JP6947074B2 - Manufacturing method of composite member - Google Patents

Manufacturing method of composite member Download PDF

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JP6947074B2
JP6947074B2 JP2018029176A JP2018029176A JP6947074B2 JP 6947074 B2 JP6947074 B2 JP 6947074B2 JP 2018029176 A JP2018029176 A JP 2018029176A JP 2018029176 A JP2018029176 A JP 2018029176A JP 6947074 B2 JP6947074 B2 JP 6947074B2
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metal plate
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一記 小森谷
一記 小森谷
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Toyota Motor Corp
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金属部品と、前記金属部品を補強する繊維強化樹脂材とを備えた筒状の複合部材の製造方法に関する。 The present invention relates to a method for manufacturing a tubular composite member including a metal part and a fiber-reinforced resin material for reinforcing the metal part.

従来から、金属部品に、強化繊維に高分子樹脂を含浸させた繊維強化樹脂材を貼着して、金属部品を補強した複合部材が製造される。このような複合部材として、特許文献１には、アルミニウム合金製の筒状部材に対して曲げ荷重が作用することを想定し、この筒状部材の表面のうち、曲げ荷重の作用する側の表面に、繊維強化樹脂材を配置した複合部材が開示されている。この複合部材を製造する際には、金属部品の表面に、繊維強化樹脂材が接着剤等を介して直接貼着される。 Conventionally, a composite member in which a metal part is reinforced is manufactured by attaching a fiber-reinforced resin material obtained by impregnating a reinforcing fiber with a polymer resin to a metal part. As such a composite member, Patent Document 1 assumes that a bending load acts on a cylindrical member made of an aluminum alloy, and the surface of the surface of the tubular member on the side on which the bending load acts. Discloses a composite member in which a fiber-reinforced resin material is arranged. When manufacturing this composite member, a fiber reinforced resin material is directly attached to the surface of the metal part via an adhesive or the like.

特開２００３−１２９６１１号公報Japanese Unexamined Patent Publication No. 2003-129611

ところで、図６（ａ）、（ｂ）に示すように、上述した筒状部材を曲げ加工して得られた金属部品９を補強するために、一方向に配向された強化繊維に未硬化の熱硬化性樹脂を含浸した繊維強化樹脂材９５を貼着し、この熱硬化性樹脂を熱硬化させることがある。しかしながら、内側に曲げられた金属部品９の外壁部９１に、未硬化の熱硬化性樹脂を含む繊維強化樹脂材９５を貼り付けて、熱硬化性樹脂を熱硬化させても、金属部品９が十分に補強されないことがあった。 By the way, as shown in FIGS. 6A and 6B, in order to reinforce the metal part 9 obtained by bending the above-mentioned tubular member, the reinforcing fibers oriented in one direction are uncured. A fiber-reinforced resin material 95 impregnated with a thermosetting resin may be attached to heat-cure the thermosetting resin. However, even if the fiber reinforced resin material 95 containing the uncured thermosetting resin is attached to the outer wall portion 91 of the metal component 9 bent inward and the thermosetting resin is thermally cured, the metal component 9 is still formed. Sometimes it wasn't reinforced enough.

これは、曲げ加工時に、曲げ方向の内側の筒状部材の外壁部９１に対して、長手方向に圧縮応力が作用するため、図６（ｃ）に示すように、得られた金属部品９の外壁部９１が波打つように変形し、外壁部９１の表面に凹部９１ａと凸部９１ｂが交互に形成されるからであると考えられる。この凹部９１ａと凸部９１ｂが交互に形成された表面に、繊維強化樹脂材９５を貼り付けると、一方向に配向された強化繊維も、この凹部および凸部に倣うようにうねってしまう。この結果、強化繊維の配向が乱れ、本来期待されていた強化繊維による補強効果を十分に得ることができないと考えられる。 This is because compressive stress acts in the longitudinal direction on the outer wall portion 91 of the cylindrical member inside in the bending direction during bending, so that the obtained metal part 9 is as shown in FIG. 6 (c). It is considered that this is because the outer wall portion 91 is deformed in a wavy manner, and the concave portions 91a and the convex portions 91b are alternately formed on the surface of the outer wall portion 91. When the fiber reinforced resin material 95 is attached to the surface on which the concave portions 91a and the convex portions 91b are alternately formed, the unidirectionally oriented reinforcing fibers also undulate so as to imitate the concave portions and the convex portions. As a result, the orientation of the reinforcing fibers is disturbed, and it is considered that the originally expected reinforcing effect of the reinforcing fibers cannot be sufficiently obtained.

