JP2007196545A - Metal-resin composite structure and its manufacturing method - Google Patents
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本発明は、金属樹脂複合構造体及びその製造方法に係り、更に詳細には、金属板と繊維強化樹脂組成物が発泡樹脂組成物を介して接合され、金属板／発泡樹脂組成物／繊維強化樹脂の３層構造をなす金属樹脂複合構造体及びその製造方法に関する。 The present invention relates to a metal resin composite structure and a method for producing the same, and more specifically, a metal plate and a fiber reinforced resin composition are joined via a foamed resin composition, and the metal plate / foamed resin composition / fiber reinforced The present invention relates to a metal resin composite structure having a resin three-layer structure and a method for producing the same.
最近、土木・建築物、自動車、船舶などの補強部材として、金属と繊維強化樹脂組成物を接合した複合材料が普及してきている。 Recently, composite materials obtained by joining a metal and a fiber reinforced resin composition have become widespread as reinforcing members for civil engineering / buildings, automobiles, ships, and the like.
例えば、軽金属と繊維強化組成物を接着剤で一体化し、耐食性に優れ、強度・衝撃エネルギー吸収性能を向上させた軽金属／ＣＦＲＰハイブリッド構造材が提案されている（特許文献１参照）。
また、鉄やアルミニウムと繊維強化樹脂組成物を両面粘着テープなどの粘着材で粘着接合した輸送機器用バンパーのエネルギー吸収部材が提案されている（特許文献２参照）。
更に、アルミニウム材と繊維強化樹脂組成物をボルト接合で一体化し、自動車等の衝撃エネルギー吸収特性を向上させ、且つその変形量を小さくする自動車用のドア・サイドビームやバンパービーム等に使用される複合構造の衝撃吸収用部材が提案されている（特許文献３参照）。
更にまた、金属と繊維強化樹脂組成物とをボルト接合した場合、接合部で応力集中が発生して金属材料と繊維強化樹脂組成物の間の応力伝達が非効率的であるという理由から、接着剤で接着接合した衝撃エネルギー吸収部材が提案されている（特許文献４参照）。
In addition, an energy absorbing member for a bumper for transportation equipment in which iron or aluminum and a fiber reinforced resin composition are adhesively bonded with an adhesive such as a double-sided adhesive tape has been proposed (see Patent Document 2).
In addition, aluminum materials and fiber reinforced resin compositions are integrated by bolt joints to improve impact energy absorption characteristics of automobiles, etc., and to be used for automobile doors, side beams, bumper beams, etc. A composite structure shock absorbing member has been proposed (see Patent Document 3).
Furthermore, when a metal and a fiber reinforced resin composition are bolted together, stress concentration occurs at the joint, and the stress transmission between the metal material and the fiber reinforced resin composition is inefficient. An impact energy absorbing member adhesively bonded with an agent has been proposed (see Patent Document 4).
しかしながら、金属と繊維強化樹脂との接合に、熱硬化性接着剤を用いて両者を接着接合した場合には、金属材料と繊維強化樹脂との線膨張係数の差により、熱をかけてから冷却した際、硬化時に貼り付け部材がそってしまい、備品の形状が変化してしまうという問題が生じていた。
これを防ぐために、常温硬化性接着剤を使用すると、硬化までに長時間放置する必要があり、量産製品の製造ラインに適用することが難しかった。
However, when both a metal and fiber reinforced resin are bonded using a thermosetting adhesive, the metal material and the fiber reinforced resin are cooled after being heated due to the difference in coefficient of linear expansion between the metal material and the fiber reinforced resin. When it did, the sticking member will bend at the time of hardening, and the problem that the shape of fixtures changed had arisen.
In order to prevent this, if a room temperature curable adhesive is used, it must be left for a long time before curing, and it has been difficult to apply it to a production line for mass-produced products.
また、接着剤を用いた接合方法においては、作業工程に事前混合、塗布、硬化という時間とコストがかかるという問題があった。
即ち、液固状の接着剤では粘性が高いため、短時間に広い面積への塗布に多大な時間がかかり、液状の接着剤では作業環境が汚れる、厚み管理が難しい等、大量生産やライン導入には不適な側面があった。
Moreover, in the joining method using an adhesive agent, there is a problem that the work process takes time and cost of premixing, coating, and curing.
In other words, liquid-solid adhesives have high viscosity, so it takes a lot of time to apply over a large area in a short time, and liquid adhesives contaminate the work environment, making it difficult to control thickness, etc. There were unsuitable aspects.
更に、粘着テープでの接合は簡便であるが、例えば６０ｋｍで走行する車にかかる衝撃には耐えられず、衝撃を受けたときに、接着面が剥がれたり切れたりしてしまうという問題があった。 Furthermore, although joining with an adhesive tape is simple, there is a problem that, for example, it cannot withstand an impact applied to a car traveling at 60 km, and the adhesive surface is peeled off or cut when subjected to the impact. .
更にまた、金属のレインフォースを溶接して補強すると、重量が増加してしまい、輸送機器などに使用した際は燃費が低下するという問題があった。 Furthermore, when metal reinforcement is reinforced by welding, the weight increases, and there is a problem that the fuel consumption decreases when used for transportation equipment.
本発明は、このような従来技術の有する課題及び新たな知見に鑑みてなされたものであり、その目的とするところは、加熱硬化後のそり発生を抑制し、短期間で製造でき、使用時の補強効果が十分な金属樹脂複合構造体及びその製造方法を提供することにある。 The present invention has been made in view of the problems and new knowledge of the prior art, and the object of the present invention is to suppress the occurrence of warping after heat-curing, and can be manufactured in a short period of time. An object of the present invention is to provide a metal resin composite structure having a sufficient reinforcing effect and a method for producing the same.
本発明者らは、上記目的を達成すべく鋭意検討を重ねた結果、金属板と繊維強化樹脂組成物を、エポキシ樹脂を主成分とし、炭素繊維やガラス繊維、エポキシ樹脂用熱活性型硬化剤、エポキシ樹脂用熱活性型硬化触媒、熱分解型有機系発泡剤、無機系充填剤、気泡防止剤を所定量含めた発泡樹脂組成物を用いて接合することにより、上記課題が解決できることを見出し、本発明を完成するに至った。 As a result of intensive studies to achieve the above object, the present inventors have made a metal plate and a fiber reinforced resin composition mainly composed of an epoxy resin, carbon fiber, glass fiber, and a thermally activated curing agent for epoxy resin. And found that the above problems can be solved by joining with a foamed resin composition containing a predetermined amount of a thermally activated curing catalyst for epoxy resin, a pyrolytic organic foaming agent, an inorganic filler, and an anti-bubble agent. The present invention has been completed.
