtained by X-ray CT. From the obtained three-dimensional image, information on a cross section that crosses the half-thickness position of the foam along the surface direction is obtained. Each of the multiple bubbles contained in the cross section is converted into a circle of the same area to determine the circle-equivalent diameter. The number average value of each circle-equivalent diameter is regarded as the "bubble size".
  • X-ray CT measuring device Xradia520Versa (manufactured by ZEISS) Tube voltage: 30 kV Tube current: 0.67mA Magnification ratio: 0.4x (lens magnification) Analysis method: Analysis using Thermo Fisher Scientific's image analysis software "Avizo Inspect"
  • Bubbles are identified by using two functions, Watershed (Separate Object) and Opening, of the image analysis software "Avizo Inspect" in the 3D images obtained by X-ray CT.
  • Watershed is a method for identifying two connected bubbles as two bubbles rather than one. Specifically, a point that is a certain distance away from the bubble's outline is set as the bubble's core, and the area when the core is expanded until it touches the bubble's outline or another core is considered to be a bubble.
  • Opening is a method for identifying each bubble when multiple connected bubbles form a dumbbell shape. Specifically, when a bubble is compressed, the axis of the dumbbell shape disappears, and the two separated bubbles can be identified. The bubble size is then returned to the original size by the amount of compression, and the area that disappeared can be identified as a single bubble from the difference between the images before and after compression.
  • the elastic modulus of the resin constituting the foamed resin 32 (a portion of the foamed resin 32 excluding the bubbles 32b) is within a predetermined range, the effect of improving the loss factor ⁇ 1 by introducing the bubbles 32b tends to be more remarkable.
  • the elastic modulus of the resin at 0 to 30° C. may be 1200 MPa or more and 3000 MPa or less.
  • the elastic modulus may be 1500 MPa or more, 1750 MPa or more, or 2000 MPa or more, and may be 2750 MPa or less, 2500 MPa or less, or 2250 MPa or less.
  • the loss factor ⁇ 1 is more likely to be improved.
  • the "elastic modulus" of the resin refers to that measured by a tensile test.
  • the foamed resin 32 is sandwiched between the first part 10 and the second part 20.
  • the thickness of the foamed resin 32 (thickness of the adhesive layer) is thin enough to allow the above-mentioned welding or mechanical joining (e.g., spot welding).
  • the thickness of the foamed resin 32 may be, for example, 1.0 ⁇ m or more and 1.0 mm or less, or 10 ⁇ m or more and 0.2 mm or less.
  • the automobile part 100 has excellent vibration damping properties. For example, even if the thickness of the foamed resin 32 is 0.50 mm or less, excellent vibration damping performance can be exhibited.
  • the thickness of the foamed resin 32 may be 0.10 mm or more and 0.50 mm or less.
  • the thickness may be 0.15 mm or more, 0.20 mm or more, or 0.25 mm or more, and may be 0.45 mm or less, 0.40 mm or less, or 0.35 mm or less. These lower and upper limits may be any combination.
  • the foamed resin 32 does not have to be present in the entire joint 30.
  • a part of the first part 10 and a part of the second part 20 are overlapped, and the area ratio of the foamed resin 32 in the entire overlapping part of the first part 10 and the second part 20 may be 50% or more, 55% or more, 60% or more, 65% or more, 70% or more, 75% or more, or 80% or more.
  • the upper limit of the area ratio of the foamed resin 32 depends on the area ratio of the spot welded part 31.
  • a resin that does not contain air bubbles may be used in combination with the welded part 31, the mechanical joint, and the foamed resin 32.
  • Loss factor ⁇ 1 According to the inventor's new findings, the effect of improving the loss factor ⁇ 1 by introducing the air bubbles 32b into the foamed resin 32 becomes remarkable, especially when the loss factor ⁇ 1 of the automobile part 100 is within a certain range. In a region where the loss factor ⁇ 1 of the automobile part 100 exceeds a certain value, the loss factor ⁇ 1 of the automobile part 100 is more likely to be increased when the foamed resin 32 does not contain air bubbles than when the foamed resin 32 contains air bubbles 32b.
  • the loss factor ⁇ 1 of the automobile part 100 exceeds a certain value, the advantageous effect of introducing the air bubbles 32b into the foamed resin 32 is lost, and rather, there are cases where the automobile part 100 has better performance without introducing the air bubbles 32b.