本発明は、この点を鑑みてなされたものであり、曲げ加工して得られた金属部品に対して、繊維強化樹脂材による補強効果を充分発揮することができる複合部材の製造方法を提供する。 The present invention has been made in view of this point, and provides a method for manufacturing a composite member capable of sufficiently exerting a reinforcing effect of a fiber reinforced resin material on a metal part obtained by bending. ..

前記課題を鑑みて、本発明に係る複合部材の製造方法は、金属部品と、前記金属部品を補強する繊維強化樹脂材とを備えた筒状の複合部材の製造方法であって、長手方向に沿って凹部が形成された金属部材を、前記凹部の開口部側に屈曲するように曲げ加工することにより、前記金属部品を作製する工程と、前記金属部品の凹部の開口部を覆う形状の金属板の表面に、一方向に配向した強化繊維を含む繊維基材に未硬化の熱硬化性樹脂を含浸した繊維強化樹脂材を貼着した後、前記熱硬化性樹脂を熱硬化させて、補強材を作製する工程と、前記金属部品の前記開口部を覆うように、前記補強材の前記金属板を接合する工程と、を含むことを特徴とする。 In view of the above problems, the method for manufacturing a composite member according to the present invention is a method for manufacturing a tubular composite member including a metal part and a fiber-reinforced resin material for reinforcing the metal part, in the longitudinal direction. A process of manufacturing the metal part by bending a metal member having a recess formed along the metal member so as to bend toward the opening side of the recess, and a metal having a shape that covers the opening of the recess of the metal part. A fiber-reinforced resin material impregnated with an uncured thermosetting resin is attached to a fiber base material containing reinforcing fibers oriented in one direction on the surface of the plate, and then the thermosetting resin is thermally cured to reinforce it. It is characterized by including a step of producing a material and a step of joining the metal plate of the reinforcing material so as to cover the opening of the metal part.

本発明によれば、長手方向に沿って凹部が形成された金属部材を、凹部の開口部側に屈曲するように曲げ加工することにより、金属部品を作製するので、筒状の金属部材を曲げ加工した際の外壁部の波打つような変形は生じない。 According to the present invention, a metal part is produced by bending a metal member having a recess formed along the longitudinal direction so as to bend toward the opening side of the recess, so that the tubular metal member is bent. There is no wavy deformation of the outer wall when processed.

そして、補強材を作製する工程では、繊維強化樹脂材が貼着される金属板の表面は、曲げ加工時のような波打ちの無い平滑な表面であるので、繊維強化樹脂材に含まれる強化繊維の配向性が損なわれることはない。 Then, in the process of producing the reinforcing material, the surface of the metal plate to which the fiber reinforced resin material is attached is a smooth surface without waviness as in the bending process, so that the reinforcing fibers contained in the fiber reinforced resin material are used. The orientation of the is not impaired.

このような補強材を用いて、金属部品の開口部を覆うように補強材の金属板を接合すると、金属部品と金属板とにより、金属製の筒状体が形成され、この筒状体の表面に繊維強化樹脂材は配置された複合部材を得ることができる。得られた複合部材は、曲げ加工して得られた金属部品に対して、繊維強化樹脂材による補強効果を充分発揮することができる。 When the metal plate of the reinforcing material is joined so as to cover the opening of the metal part by using such a reinforcing material, a metal tubular body is formed by the metal part and the metal plate, and the tubular body is formed. A composite member in which the fiber-reinforced resin material is arranged on the surface can be obtained. The obtained composite member can sufficiently exert the reinforcing effect of the fiber reinforced resin material on the metal parts obtained by bending.

本発明の実施形態に係る複合部材の製造方法を説明するためのフロー図である。It is a flow chart for demonstrating the manufacturing method of the composite member which concerns on embodiment of this invention. 図１に示す金属部品作製工程を説明するための模式的概念図である。It is a schematic conceptual diagram for demonstrating the metal part manufacturing process shown in FIG. 図１に示す金属板作製工程を説明するための模式的斜視図である。It is a schematic perspective view for demonstrating the metal plate manufacturing process shown in FIG. 図１に示す補強材作製工程を説明するための模式的概念図である。It is a schematic conceptual diagram for demonstrating the reinforcing material manufacturing process shown in FIG. 図１に示す接合工程を説明するための模式的概念図である。It is a schematic conceptual diagram for demonstrating the joining process shown in FIG. 従来の複合部材の製造方法を説明するための模式的斜視図であり、（ａ）は、金属部品の曲げ加工により得られた金属部品の模式的斜視図であり、（ｂ）は、（ａ）に示す金属部品に繊維強化樹脂材を貼着して得られた複合部材の模式的斜視図であり、（ｃ）は（ａ）のＡ−Ａ線に沿った矢視方向の断面図である。It is a schematic perspective view for demonstrating the manufacturing method of the conventional composite member, (a) is a schematic perspective view of a metal part obtained by bending process of a metal part, (b) is (a). It is a schematic perspective view of the composite member obtained by adhering a fiber reinforced resin material to the metal part shown in), and FIG. be.