即ち、本発明の金属樹脂複合構造体は、金属板と繊維強化樹脂組成物が、発泡樹脂組成物を介して接合されている３層の金属樹脂複合構造体であって、
上記発泡樹脂組成物は、エポキシ樹脂１００重量部に対して、繊維長１〜３ｍｍ、繊維径５〜２０μｍの炭素繊維及び／又はガラス繊維を２〜３０重量部、エポキシ樹脂用熱活性型硬化剤を３〜３０重量部、エポキシ樹脂用熱活性型硬化触媒を０．５〜１５重量部、熱分解型有機系発泡剤を０．５〜１５重量部、アスペクト比が２：１以上の無機系充填剤を５０〜２００重量部、気泡防止剤を２〜１５重量部、含んで成ることを特徴とする。
That is, the metal resin composite structure of the present invention is a three-layer metal resin composite structure in which a metal plate and a fiber reinforced resin composition are joined via a foamed resin composition,
The foamed resin composition comprises 2 to 30 parts by weight of a carbon fiber and / or glass fiber having a fiber length of 1 to 3 mm and a fiber diameter of 5 to 20 μm with respect to 100 parts by weight of the epoxy resin. 3 to 30 parts by weight, 0.5 to 15 parts by weight of thermally activated curing catalyst for epoxy resin, 0.5 to 15 parts by weight of thermally decomposable organic foaming agent, and an inorganic system having an aspect ratio of 2: 1 or more It comprises 50 to 200 parts by weight of a filler and 2 to 15 parts by weight of an anti-bubble agent.
また、本発明の自動車用車体構造は、上記金属樹脂複合構造体を用いた自動車用車体構造であって、該金属板が車体鋼板であることを特徴とする。 The vehicle body structure of the present invention is a vehicle body structure using the metal resin composite structure, wherein the metal plate is a vehicle body steel plate.
更に、本発明の金属樹脂複合構造体の製造方法は、上記金属樹脂複合構造体を製造するに当たり、金属板又は繊維強化樹脂組成物の上に発泡体樹脂組成物を配設し、更に繊維強化樹脂組成物又は金属板を配設した後に、該発泡樹脂組成物を発泡させ硬化させることを特徴とする。 Furthermore, in the method for producing a metal resin composite structure according to the present invention, in producing the metal resin composite structure, a foam resin composition is disposed on a metal plate or a fiber reinforced resin composition, and further fiber reinforced. After the resin composition or the metal plate is disposed, the foamed resin composition is foamed and cured.
本発明によれば、金属板と繊維強化樹脂組成物を、エポキシ樹脂を主成分とし、炭素繊維やガラス繊維、エポキシ樹脂用熱活性型硬化剤、エポキシ樹脂用熱活性型硬化触媒、熱分解型有機系発泡剤、無機系充填剤、気泡防止剤を所定量含めた発泡樹脂組成物を用いて接合することとしたため、加熱硬化後のそり発生を抑制し、短期間で製造でき、使用時の補強効果が十分な金属樹脂複合構造体及びその製造方法を提供できる。 According to the present invention, the metal plate and the fiber reinforced resin composition are mainly composed of epoxy resin, carbon fiber or glass fiber, thermally activated curing agent for epoxy resin, thermally activated curing catalyst for epoxy resin, thermal decomposition type. Since it was decided to join using a foamed resin composition containing a predetermined amount of an organic foaming agent, inorganic filler, and anti-bubble agent, it can be produced in a short period of time by suppressing warpage after heat curing. A metal-resin composite structure having a sufficient reinforcing effect and a method for producing the same can be provided.
以下、本発明の金属樹脂複合構造体について説明する。なお、本明細書において、「％」は特記しない限り、質量百分率を表わすものとする。 Hereinafter, the metal resin composite structure of the present invention will be described. In the present specification, “%” represents mass percentage unless otherwise specified.
本発明の金属樹脂複合構造体は、金属板と繊維強化樹脂組成物が、発泡樹脂組成物を介して接合されている３層構造をなす。
また、上記発泡樹脂組成物は、エポキシ系の発泡樹脂組成物であり、以下（ａ）〜（ｇ）の材料、
（ａ）エポキシ樹脂
エポキシ樹脂１００重量部に対して、
（ｂ）繊維長１〜３ｍｍ、繊維径５〜２０μｍの炭素繊維、ガラス繊維のいずれか一方又は双方を２〜３０重量部、
（ｃ）エポキシ樹脂用熱活性型硬化剤を３〜３０重量部、
（ｄ）エポキシ樹脂用熱活性型硬化触媒を０．５〜１５重量部、
（ｅ）熱分解型有機系発泡剤を０．５〜１５重量部、
（ｆ）アスペクト比が２：１以上の無機系充填剤を５０〜２００重量部、
（ｇ）気泡防止剤を２〜１５重量部、
を含んで成る。
The metal resin composite structure of the present invention has a three-layer structure in which a metal plate and a fiber reinforced resin composition are joined via a foamed resin composition.
The foamed resin composition is an epoxy-based foamed resin composition, and the following materials (a) to (g):
(A) Epoxy resin For 100 parts by weight of epoxy resin,
(B) 2 to 30 parts by weight of one or both of carbon fiber and glass fiber having a fiber length of 1 to 3 mm and a fiber diameter of 5 to 20 μm,
(C) 3 to 30 parts by weight of a thermally activated curing agent for epoxy resin,
(D) 0.5 to 15 parts by weight of a thermally activated curing catalyst for epoxy resin,
(E) 0.5 to 15 parts by weight of a pyrolytic organic foaming agent,
(F) 50 to 200 parts by weight of an inorganic filler having an aspect ratio of 2: 1 or more,
(G) 2 to 15 parts by weight of an anti-bubble agent,
Comprising.
接合部に用いる発泡樹脂組成物を上記構成とすることで、十分な発泡反応が起こり、衝撃吸収性の高い発泡体層が得られる。
例えば、図１に示すような、金属板Ａ／発泡樹脂組成物Ｃ／繊維強化樹脂組成物Ｂの３層構造体となる。
By setting the foamed resin composition used for the joint part to the above-described configuration, a sufficient foaming reaction occurs, and a foam layer having high impact absorption is obtained.
For example, a three-layer structure of metal plate A / foamed resin composition C / fiber reinforced resin composition B as shown in FIG.
ここで、エポキシ樹脂（ａ）は、接着性、機械的な性質、電気的性質、化学的性質、寸法精度などに優れているという観点から、ビスフェノール型であることが好ましい。
また、上記無機系充填剤（ｆ）は、代表的には、針状、柱状、板状などの形状のものを用いることができる。
Here, the epoxy resin (a) is preferably a bisphenol type from the viewpoint of excellent adhesion, mechanical properties, electrical properties, chemical properties, dimensional accuracy, and the like.