  • the loss factor ⁇ 1 of the automobile part 100 is below a certain value, the loss factor is difficult to improve even if the air bubbles 32b are introduced.
  • the effect of improving the loss factor ⁇ 1 by introducing the bubbles 32b into the foamed resin 32 becomes significant when the automobile component 100 has a loss factor ⁇ 1 of 0.02 or more and 0.25 or less.
  • the loss factor ⁇ 1 of the automobile component 100 when the loss factor ⁇ 1 of the automobile component 100 is 0.10 or more and 0.25 or less, the effect of introducing the bubbles is more excellent.
  • the loss factor ⁇ 1 of the automobile component 100 may be 0.03 or more, 0.04 or more, 0.05 or more, 0.06 or more, 0.07 or more, 0.08 or more, 0.09 or more, 0.10 or more, 0.11 or more, or 0.12 or more, and may be 0.24 or less, 0.23 or less, 0.22 or less, 0.21 or less, or 0.20 or less.
  • the effect of improving the loss factor ⁇ 1 of the automobile part 100 by introducing the air bubbles 32b is likely to be enhanced.
  • the amount of components not incorporated into the crosslinked structure of the resin increases, the crosslink density of the cured product decreases, and the elastic modulus decreases.
  • the decrease in the elastic modulus of the resin increases the density of the strain energy concentrated at the interface between the voids caused by the air bubbles and the resin, thereby improving the loss factor and further enhancing the vibration damping effect.
  • the elastic modulus further decreases, making it difficult to maintain the shape, and it becomes impossible to introduce the air bubbles 32b into the foamed resin 32, making it difficult to contribute to an increase in the loss factor.
  • the loss factor of the resin constituting the foamed resin 32 itself is 0.02 or more and 0.25 or less, the effect of increasing the loss factor by introducing the air bubbles is remarkable.
  • the loss factor of the resin itself When the loss factor of the resin itself is less than 0.02, the elastic modulus is high and the density of the strain energy concentrated at the interface between the voids caused by the air bubbles and the resin is small, so the effect of increasing the loss factor by introducing air bubbles is small.
  • the loss factor of the resin itself exceeds 0.25, the elastic modulus is very low, so it becomes difficult to maintain the shape, and air bubbles cannot be introduced into the cured resin, so the effect of increasing the loss factor is small.
  • the "loss factor ⁇ 1 of an automobile part” refers to a loss factor measured by dynamic mechanical analysis (DMA) in a three-point bending mode at a measurement frequency of 10 Hz, and is the largest among the loss factors between 0°C and 30°C.
  • DMA is a method for measuring the mechanical properties of a sample by applying a time-varying strain or stress (vibration) to the sample and measuring the resulting stress or strain.
  • Vibration time-varying strain or stress
  • the loss factor ⁇ 1 of an automobile part can be measured by placing a sample obtained by cutting out a part of the automobile part in a predetermined position of an apparatus for measuring the loss factor.
  • the size of the sample is not particularly limited as long as the loss factor can be measured. For example, a sample having a width of 10 mm and a length of 20 to 55 mm is cut out from the automobile part using a cutter, and the loss factor is measured. The desirable size is 10 mm wide and 40 mm long.
  • the sample does not include the mechanical joint. That is, a portion consisting of the first part, the second part, and the foamed resin arranged between them is cut out from the joint of the automobile part, and the loss factor ⁇ 1 is measured using this as a sample.
  • a DMA7100 manufactured by Hitachi High-Tech Science Corporation is used as an apparatus for measuring the loss factor.
  • the measurement conditions are two-cycle heating, in which the temperature is raised from -100°C to 200°C at 2°C/min, then the temperature is lowered from 200°C to -100°C, and the temperature is raised again from -100°C to 200°C at 2°C/min, the measurement frequency is set to 10Hz, and the loss factor at the second heating cycle is measured in three-point bending mode.
  • the "loss factor of the resin (cured resin) itself constituting the foamed resin” In this case, a cured resin not containing air bubbles may be separately prepared and the loss factor may be measured in the same manner.
  • the first plate-like member and the second plate-like member are peeled off to prepare the cured resin for measuring the loss factor.
  • the loss factor of a composite consisting of the first plate-like member, the second plate-like member, and the cured resin sandwiched between them may be substantially the same as the loss factor of the cured resin regardless of the presence or absence of the first plate-like member and the second plate-like member (the influence of the plate itself on the loss factor is small).