以下に本発明のいくつかの実施形態を図１〜５を参照しながら説明する。
本実施形態では、図５の下図に示すように、金属部品２と、金属部品２を補強する繊維強化樹脂材５とを少なくとも備えた複合部材１を製造する。 Hereinafter, some embodiments of the present invention will be described with reference to FIGS. 1 to 5.
In the present embodiment, as shown in the lower figure of FIG. 5, a composite member 1 including at least a metal component 2 and a fiber reinforced resin material 5 for reinforcing the metal component 2 is manufactured.

１．金属部品作製工程Ｓ１について
まず、金属部品作製工程Ｓ１を行う。この工程では、補強される部品として、長手方向と直交する断面がコの字状の金属部品２を作製する。具体的には、図２の上図に示すように、長手方向に沿って平板状の外壁部２１Ａ〜２３Ａが延在した金属部材２Ａを準備する。 1. 1. About the metal part manufacturing step S1 First, the metal part manufacturing step S1 is performed. In this step, as a part to be reinforced, a metal part 2 having a U-shaped cross section orthogonal to the longitudinal direction is produced. Specifically, as shown in the upper part of FIG. 2, a metal member 2A having flat plate-shaped outer wall portions 21A to 23A extending along the longitudinal direction is prepared.

本実施形態では、金属部材２Ａは、対向した一対の外壁部２１Ａ、２３Ａを側壁部とし、これらに連続した外壁部２２Ａを底壁部とした金属製のチャンネル材である。金属部材２Ａは、金属部材２Ａの長手方向に沿って凹部２４が形成され、外壁部２２Ａと対向した位置に、凹部２４Ａの開口部２５Ａが形成されている。 In the present embodiment, the metal member 2A is a metal channel material having a pair of outer wall portions 21A and 23A facing each other as side wall portions and a continuous outer wall portion 22A as a bottom wall portion. The metal member 2A has a recess 24 formed along the longitudinal direction of the metal member 2A, and an opening 25A of the recess 24A is formed at a position facing the outer wall portion 22A.

準備される金属部材２Ａは、金属材料からなり、その材料としては、炭素鋼、ステンレス鋼、アルミニウム合金などを挙げることができ、本実施形態では、アルミニウム合金である。アルミニウム合金としては、Ａｌ−Ｃｕ系アルミニウム合金、Ａｌ−Ｃｕ−Ｍｇ系アルミニウム合金、Ａｌ−Ｃｕ−Ｍｇ−Ｎｉ系アルミニウム合金、Ａｌ−Ｓｉ系アルミニウム合金、Ａｌ−Ｓｉ−Ｍｇ系アルミニウム合金、Ａｌ−Ｓｉ−Ｃｕ−Ｍｇ系アルミニウム合金などを挙げることができる。 The metal member 2A to be prepared is made of a metal material, and examples of the material include carbon steel, stainless steel, and an aluminum alloy. In the present embodiment, the metal member 2A is an aluminum alloy. Examples of aluminum alloys include Al-Cu-based aluminum alloys, Al-Cu-Mg-based aluminum alloys, Al-Cu-Mg-Ni-based aluminum alloys, Al-Si-based aluminum alloys, Al-Si-Mg-based aluminum alloys, and Al-. Examples thereof include Si—Cu—Mg-based aluminum alloys.

次に、図２の下図に示すように、外壁部２２Ａを曲げ方向の外側にして、凹部２４Ａの開口部２５Ａ側に屈曲するように、準備した金属部材２Ａを曲げ加工し、金属部品２を作製する。本実施形態では、金属部材２Ａの両側を曲げ加工する。 Next, as shown in the lower part of FIG. 2, the prepared metal member 2A is bent so that the outer wall portion 22A is outside in the bending direction and the recess 24A is bent toward the opening 25A, and the metal part 2 is formed. To make. In the present embodiment, both sides of the metal member 2A are bent.