Moreover, the said inorganic type filler (f) can use the thing of shapes, such as needle shape, column shape, and plate shape, typically.
更に、本発明の金属樹脂複合構造体は、上記発泡樹脂組成物の板厚に対して、上記金属板の板厚は０．０２〜０．５倍、上記繊維強化樹脂組成物の板厚は０．０２〜１．０倍であることが好ましい。 Further, in the metal resin composite structure of the present invention, the plate thickness of the metal plate is 0.02 to 0.5 times the plate thickness of the foamed resin composition, and the plate thickness of the fiber reinforced resin composition is It is preferable that it is 0.02-1.0 times.
上記金属板の板厚が０．０２倍よりも小さければ、発泡体に対する接着強度が低下してしまい、補強効果を得るための十分な強度が保持されないことがある。また、０．５倍より大きければ、衝撃エネルギー吸収特性を発揮することができない。例えば、金属板平面への衝撃により大きな荷重がかかったとき、その衝撃で金属板から繊維強化樹脂組成物が剥がれてしまい、衝撃を受け止めるのが金属板単体となってしまうことがある。 If the thickness of the metal plate is smaller than 0.02 times, the adhesive strength to the foam is lowered, and sufficient strength for obtaining a reinforcing effect may not be maintained. Moreover, if it is larger than 0.5 times, the impact energy absorption characteristic cannot be exhibited. For example, when a large load is applied due to an impact on the flat surface of the metal plate, the fiber reinforced resin composition may be peeled off from the metal plate by the impact, and the metal plate alone may receive the impact.
上記繊維強化樹脂組成物の板厚が０．０２倍よりも小さければ、補強効果を得るために十分な強度が得られないことがある。１．０倍より大きければ、強度は得られるが、より多くの成形時間とコストがかかり、値段と性能が見合わなくなる。 If the plate thickness of the fiber reinforced resin composition is smaller than 0.02 times, sufficient strength may not be obtained to obtain a reinforcing effect. If it is larger than 1.0 times, the strength can be obtained, but more molding time and cost are required, and the price and performance are not matched.
また、上記発泡樹脂組成物は、比重が０．３〜０．８ｇ／ｃｍ３であることが好ましい。
比重が０．３ｇ／ｃｍ３より小さいと、複合構造体に力が加わって曲げられたときに十分な強度が得られないことがある。０．８ｇ／ ｃｍ３より大きいと、軽量化効果が得られないことがある。
The foamed resin composition preferably has a specific gravity of 0.3 to 0.8 g / cm 3 .
If the specific gravity is less than 0.3 g / cm 3 , sufficient strength may not be obtained when the composite structure is bent by applying force. If it is greater than 0.8 g / cm 3 , the lightening effect may not be obtained.
更に、上記発泡樹脂組成物は、衝撃剪断強度が高いことが好ましく、代表的には、金属板や繊維強化樹脂組成物との接合剪断強度が０．１〜１０ＭＰａの範囲内であることが良い。 Further, the foamed resin composition preferably has a high impact shear strength, and typically has a joining shear strength with a metal plate or a fiber reinforced resin composition in the range of 0.1 to 10 MPa. .
上記金属板としては、特にその材質は限定されないが、代表的には、鋼板、アルミニウム板、チタニウム板など、又はこれらを任意に組合わせた合金等を使用できる。特に、アルミニウム板の線膨張係数は、２３×１０−６ｋ−１と、鋼板の１０×１０−６ｋ−１に比べて大きく、加熱時に伸びる割合も大きいため、発泡樹脂組成物使用によるそりを防ぐ効果を高めることができる。 Although the material in particular is not limited as said metal plate, Typically, a steel plate, an aluminum plate, a titanium plate etc. or the alloy etc. which combined these arbitrarily can be used. In particular, the linear expansion coefficient of the aluminum plate, a 23 × 10 -6 k -1, 10 × 10 -6 k -1 greater than that of steel, for larger proportion of extending the time of heating, warping due to foaming resin composition used The effect which prevents can be heightened.
また、上記金属板には、比重が１〜９ｇ／ｃｍ３の範囲内の金属を使用するのが良い。このときは、金属樹脂複合構造体を軽量化でき、輸送機器に用いた場合には燃料消費を抑えることができるとともに、取り付け／組み立て作業時の取扱い性が容易となるので有効である。 Moreover, it is good to use the metal in the range whose specific gravity is 1-9 g / cm < 3 > for the said metal plate. In this case, the metal-resin composite structure can be reduced in weight, and when used in transportation equipment, fuel consumption can be suppressed, and handling at the time of attachment / assembly is facilitated, which is effective.
上記繊維強化樹脂組成物は、補強繊維成分とマトリックス樹脂成分とから構成することができる。
ここで、補強繊維成分としては、例えば、（１）炭素繊維、黒鉛繊維、炭化ケイ素繊維、アルミナ繊維、ボロン繊維、タングステンカーバイド繊維、ガラス繊維等の無機繊維、（２）全芳香族ポリエステル繊維（高強力ポリアリレート繊維を含む）、ポリエチレンテレフタレート繊維、ポリエチレン−２，６−ナフタレート繊維等のポリエステル繊維、ポリパラフェニレンベンゾビスオキサゾール繊維（以下ＰＢＯ繊維）、パラ型アラミド繊維、メタ型アラミド繊維、ポリアセタール繊維、超高分子量ポリエチレン繊維等の耐熱性合成繊維、ポリアクリロニトリル繊維等の有機繊維、及び（３）セルロース系繊維等の天然繊維、を使用できる。
これら補強繊維成分であれば特に限定されないが、鋼性・強度に優れることから炭素繊維が好ましい。また、炭素繊維の中でも更に構造材としての強度と弾性率のバランスが良い、強度３．５〜１０ＧＰａの範囲内、弾性率２００〜５００ＧＰａの範囲内のポリアクリルニトリル系の炭素繊維を使用するのが特に好ましい。
The fiber reinforced resin composition can be composed of a reinforcing fiber component and a matrix resin component.
Here, as the reinforcing fiber component, for example, (1) inorganic fiber such as carbon fiber, graphite fiber, silicon carbide fiber, alumina fiber, boron fiber, tungsten carbide fiber, glass fiber, (2) wholly aromatic polyester fiber ( High-strength polyarylate fibers), polyester fibers such as polyethylene terephthalate fibers, polyethylene-2,6-naphthalate fibers, polyparaphenylene benzobisoxazole fibers (hereinafter PBO fibers), para-type aramid fibers, meta-type aramid fibers, polyacetals Fibers, heat resistant synthetic fibers such as ultra high molecular weight polyethylene fibers, organic fibers such as polyacrylonitrile fibers, and (3) natural fibers such as cellulosic fibers can be used.