  • the loss factor of the composite itself may be measured without peeling off the first plate-like member and the second plate-like member, and this may be regarded as the loss factor of the cured resin itself.
  • the manufacturing method of the automobile part 100 including the first part 10 and the second part 20 may include applying a resin composition to one or both of a part of the first part 10 and a part of the second part 20 (application step), adhering the first part 10 and the second part 20 via the resin composition (adhesion step), foaming the resin composition (foaming step), and performing one or both of welding and mechanical joining on the adhesion part between the first part 10 and the second part 20 (joining step).
  • a resin composition is applied to one or both of a portion of the first component 10 and a portion of the second component 20.
  • the resin composition may contain, for example, the above-mentioned resin component (A), curing agent (B), and foaming agent (C).
  • the method of applying the resin composition is not particularly limited. For example, an applicator or the like may be used.
  • the application area and application amount may be appropriately determined depending on the area, thickness, and the like of the foamed resin 32 to be finally obtained.
  • the first component 10 and the second component 20 are adhered to each other via the above-mentioned resin composition.
  • the first component 10 and the second component 20 can be adhered to each other by overlapping the first component 10 and the second component 20 with the resin composition therebetween and curing the resin composition by heating or the like. At this time, a foaming step described later may be performed.
  • the heating means and heating temperature are not particularly limited.
  • the resin composition is foamed. Specifically, the resin composition is heated, etc., to generate bubbles due to the action of the foaming agent (C) contained in the resin composition.
  • the foaming step may be performed simultaneously with the adhesion step, or may be performed at a different time.
  • the joining process In the joining process, one or both of welding and mechanical joining are performed on the bonding portion between the first component 10 and the second component 20.
  • the "bonding portion" refers to a portion including the portion to which the resin composition is applied and which will ultimately become the bonding portion 30.
  • the joining process may be performed after the curing or foaming of the resin composition, for example, as shown in FIG. 6A, or may be performed before that, as shown in FIG. 6B.
  • the conditions for welding or mechanical joining are not particularly limited. The types of welding or mechanical joining are as described above.
  • the two steel plates were bonded together via the adhesive by heating and pressing them with a hot press machine.
  • the amount of foaming agent (C) contained in the adhesive was changed to prepare a plurality of sandwich steel plates with different foam ratios in the adhesive resin layer. Specifically, a sandwich steel plate A with a foam ratio of 0%, a sandwich steel plate B with a foam ratio of 6%, and a sandwich steel plate C with a foam ratio of 20% were obtained.
  • the air bubble ratio of the adhesive resin layer in each sandwich steel plate was measured as follows.
  • a 30 mm x 250 mm plate-shaped test piece (sample) was prepared in which a resin layer of 300 ⁇ m ⁇ 30 ⁇ m with different air bubble ratios was sandwiched between two 0.8 mmt steel plates, and the steel plates were placed in distilled water with the top and bottom facing up.
  • a 10 mm x 10 mm field of view was observed from above with a reflection-type scanning ultrasonic microscope at an ultrasonic frequency of 50 MHz at the center side part 1 mm or more away from the edge of the sample, and image information of the scanning ultrasonic microscope image of five fields of view was collected.
  • the area of the binarized circular or elliptical section was regarded as the area of the bubbles observed from above the sample, and the total area ratio of the bubbles was determined by image analysis, and the average value was determined in the 10 fields of view, and this average value was regarded as the "bubble ratio" (if a field of view of 10 mm x 10 mm cannot be secured due to the size of the sample, the "bubble ratio" can be determined by the above image analysis from the observation results in an area of 1000 mm2 in total in all fields of view).
  • the reason why the sample was observed from both sides with an ultrasonic microscope as described above is that it is considered that the image of the entire resin layer of 300 ⁇ m thickness could not be obtained because ultrasonic waves are difficult to transmit through the resin and are attenuated.
  • the bubble ratio can be considered to be uniform in the resin thickness direction, the bubble ratio can be determined by measuring with the above observation method even if the resin thickness is 300 ⁇ m or more.
  • the influence of the chemical components and thickness of the steel plate can be substantially ignored, and substantially the same results can be obtained at least up to a steel plate thickness of 2.0 mm.
  • the loss factor is improved by including air bubbles in the adhesive resin layer.
  • a double hat-shaped frame (plate thickness: 1.0 mm) was bonded to both ends of a flat panel (side: 990 mm, thickness: 1.0 mm) with an adhesive resin layer, and spot welding (spot welding interval: 30 mm) was performed on the bonded portion.