これにより、両側が屈曲した金属部品２であって、外壁部２１、２３を側壁部とし、外壁部２２を底壁部とし、長手方向に沿って凹部２４が形成された金属部品２を得ることができる。底壁部となる外壁部２２は、凹部２４の開口部２５に対向した位置に形成される。このように、本実施形態では、筒状の金属部材を曲げ加工した際に生じる外壁部の波打つような変形はない（たとえば図６（ｃ）参照）。 As a result, it is possible to obtain a metal part 2 in which both sides are bent, the outer wall portions 21 and 23 are the side wall portions, the outer wall portion 22 is the bottom wall portion, and the recesses 24 are formed along the longitudinal direction. Can be done. The outer wall portion 22 serving as the bottom wall portion is formed at a position facing the opening 25 of the recess 24. As described above, in the present embodiment, there is no wavy deformation of the outer wall portion that occurs when the tubular metal member is bent (see, for example, FIG. 6C).

２．金属板作製工程Ｓ２について
次に、金属板作製工程Ｓ２を行う。この工程では、後述する接合工程Ｓ４において、金属部品２の凹部２４の開口部２５を覆う形状の金属板３を作製する。本実施形態では、図３に示すように、平板状の金属板３Ａを準備し、この金属板３Ａを、金属部品２の開口部２５を覆う形状に曲げ加工する。 2. About the metal plate manufacturing step S2 Next, the metal plate manufacturing step S2 is performed. In this step, in the joining step S4 described later, a metal plate 3 having a shape covering the opening 25 of the recess 24 of the metal part 2 is produced. In the present embodiment, as shown in FIG. 3, a flat metal plate 3A is prepared, and the metal plate 3A is bent into a shape that covers the opening 25 of the metal part 2.

金属板３は、後述する強化繊維の配向を乱さず、開口部２５を覆うように金属部品２に接合することができるものであれば、その大きさ、厚さ、およびその材料は特に限定されるものではない。 The size, thickness, and material of the metal plate 3 are particularly limited as long as the metal plate 3 can be joined to the metal part 2 so as to cover the opening 25 without disturbing the orientation of the reinforcing fibers described later. It's not something.

金属板３の材料は、炭素鋼、ステンレス鋼、アルミニウム合金などを挙げることができるが、本実施形態では、アルミニウム合金であり、アルミニウム合金としては、金属部材２Ａにおいて例示した材料を挙げることができる。金属板３の材料を、アルミニウム合金とすることにより、アルミニウム合金からなる金属部品２に対する金属板３の接合性を高めることができる。なお、後述する強化繊維が炭素繊維である場合、金属板３の表面のうち、繊維強化樹脂材５が貼着される表面に、強化繊維が接触しないように、防食用の電着塗装を施してもよい。 Examples of the material of the metal plate 3 include carbon steel, stainless steel, and an aluminum alloy. In the present embodiment, the metal plate 3 is an aluminum alloy, and examples of the aluminum alloy include the materials exemplified in the metal member 2A. .. By using an aluminum alloy as the material of the metal plate 3, the bondability of the metal plate 3 to the metal component 2 made of the aluminum alloy can be improved. When the reinforcing fibers described later are carbon fibers, anticorrosion coating is applied to the surface of the metal plate 3 to which the fiber reinforced resin material 5 is attached so that the reinforcing fibers do not come into contact with the surface. You may.

３．補強材作製工程Ｓ３について
次に、補強材作製工程Ｓ３を行う。この工程では、まず、図４に示すように、作製した金属板３の表面に、熱硬化型の接着剤４Ａを介して、繊維強化樹脂材５Ａを貼着する。繊維強化樹脂材５Ａは、一方向に配向された強化繊維５ａを含む繊維基材５ｂに、未硬化の熱硬化性樹脂を含浸したプリプレグである。 3. 3. Reinforcing material manufacturing step S3 Next, the reinforcing material manufacturing step S3 is performed. In this step, first, as shown in FIG. 4, the fiber reinforced resin material 5A is attached to the surface of the produced metal plate 3 via the thermosetting adhesive 4A. The fiber reinforced resin material 5A is a prepreg in which a fiber base material 5b containing unidirectionally oriented reinforcing fibers 5a is impregnated with an uncured thermosetting resin.

より具体的には、金属部品２を補強する際に、強化繊維５ａが、金属部品２の長手方向に沿って配向されるように、金属板３の表面に、繊維強化樹脂材５Ａを貼着する。しかしながら、たとえば、強化繊維５ａが一方向に配向されていれば、強化繊維５ａが、金属部品２の長手方向に交差するように配向されていてもよい。 More specifically, when the metal component 2 is reinforced, the fiber reinforced resin material 5A is attached to the surface of the metal plate 3 so that the reinforcing fibers 5a are oriented along the longitudinal direction of the metal component 2. do. However, for example, if the reinforcing fibers 5a are oriented in one direction, the reinforcing fibers 5a may be oriented so as to intersect with each other in the longitudinal direction of the metal part 2.