Although it will not specifically limit if it is these reinforcement fiber components, Since it is excellent in steel property and intensity | strength, carbon fiber is preferable. In addition, among the carbon fibers, polyacrylonitrile-based carbon fibers having a good balance between strength and elastic modulus as a structural material, strength in the range of 3.5 to 10 GPa, and elastic modulus in the range of 200 to 500 GPa are used. Is particularly preferred.
なお、上記繊維強化樹脂組成物は連続繊維であることが好ましい。ここで言う「連続繊維」とは、５０ｍｍ以上の長さをもつものを言う。 In addition, it is preferable that the said fiber reinforced resin composition is a continuous fiber. The “continuous fiber” referred to here is one having a length of 50 mm or more.
一方、上記繊維強化樹脂組成物のマトリックス樹脂成分としては、例えば、（１）エポキシ樹脂、フェノール樹脂、ビニルエステル樹脂、ウレタン樹脂、不飽和ポリエステル樹脂などの熱硬化性樹脂、（２）ポリエチレン、ポリプロピレン樹脂、ポリアミド樹脂、ポリスチレン、ＡＢＳ樹脂、メタクリル樹脂、ポリ塩化ビニル、ポリエチレンテレフタレート、ＰＢＴなどのポリエステル樹脂、ポリアミド樹脂、ポリイミド樹脂、ポリアミノアミド樹脂、ＰＥＳ（ポリエーテルサルフォン）樹脂、ＰＥＥＫ（ポリエーテルエーテルケトン樹脂）、ナイロン、ポリアセタール、ポリカーボネート、ポリアミドイミドなどの熱可塑性樹脂、を使用できる。
これらマトリックス樹脂成分であれば特に限定されないが、優れた成形性、耐薬品性及び耐候性を付与する観点からは、エポキシ樹脂、ポリエステル樹脂、ビニルエステル樹脂、フェノール樹脂を使用するのが好ましい。
On the other hand, examples of the matrix resin component of the fiber reinforced resin composition include (1) thermosetting resins such as epoxy resins, phenol resins, vinyl ester resins, urethane resins and unsaturated polyester resins, and (2) polyethylene and polypropylene. Resin, polyamide resin, polystyrene, ABS resin, methacrylic resin, polyvinyl chloride, polyethylene terephthalate, polyester resin such as PBT, polyamide resin, polyimide resin, polyaminoamide resin, PES (polyethersulfone) resin, PEEK (polyetherether) Ketone resin), nylon, polyacetal, polycarbonate, polyamideimide and other thermoplastic resins.
Although it will not specifically limit if it is these matrix resin components, From a viewpoint of providing the outstanding moldability, chemical resistance, and a weather resistance, it is preferable to use an epoxy resin, a polyester resin, a vinyl ester resin, and a phenol resin.
これらマトリックス樹脂成分は、繊維強化樹脂組成物の強度が高められる観点からは、樹脂の伸びが上記補強繊維成分より大きい方が好ましい。また、発泡樹脂組成物の発泡工程における加熱・加圧処理時の変形を小さくする観点からは、熱硬化性樹脂の方が好ましい。 From the viewpoint of increasing the strength of the fiber-reinforced resin composition, these matrix resin components preferably have a resin elongation larger than that of the reinforcing fiber component. Moreover, the thermosetting resin is more preferable from the viewpoint of reducing deformation during the heating / pressurizing process in the foaming process of the foamed resin composition.
上述した本発明の金属樹脂複合構造体は、金属板／発泡樹脂組成物／繊維強化樹脂組成物の３層構造体であり、優れた衝撃吸収効果を有する。これにより、用途としては、自動車などの輸送機器や、家屋や棚の梁などの建築物、建造物が挙げられる。
特に、自動車用車体構造として代表的な適用箇所には、図２に示すように、ダッシュ（Ｉ）、サイドドア（Ｇ）、バンパー（Ｈ）、バンパー補強材、ボンネット、各種フレーム、サブフレーム、各種ロッド、インパクトビーム、サイドビーム、サイドピラーなどがあり、広い範囲で適用が可能である。
また、自動車のダッシュやサイドドアとして適用した場合には、車室内の騒音を低減することができる。即ち、単に接着材で鋼板に繊維強化樹脂組成物を貼り付けた従来品に比べて、吸音性能、遮音性能がともに向上し、高い吸音・遮音性能を発現できる。
なお、吸音性能を表す垂直入射率はＪＩＳ Ａ１４０５、遮音性能を洗わず透過損失はＪＩＳ Ａ１４１６によって測定することができる。
The metal resin composite structure of the present invention described above is a three-layer structure of metal plate / foamed resin composition / fiber reinforced resin composition, and has an excellent impact absorbing effect. Thereby, as a use, buildings and structures, such as transport equipment, such as a car, a house, and a beam of a shelf, are mentioned.
In particular, as shown in FIG. 2, typical application locations for automobile body structures include a dash (I), side door (G), bumper (H), bumper reinforcement, bonnet, various frames, subframes, There are various rods, impact beams, side beams, side pillars, etc., which can be applied in a wide range.
Moreover, when applied as a dash or a side door of an automobile, noise in the passenger compartment can be reduced. That is, both the sound absorption performance and the sound insulation performance are improved as compared with the conventional product in which the fiber reinforced resin composition is simply bonded to the steel sheet with an adhesive, and high sound absorption / sound insulation performance can be expressed.
Note that the normal incidence rate representing the sound absorption performance can be measured according to JIS A1405, and the transmission loss can be measured according to JIS A1416 without washing the sound insulation performance.
次に、本発明の金属樹脂複合構造体の製造方法について説明する。
本発明の製造方法では、上述した金属樹脂複合構造体を製造するに当たり、金属板又は繊維強化樹脂組成物の上に発泡体樹脂組成物を配設し、更に繊維強化樹脂組成物又は金属板を配設した後に、該発泡樹脂組成物を発泡させ硬化させる。
Next, the manufacturing method of the metal resin composite structure of this invention is demonstrated.
In the production method of the present invention, in producing the above-described metal resin composite structure, the foam resin composition is disposed on the metal plate or the fiber reinforced resin composition, and the fiber reinforced resin composition or the metal plate is further disposed. After disposing, the foamed resin composition is foamed and cured.
例えば、金属板及び繊維強化樹脂組成物を予め成形しておき、これらを発泡体樹脂組成物を介して張り合わせ、加熱処理を行い発泡体樹脂組成物を発泡させ、硬化させることによって、金属樹脂複合構造体が得られる。 For example, a metal plate and a fiber reinforced resin composition are preliminarily molded, bonded together via a foam resin composition, heat-treated to foam and cure the foam resin composition, and thus a metal resin composite A structure is obtained.