  • the vibration damping was evaluated. Specifically, vibration was applied to one end face of one frame, while the other end faces of the frame were fixed, and the magnitude of the radiation sound from the panel was evaluated by simulation.
  • the noise level when the application area of the adhesive without air bubbles is 100% was set as the standard (100%), and the extent to which the noise level was reduced when part or all of the adhesive without air bubbles was replaced with an adhesive containing air bubbles was evaluated.
  • Nastran of MSC Software was used as the analysis software.
  • FIGS. 10A and 10B show the relationship between the application area ratio of the adhesive resin layer containing air bubbles ([application area of adhesive resin layer containing air bubbles]/[total application area of adhesive]) and the panel radiation sound.
  • FIG. 10A shows the relationship between the area ratio of the adhesive containing air bubbles and the adhesive without air bubbles and the maximum panel radiation sound ratio (relative to the maximum panel radiation sound when 100% of the adhesive without air bubbles is applied as 100%)
  • FIG. 10B shows the relationship between the area ratio of the adhesive containing air bubbles and the adhesive without air bubbles and the average panel radiation sound ratio (relative to the average panel radiation sound when 100% of the adhesive without air bubbles is applied as 100%).
  • the panel radiation sound becomes smaller as the application area of the adhesive resin layer containing air bubbles increases, and it can be seen that the maximum panel radiation sound is particularly stable when the area ratio of the adhesive resin layer containing air bubbles is 50% or more.
  • a form in which foamed resin is combined at the joint of an automobile part having a double hat member as a skeleton and a panel is exemplified, but the technology of the present disclosure is not limited to this form. It is believed that the predetermined effect can be achieved by adopting the technology of the present disclosure even when joining skeletons to skeletons or panels to panels.
  • a form in which spot welding is used at the joint of an automobile part is exemplified, but the technology of the present disclosure is not limited to this form. It is believed that a part with excellent vibration damping properties can be obtained even when the joint is formed by welding or mechanical joining other than spot welding by combining the welding or mechanical joining with foamed resin.
  • a form in which an automobile part is formed using steel plate is exemplified, but the material and shape of the automobile part are not limited to this.
  • foamed resin in conjunction with welding and/or mechanical joining at the joints between the frame and the panel, and it is particularly preferable to use foamed resin in conjunction with welding (particularly spot welding) at the joints between the steel frame and the steel panel.
  • An automobile part includes a first part, a second part, and a joint portion that joins the first part and the second part.
  • the joint includes one or both of a weld and a mechanical joint, and a foamed resin that bonds the first component and the second component.
  • a composite having a foamed resin between two steel plates is prepared using an epoxy resin (YD-127 manufactured by Nippon Steel Chemical & Material Co., Ltd.) or a copolymer polyester composition (Pylon (registered trademark) UR manufactured by Toyobo MC Co., Ltd.) as the resin (A), but the type of resin (A) applicable to the technology of the present disclosure is not limited to these.
  • compositions shown in Tables 1 to 4 below those using DICY as the curing agent (B) were prepared as follows. First, a part of the resin (A) was set aside, and the foaming agent (C) and foaming assistant (D), the curing agent (B) (product name: DICY15), and the curing accelerator (E) (product name: DCMU) were uniformly dispersed using a three-roll mill to prepare composition X. All of the components shown in Tables 1 to 4 below, except for those used in the preparation of composition X, were weighed into a glass flask and mixed with heating at 150°C to obtain a uniform master batch.
  • composition of the obtained resin composition is as shown in Tables 1 to 4 below.
  • composition of the obtained resin composition is as shown in Tables 1 to 4 below.
  • the loss factor ⁇ 1 of the obtained composite was measured.
  • the measurement method of the loss factor ⁇ 1 was as described in the embodiment (the loss factor is the largest loss factor measured in a three-point bending mode at a measurement frequency of 10 Hz by dynamic viscoelasticity measurement at a temperature between 0°C and 30°C).
  • Tables 1 to 4 show the composition of each resin composition, the curing temperature, the curing time, the presence or absence of air bubbles, the loss factor ⁇ 1 when air bubbles are present, and the loss factor ⁇ 2 when air bubbles are not present.
  • "Kane Ace MX-154" in Tables 1 to 4 is a master batch in which 40% core-shell rubber is dispersed in 60% epoxy resin.