また、本発明の製造方法では、金属板、発泡体樹脂組成物及び繊維強化樹脂組成物を３層構造に形成した後に、該金属板と繊維強化樹脂組成物との距離を一定に保持しながら、該発泡樹脂組成物を発泡させ硬化させることが好ましい。 In the production method of the present invention, the metal plate, the foam resin composition, and the fiber reinforced resin composition are formed in a three-layer structure, and then the distance between the metal plate and the fiber reinforced resin composition is kept constant. The foamed resin composition is preferably foamed and cured.
具体的には、例えば、金属板と、発泡樹脂組成物を貼り付けた繊維強化樹脂組成物とを、該発泡樹脂組成物を介してこれらが一定の距離を保つように固定具を用いて金属樹脂複合構造体を得ることができる。
また、発泡樹脂組成物を貼り付けた金属板と、繊維強化樹脂組成物とを、該発泡樹脂組成物を介してこれらが一定の距離を保つように固定具を用いて金属樹脂複合構造体を得ることができる。
更に、上記固定具の代わりに、又は上記固定具と併用して、発泡樹脂組成物の発泡時に金属板、繊維強化樹脂組成物のいずれか一方又は双方を外側から押止できる治具を配設することもできる。
更にまた、図３に示すように、金属板、発泡体樹脂組成物及び繊維強化樹脂組成物の３層構造体を、部品形状に成形された型内に固定した後に、加熱発泡させ、硬化させることによって金属樹脂複合構造体を得ることもできる。
かかる固定具や治具や型を用いることで、加熱発泡の際に任意の厚さに制御することが可能となり、密着力、衝撃剪断強度の高い金属樹脂複合構造体が得られる。
Specifically, for example, a metal plate and a fiber reinforced resin composition to which a foamed resin composition is attached are bonded to a metal using a fixture so that they maintain a certain distance through the foamed resin composition. A resin composite structure can be obtained.
In addition, the metal plate composite structure with the metal plate with the foamed resin composition and the fiber reinforced resin composition is fixed using a fixture so that the foamed resin composition keeps a certain distance through the foamed resin composition. Obtainable.
Furthermore, a jig that can hold either or both of the metal plate and the fiber reinforced resin composition from the outside when the foamed resin composition is foamed is provided in place of the fixture or in combination with the fixture. You can also
Furthermore, as shown in FIG. 3, a three-layer structure of a metal plate, a foam resin composition, and a fiber reinforced resin composition is fixed in a mold formed into a part shape, and then heated, foamed and cured. Thus, a metal resin composite structure can be obtained.
By using such a fixture, jig, or mold, it is possible to control the thickness to any value during heating and foaming, and a metal resin composite structure with high adhesion and impact shear strength can be obtained.
更に、本発明の製造方法で用いる発泡樹脂組成物は、熱をかけると内部に気孔が発生し、発泡する。この発泡反応は、１４０℃〜２３０℃の加熱処理を行うことで促進できる。
かかる温度域で発泡樹脂組成物は柔らかくなり、加熱により伸びた金属板及び繊維強化樹脂組成物と共に伸びる。この発泡樹脂組成物の柔らかい状態は、完全に冷えて固まるまで保たれるため、金属板や繊維強化樹脂組成物が冷えて収縮した際にも該発泡樹脂組成物が追従し、線膨張係数の差による反りを生じることなく、硬化することができる。
Furthermore, when the foamed resin composition used in the production method of the present invention is heated, pores are generated inside and foamed. This foaming reaction can be promoted by performing a heat treatment at 140 ° C. to 230 ° C.
In such a temperature range, the foamed resin composition becomes soft and stretches together with the metal plate and the fiber reinforced resin composition stretched by heating. Since the soft state of the foamed resin composition is maintained until it is completely cooled and solidified, the foamed resin composition follows even when the metal plate or the fiber reinforced resin composition is cooled and contracted, and the linear expansion coefficient is reduced. It can be cured without causing warping due to the difference.
更にまた、発泡樹脂組成物は、金属や繊維強化樹脂組成物と接触するだけで粘着するものであるが、衝撃剪断強度を向上させるためには、加熱した後に冷却して硬化させることが有効である。
目安としては、１４０℃〜２３０℃で１０〜３０分間の加熱処理を行うことが適切である。１４０℃より低い温度では十分な発泡反応が起こりにくく、２３０℃より高温度では、発泡樹脂組成物が変性してしまい、十分な性能が得られないことがある。
Furthermore, the foamed resin composition adheres only to contact with a metal or fiber reinforced resin composition, but in order to improve the impact shear strength, it is effective to cool and cure after heating. is there.
As a guideline, it is appropriate to perform heat treatment at 140 to 230 ° C. for 10 to 30 minutes. When the temperature is lower than 140 ° C., a sufficient foaming reaction hardly occurs, and when the temperature is higher than 230 ° C., the foamed resin composition is denatured and sufficient performance may not be obtained.
なお、金属板／発泡樹脂組成物／繊維強化樹脂組成物の３層構造体において、発泡樹脂組成物を発泡させ３層を接合する際は、ネジ、ボルト、リベット、クリップなどの機械接合を併用して脱落を防止しても差し支えない。
また、金属板として車体鋼板を用いた車体部品を製造する際は、加熱発泡工程は、製造ラインでの電着塗装焼付け工程を利用できるため、新たな工程、設備投入の必要もなく、経済的となる。
In the three-layer structure of metal plate / foamed resin composition / fiber reinforced resin composition, when joining the three layers by foaming the foamed resin composition, mechanical joints such as screws, bolts, rivets, clips, etc. are also used. It is safe to prevent the dropout.
In addition, when manufacturing car body parts using car body steel plates as metal plates, the heating and foaming process can use the electrodeposition coating baking process on the production line, so there is no need for new processes and equipment input, making it economical. It becomes.
以下、本発明を実施例及び比較例により更に詳細に説明するが、本発明はこれら実施例に限定されるものではない。 EXAMPLES Hereinafter, although an Example and a comparative example demonstrate this invention further in detail, this invention is not limited to these Examples.
（実施例１）
ビスフェノールＡ型エポキシ樹脂（ａ）に、このエポキシ樹脂を１００重量部とすると、繊維長２ｍｍ、繊維径１０μｍの炭素繊維（ｂ）を５重量部、硬化剤（ｃ）であるジシアンジアミドを１１重量部、硬化触媒（ｄ）であるアミンアダクト（エポキシ化合物付加ポリアミン）を６重量部、有機系発泡剤（ｅ）であるアゾジカルボンアミドを６重量部、無機系充填剤（ｆ）である珪酸カルシウムを１３０重量部、及び気泡防止剤（ｇ）である酸化カルシウムを９重量部、プラネタリーミキサーを用いて室温で混合し、発泡樹脂組成物を調製した。
Example 1
When 100 parts by weight of this epoxy resin is added to bisphenol A type epoxy resin (a), 5 parts by weight of carbon fiber (b) having a fiber length of 2 mm and a fiber diameter of 10 μm, and 11 parts by weight of dicyandiamide as a curing agent (c) 6 parts by weight of amine adduct (epoxy compound-added polyamine) as curing catalyst (d), 6 parts by weight of azodicarbonamide as organic foaming agent (e), and calcium silicate as inorganic filler (f) 130 parts by weight and 9 parts by weight of calcium oxide as an anti-bubble agent (g) were mixed at room temperature using a planetary mixer to prepare a foamed resin composition.
鋼板（幅２５ｍｍ、長さ２５０ｍｍ、厚さ０．７ｍｍ）に、上記発泡樹脂組成物を貼り付けた。この発泡樹脂組成物に対向するように、繊維強化樹脂組成物（幅２５ｍｍ、長さ２５０ｍｍ、厚さ０．６ｍｍ）を、鋼板からの距離を２０ｍｍに保った状態で治具にて固定し、恒温槽にて１５０℃で３０分間加熱し、エポキシ系発泡樹脂組成物を発泡、硬化させ、はみ出した部分をカッターナイフで切り落として、本例の金属樹脂複合構造体を得た。
なお、上記繊維強化樹脂組成物の構成は、強化繊維として炭素繊維（引張強度５ＧＰａ、弾性率２３０ＧＰａ、破断伸度１．５％）の織物、マトリックス樹脂としてエポキシ樹脂を使用し、予め硬化させておいたものである。
The foamed resin composition was attached to a steel plate (width 25 mm, length 250 mm, thickness 0.7 mm). Fix the fiber reinforced resin composition (width 25 mm, length 250 mm, thickness 0.6 mm) with a jig in a state where the distance from the steel plate is kept at 20 mm so as to face this foamed resin composition, The epoxy resin foamed resin composition was foamed and cured by heating at 150 ° C. for 30 minutes in a thermostatic bath, and the protruding part was cut off with a cutter knife to obtain a metal resin composite structure of this example.
In addition, the structure of the said fiber reinforced resin composition uses the woven fabric of carbon fiber (tensile strength 5GPa, elastic modulus 230GPa, breaking elongation 1.5%) as a reinforced fiber, uses an epoxy resin as a matrix resin, and makes it harden | cure beforehand. It is a thing.
（実施例２）
発泡樹脂組成物において、（ｂ）成分として、繊維長２ｍｍ、繊維径１０μｍの炭素繊維１重量部用いたこと以外は、実施例１と同様の操作を繰返して、本例の金属樹脂複合構造体を得た。
(Example 2)
In the foamed resin composition, the same operation as in Example 1 was repeated except that 1 part by weight of carbon fiber having a fiber length of 2 mm and a fiber diameter of 10 μm was used as the component (b). Got.
（実施例３）
発泡樹脂組成物において、（ｂ）成分として、繊維長２ｍｍ、繊維径１０μｍの炭素繊維２０重量部用いたこと以外は、実施例１と同様の操作を繰返して、本例の金属樹脂複合構造体を得た。
(Example 3)
In the foamed resin composition, the same operation as in Example 1 was repeated except that 20 parts by weight of carbon fiber having a fiber length of 2 mm and a fiber diameter of 10 μm was used as the component (b). Got.
（実施例４）
鋼板と繊維強化樹脂組成物の距離を５ｍｍに保った状態で治具にて固定したこと以外は、実施例１と同様の操作を繰返して、本例の金属樹脂複合構造体を得た。
Example 4
Except that the distance between the steel sheet and the fiber reinforced resin composition was fixed with a jig while maintaining a distance of 5 mm, the same operation as in Example 1 was repeated to obtain a metal resin composite structure of this example.
（実施例５）
繊維強化樹脂組成物の強化繊維に、ガラス繊維（引張強度３ＧＰａ、弾性率７０ＧＰａ、破断伸度４％）の織物を用いたこと、発泡樹脂組成物の（ｂ）成分として、繊維長２ｍｍ、繊維径１７μｍのガラス繊維を５重量部用いたこと以外は、実施例１と同様の操作を繰返して、本例の金属樹脂複合構造体を得た。
(Example 5)
Glass fiber (tensile strength 3 GPa, elastic modulus 70 GPa, elongation at break 4%) was used as the reinforcing fiber of the fiber reinforced resin composition, and the fiber length 2 mm, fiber as component (b) of the foamed resin composition Except for using 5 parts by weight of glass fiber having a diameter of 17 μm, the same operation as in Example 1 was repeated to obtain a metal resin composite structure of this example.
（実施例６）
繊維強化樹脂組成物の強化繊維に、高強力ポリアリレート繊維（引張強度３ＧＰａ、弾性率１０４ＧＰａ、破断伸度２．７％）の織物を用いたこと以外は、実施例１と同様の操作を繰返して、本例の金属樹脂複合構造体を得た。
(Example 6)
The same operation as in Example 1 was repeated, except that a high-strength polyarylate fiber (tensile strength 3 GPa, elastic modulus 104 GPa, elongation at break 2.7%) was used as the reinforcing fiber of the fiber-reinforced resin composition. Thus, a metal resin composite structure of this example was obtained.
（実施例７）
繊維強化樹脂組成物の強化繊維に、パラ型アラミド繊維（引張強度２．８ＧＰａ、弾性率１０９ＧＰａ、破断伸度２．４％）の織物を用いたこと以外は、実施例１と同様の操作を繰返して、本例の金属樹脂複合構造体を得た。
(Example 7)
The same operation as in Example 1 was performed except that a woven fabric of para-type aramid fiber (tensile strength 2.8 GPa, elastic modulus 109 GPa, breaking elongation 2.4%) was used as the reinforcing fiber of the fiber reinforced resin composition. The metal resin composite structure of this example was obtained by repeating.
（実施例８）
繊維強化樹脂組成物の強化繊維に、炭素繊維（引張強度５ＧＰａ、弾性率２３０ＧＰａ、破断伸度１．５％）を一方向に配置したものを用いたこと以外は、実施例１と同様の操作を繰返して、本例の金属樹脂複合構造体を得た。
(Example 8)
The same operation as in Example 1 except that a carbon fiber (tensile strength 5 GPa, elastic modulus 230 GPa, elongation at break 1.5%) was used in one direction as the reinforcing fiber of the fiber reinforced resin composition. Was repeated to obtain a metal-resin composite structure of this example.