  • the values in parentheses shown for the examples using "Kane Ace MX-154" are overall values obtained by dividing Kane Ace MX-154 into epoxy resin and core-shell rubber, and assuming resin (A) to be 100 parts by mass.
  • the loss factor ⁇ 1 of the composite when air bubbles are included in the cured resin may be significantly improved compared to the loss factor ⁇ 2 of the composite when air bubbles are not included. It is considered that the inclusion of air bubbles in the cured resin concentrates strain energy at the interface between the voids of the air bubbles and the resin when the composite vibrates, thereby enhancing the vibration damping effect. Such an effect of introducing air bubbles is particularly noticeable when the loss factor ⁇ 1 of the composite is in the range of 0.02 to 0.25.
  • the loss factor ⁇ 1 of the composite exceeds 0.25, the loss factor ⁇ 2 when air bubbles are not included is larger than the loss factor ⁇ 1 when air bubbles are included in the cured resin, that is, it can be seen that the effect of introducing air bubbles may be lost.
  • the loss factor ⁇ 1 in the region where the loss factor ⁇ 1 is less than 0.02, the loss factor ⁇ 1 can be improved by including air bubbles in the cured resin, but the effect is small.
  • the reason why the introduction of air bubbles does not contribute to the improvement of the loss factor ⁇ 1 in the region where the loss factor ⁇ 1 exceeds 0.25 is considered to be, for example, as follows: That is, when the loss factor is high and the elastic modulus is low (soft), the air bubbles escape together with the resin during foaming and curing, so that the air bubbles are not introduced into the resin in an appropriate form, and further, the amount of resin is reduced.
  • the reason why the effect of improving the loss factor ⁇ 1 by introducing air bubbles decreases in a region where the loss factor ⁇ 1 is below 0.02 is, for example, considered to be as follows: That is, even if air bubbles are introduced into a resin having a small loss factor and a high elastic modulus (hard), when the composite vibrates, concentration of strain energy is unlikely to occur at the interface between the voids caused by the air bubbles and the resin, and it is possible that almost no vibration damping effect is obtained.
  • the loss factor ⁇ 1 increases with increasing amount of foaming agent added up to 5 parts by mass relative to 100 parts by mass of resin. It is believed that this is because the increase in the amount of foaming agent added increases the bubble ratio in the cured resin, and air bubbles are appropriately and abundantly introduced.
  • the amount of foaming agent added is 10 parts by mass or 20 parts by mass
  • the loss modulus ⁇ 1 tends to be smaller than when the amount of foaming agent added is 5 parts by mass.
  • the foaming agent is excessive, the foaming ratio becomes excessive, and the amount of resin decreases accordingly, which is believed to be the reason for the decrease in the loss factor.
  • the foaming agent is excessive, in some cases, air bubbles may escape between the plates during the curing of the resin, and the air bubbles may not be properly introduced.

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PCT/JP2024/013080 2023-05-09 2024-03-29 自動車部品及び自動車部品の製造方法 WO2024232185A1 (ja)

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS6097842A (ja) * 1983-11-02 1985-05-31 日東電工株式会社 金属板の制振防音方法
JPS628853U (enrdf_load_stackoverflow) * 1985-07-03 1987-01-20
JPH1081142A (ja) * 1996-09-11 1998-03-31 Tokai Rubber Ind Ltd 車両用制振吸音部材
JP2002028934A (ja) * 2000-04-07 2002-01-29 Pacific Ind Co Ltd エンジンカバーおよびその製造方法
JP2006316788A (ja) * 2006-05-01 2006-11-24 Tokai Rubber Ind Ltd 低吸水・低吸油性防音材
JP2009090522A (ja) * 2007-10-05 2009-04-30 Kobe Steel Ltd 複合板および複合成形体

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS6097842A (ja) * 1983-11-02 1985-05-31 日東電工株式会社 金属板の制振防音方法
JPS628853U (enrdf_load_stackoverflow) * 1985-07-03 1987-01-20
JPH1081142A (ja) * 1996-09-11 1998-03-31 Tokai Rubber Ind Ltd 車両用制振吸音部材
JP2002028934A (ja) * 2000-04-07 2002-01-29 Pacific Ind Co Ltd エンジンカバーおよびその製造方法
JP2006316788A (ja) * 2006-05-01 2006-11-24 Tokai Rubber Ind Ltd 低吸水・低吸油性防音材
JP2009090522A (ja) * 2007-10-05 2009-04-30 Kobe Steel Ltd 複合板および複合成形体

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