（実施例９）
金属板に厚さ０．７ｍｍのアルミニウム板を使用したこと以外は、実施例１と同様の操作を繰返して、本例の金属樹脂複合構造体を得た。
Example 9
Except that a 0.7 mm thick aluminum plate was used as the metal plate, the same operation as in Example 1 was repeated to obtain a metal resin composite structure of this example.
（比較例１）
鋼板（幅２５ｍｍ、長さ２５０ｍｍ、厚さ０．７ｍｍ）に、エポキシ系室温硬化型接着材を塗布し、塗布厚さ１ｍｍになるようスペーサー（ガラスビーズ使用）を入れ、その上から遷移強化樹脂組成物（幅２５ｍｍ、長さ２５０ｍｍ、厚さ０．６ｍｍ）を貼り付け、クリップにて固定し、２３℃にて２日間静置し硬化させ、本例の構造体を得た。
このとき使用した遷移強化樹脂組成物の構成は、実施例１と同様のものである。また、この時要した作業時間は、接着剤の調合に１０分、塗布に５分、硬化に２日であった。
(Comparative Example 1)
Apply an epoxy room temperature curing adhesive to a steel plate (width 25 mm, length 250 mm, thickness 0.7 mm), and insert a spacer (using glass beads) to a coating thickness of 1 mm. A composition (25 mm in width, 250 mm in length, 0.6 mm in thickness) was applied, fixed with a clip, allowed to stand at 23 ° C. for 2 days and cured to obtain the structure of this example.
The structure of the transition reinforcing resin composition used at this time is the same as that of Example 1. The working time required at this time was 10 minutes for the preparation of the adhesive, 5 minutes for the application, and 2 days for the curing.
（比較例２）
鋼板（幅２５ｍｍ、長さ２５０ｍｍ、厚さ０．７ｍｍ）に、エポキシ系加熱硬化型接着剤を塗布し、塗布厚さ１ｍｍになるようスペーサー（ガラスビーズ使用）を入れ、その上から遷移強化樹脂組成物（幅２５ｍｍ、長さ２５０ｍｍ、厚さ０．６ｍｍ）を貼り付け、クリップにて固定し、８０℃にて６０分間加熱し硬化させ、本例の構造体を得た。
このとき使用した繊維強化樹脂組成物の構成は、実施例１と同様のものである。
(Comparative Example 2)
Apply an epoxy-based thermosetting adhesive to a steel plate (width 25 mm, length 250 mm, thickness 0.7 mm), and insert a spacer (using glass beads) to a coating thickness of 1 mm. A composition (25 mm in width, 250 mm in length, 0.6 mm in thickness) was attached, fixed with a clip, and cured by heating at 80 ° C. for 60 minutes to obtain the structure of this example.
The structure of the fiber reinforced resin composition used at this time is the same as that of Example 1.
（比較例３）
鋼板と繊維強化樹脂組成物の距離を５ｍｍに保った状態で治具にて固定し、恒温槽にて１５０℃で３０分間加熱し、ウレタン系発泡樹脂組成物を発泡、硬化させたこと以外は、比較例１と同様の操作を繰返して、本例の構造体を得た。
(Comparative Example 3)
Except that the distance between the steel plate and the fiber reinforced resin composition was kept at 5 mm with a jig and heated at 150 ° C. for 30 minutes in a thermostatic bath to foam and cure the urethane-based foamed resin composition. The same operation as in Comparative Example 1 was repeated to obtain the structure of this example.
（比較例４）
鋼板と繊維強化樹脂組成物の距離を５ｍｍに保った状態で治具にて固定し、恒温槽にて１５０℃で３０分間過熱し、ポリプロピレン系発泡樹脂組成物（ＥＰＰ：発泡ポリプロピレン）を発泡、硬化させたこと以外は、比較例１と同様の操作を繰返して、本例の構造体を得た。
(Comparative Example 4)
The distance between the steel sheet and the fiber reinforced resin composition is fixed with a jig while maintaining a distance of 5 mm, heated at 150 ° C. for 30 minutes in a thermostatic bath, and foamed polypropylene-based foamed resin composition (EPP: expanded polypropylene). Except for curing, the same operation as in Comparative Example 1 was repeated to obtain the structure of this example.
（比較例５）
鋼板（幅２５ｍｍ、長さ２５０ｍｍ、厚さ０．７ｍｍ）の上から繊維強化樹脂組成物（幅２５ｍｍ、長さ２５０ｍｍ、厚さ０．６ｍｍ）を配置し、長さ４ｍｍのリベットにて２箇所接合し、本例の構造体を得た。
このとき使用した繊維強化樹脂組成物の構成は、実施例１と同様のものである。
(Comparative Example 5)
A fiber reinforced resin composition (width 25 mm, length 250 mm, thickness 0.6 mm) is placed on the steel plate (width 25 mm, length 250 mm, thickness 0.7 mm), and two places with 4 mm length rivets The structure of this example was obtained by bonding.
The structure of the fiber reinforced resin composition used at this time is the same as that of Example 1.
実施例及び比較例で得た構造体について、以下の４つの評価を行った。結果一覧を表２に示す。 The following four evaluations were performed on the structures obtained in the examples and comparative examples. Table 2 shows the result list.
（１）硬化後のそり
本鋼板／Ｃ繊維強化樹脂組成物部材を平面上に置き、硬化後のそり高さをノギスにて計測した。測定箇所の詳細を図４に示す。
硬化後の変形量が、試験片長さの０．２％未満であるときを◎、０．２％以上０．５％未満であるとき○、それ以上を×として評価した。
(1) Warpage after curing The steel plate / C fiber reinforced resin composition member was placed on a flat surface, and the height of the warp after curing was measured with calipers. The details of the measurement location are shown in FIG.
When the amount of deformation after curing was less than 0.2% of the length of the test piece, it was evaluated as ◎, when it was 0.2% or more and less than 0.5%, ○ was evaluated as x.
（２）曲げ弾性
本鋼板／Ｃ繊維強化樹脂組成物部材を用いて、３点曲げ試験を行った。なお、３点曲げ試験は、ＪＩＳ Ｋ７１７１に準じて測定した。
強度については、０．７ｍｍ鋼板の曲げ強度の２倍より大きい強度を有するものを◎、０．７ｍｍ鋼板の曲げ強度の１倍より大きく２倍以下の強度を有するものを○、１０ｍｍ曲げたときに試験片が座屈したものを△、１０ｍｍ曲げたときに試験片が剥がれたものを×として評価した。
弾性については、曲げ試験測定値の弾性域における傾きが、０．７ｍｍの鋼板の２倍より大きいものを◎、１倍より大きく２倍以下を○、０．７ｍｍの鋼板とほぼ同等のものを△、０．７ｍｍの鋼板より小さい場合を×として評価した。
(2) Flexural elasticity Using this steel plate / C fiber reinforced resin composition member, a three-point bending test was conducted. The three-point bending test was measured according to JIS K7171.
As for the strength, when the bending strength of the 0.7 mm steel plate is greater than twice the bending strength, ◎, when the bending strength of the 0.7 mm steel plate is greater than 1 time and less than 2 times, the bending strength is 10 mm. When the test piece was buckled, Δ was evaluated as x when the test piece was peeled off when bent by 10 mm.
For elasticity, the inclination in the elastic range of the bending test measurement value is greater than twice that of a 0.7 mm steel sheet, ◎ greater than 1 time, less than 2 times less, and approximately the same as a 0.7 mm steel sheet. Δ, the case smaller than 0.7 mm steel plate was evaluated as x.
（３）シャルピー衝撃
本鋼板／Ｃ繊維強化樹脂組成物部材を用いて、シャルピー衝撃試験を行った。なお、シャルピー衝撃試験は、ＪＩＳ Ｋ７１１１に準じて測定した。
試験は、鋼板面よりハンマー入射をする形で実施した。このときの試験後の試験片の状態が、変形あるいは剥がれのないものを◎、変形がわずかに見られるが剥がれのないものを○、変形が大きいが剥がれのないものを△、変形及び剥がれがあるものを×として評価した。
(3) Charpy impact The Charpy impact test was done using this steel plate / C fiber reinforced resin composition member. The Charpy impact test was measured according to JIS K7111.
The test was conducted in the form of hammer incidence from the steel plate surface. The state of the test piece after the test at this time is ◎ if there is no deformation or peeling, ○ if there is a slight deformation but no peeling, △ if there is a large deformation but no peeling, and deformation and peeling. Some were evaluated as x.
（４）総合評価
すべての試験結果において◎又は○のみ、あるいは△が２個以下のときを○、△が３個以上あるとき又は×が１つでもあるときを×として評価した。
(4) Comprehensive evaluation In all the test results, ◎ or ○ alone, or when Δ was 2 or less, ○, when there were 3 or more Δ, or when there was at least 1 ×, were evaluated as ×.
表１及び表２に示した結果から明らかなように、実施例１〜９の金属樹脂複合構造体は、いずれも比較例２に対し、成型後のそりが生じないことで優れていた。
また、強度・衝撃特性は、金属樹脂複合構造体としての要求性能を満足することがわかる。
更に、実施例１と比較例３の結果より、発泡樹脂組成物がウレタン系では、そりは妨げるものの、十分な強度が得られず、また衝撃性能も低い。
更にまた、ポリプロピレン系やボルト接合では、いっそう強度・衝撃特性が低下する。よって、本発明で規定するエポキシ系の発泡樹脂組成物を使用すると十分な強度・衝撃性能が得られることがわかる。
As is clear from the results shown in Tables 1 and 2, the metal resin composite structures of Examples 1 to 9 were all superior to Comparative Example 2 in that no warpage occurs after molding.
Further, it can be seen that the strength and impact characteristics satisfy the required performance as a metal resin composite structure.
Furthermore, from the results of Example 1 and Comparative Example 3, when the foamed resin composition is urethane, warping is prevented but sufficient strength cannot be obtained and impact performance is low.
Furthermore, the strength and impact characteristics are further deteriorated in polypropylene and bolted joints. Therefore, it is understood that sufficient strength and impact performance can be obtained when the epoxy foamed resin composition defined in the present invention is used.
本発明の金属樹脂複合構造体は、建材、家屋等の構造物や、自動車、鉄道車両等の輸送機器などに好適に適用できる。 The metal resin composite structure of the present invention can be suitably applied to structures such as building materials and houses, and transportation equipment such as automobiles and railway vehicles.
Ａ：金属板
Ｂ：繊維強化樹脂組成物
Ｃ：発泡樹脂組成物
Ｄ：補強繊維
Ｅ：マトリックス樹脂
Ｆ：加熱発泡時に使用する固定治具
Ｇ：ドア
Ｈ：バンパー
Ｉ：ダッシュ
A: Metal plate B: Fiber reinforced resin composition C: Foamed resin composition D: Reinforcing fiber E: Matrix resin F: Fixing jig used during heating and foaming G: Door H: Bumper I: Dash
Claims (13)
上記発泡樹脂組成物は、エポキシ樹脂１００重量部に対して、繊維長１〜３ｍｍ、繊維径５〜２０μｍの炭素繊維及び／又はガラス繊維を２〜３０重量部、エポキシ樹脂用熱活性型硬化剤を３〜３０重量部、エポキシ樹脂用熱活性型硬化触媒を０．５〜１５重量部、熱分解型有機系発泡剤を０．５〜１５重量部、アスペクト比が２：１以上の無機系充填剤を５０〜２００重量部、気泡防止剤を２〜１５重量部、含んで成ることを特徴とする金属樹脂複合構造体。 The metal plate and the fiber reinforced resin composition is a three-layer metal resin composite structure joined through a foamed resin composition,
The foamed resin composition comprises 2 to 30 parts by weight of a carbon fiber and / or glass fiber having a fiber length of 1 to 3 mm and a fiber diameter of 5 to 20 μm with respect to 100 parts by weight of the epoxy resin. 3 to 30 parts by weight, 0.5 to 15 parts by weight of thermally activated curing catalyst for epoxy resin, 0.5 to 15 parts by weight of thermally decomposable organic foaming agent, and an inorganic system having an aspect ratio of 2: 1 or more A metal-resin composite structure comprising 50 to 200 parts by weight of a filler and 2 to 15 parts by weight of an anti-bubble agent.
該金属板が車体鋼板であることを特徴とする自動車用車体構造。 A vehicle body structure using the metal resin composite structure according to any one of claims 1 to 8,
A vehicle body structure for an automobile, wherein the metal plate is a vehicle body steel plate.
金属板又は繊維強化樹脂組成物の上に発泡体樹脂組成物を配設し、更に繊維強化樹脂組成物又は金属板を配設した後に、該発泡樹脂組成物を発泡させ硬化させることを特徴とする金属樹脂複合構造体の製造方法。 In producing the metal resin composite structure according to any one of claims 1 to 8,
Disposing a foam resin composition on a metal plate or a fiber reinforced resin composition, further disposing a fiber reinforced resin composition or a metal plate, and then foaming and curing the foam resin composition A method for producing a metal resin composite structure.
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