次に、繊維強化樹脂材５Ａを貼着した後、繊維強化樹脂材５Ａを加熱することにより、熱硬化性樹脂を熱硬化させる。このとき、接着剤４Ａも合わせて硬化させる。これにより、接着層４を介して繊維強化樹脂材５を金属板３に貼着させた補強材６を得ることができる。 Next, after the fiber-reinforced resin material 5A is attached, the thermosetting resin is heat-cured by heating the fiber-reinforced resin material 5A. At this time, the adhesive 4A is also cured. As a result, the reinforcing material 6 in which the fiber reinforced resin material 5 is attached to the metal plate 3 via the adhesive layer 4 can be obtained.

本実施形態では、金属板３の表面は、外壁部２１の表面の如き凹部と凸部が交互に形成された表面ではなく、平滑な表面であるため、この表面に貼着される繊維強化樹脂材５Ａの強化繊維５ａはうねることなく、その配向は乱れることがない。 In the present embodiment, the surface of the metal plate 3 is not a surface in which concave portions and convex portions are alternately formed like the surface of the outer wall portion 21, but is a smooth surface, so that the fiber reinforced resin is attached to this surface. The reinforcing fiber 5a of the material 5A does not undulate and its orientation is not disturbed.

また、金属板３の貼着される面が平坦面（単純な表面）であるため、金属板３と繊維強化樹脂材５Ａとの間に空気が入り込み難く、繊維強化樹脂材５Ａの内部にボイドが形成され難い。 Further, since the surface to which the metal plate 3 is attached is a flat surface (simple surface), it is difficult for air to enter between the metal plate 3 and the fiber reinforced resin material 5A, and a void is formed inside the fiber reinforced resin material 5A. Is difficult to form.

このようにして、強化繊維５ａの配向を確保した状態で、繊維強化樹脂材５Ａの界面および内部にボイドがほとんどない状態で、熱硬化性樹脂を熱硬化させるので、強化繊維５ａによる補強効果の高い補強材６を得ることができる。 In this way, the thermosetting resin is thermosetting with almost no voids at the interface and inside of the fiber-reinforced resin material 5A while the orientation of the reinforcing fibers 5a is secured. A high reinforcing material 6 can be obtained.

ここで、繊維基材５ｂは、一方向に配向された強化繊維を含むものであれば、平織、綾織、または朱子織された織物基材であってもよい。本実施形態では、繊維基材５ｂは、金属部品２の長手方向に沿って強化繊維５ａが配向されるように、引き揃えられた強化繊維５ａからなってもよく、それを一部に含んでいてもよい。 Here, the fiber base material 5b may be a plain weave, twill weave, or satin weave woven base material as long as it contains reinforcing fibers oriented in one direction. In the present embodiment, the fiber base material 5b may consist of the reinforcing fibers 5a aligned so that the reinforcing fibers 5a are oriented along the longitudinal direction of the metal part 2, and includes the reinforcing fibers 5a as a part thereof. You may.

強化繊維５ａとしては、たとえば、ガラス繊維、炭素繊維、アラミド繊維、アルミナ繊維、ボロン繊維、スチール繊維、ＰＢＯ繊維、又は高強度ポリエチレン繊維などの繊維を挙げることができ、本実施形態では、強化繊維５ａは、炭素繊維である。 Examples of the reinforcing fiber 5a include fibers such as glass fiber, carbon fiber, aramid fiber, alumina fiber, boron fiber, steel fiber, PBO fiber, and high-strength polyethylene fiber. In the present embodiment, the reinforcing fiber is a reinforcing fiber. 5a is a carbon fiber.

繊維基材５ｂに含浸される熱硬化性樹脂としては、たとえばエポキシ系樹脂、フェノール系樹脂、メラミン系樹脂、尿素系樹脂、シリコーン系樹脂、マレイミド系樹脂、ビニルエステル系樹脂、不飽和ポリエステル系樹脂、シアネート系樹脂、又はポリイミド系樹脂等の樹脂を挙げることができる。本実施形態では、熱硬化性樹脂は、エポキシ系樹脂である。 Examples of the thermosetting resin impregnated in the fiber base material 5b include epoxy resin, phenol resin, melamine resin, urea resin, silicone resin, maleimide resin, vinyl ester resin, and unsaturated polyester resin. , Cyanate-based resin, or resin such as polyimide-based resin. In this embodiment, the thermosetting resin is an epoxy resin.

また、接着剤４Ａは熱硬化型の接着剤であり、繊維強化樹脂材５Ａの観点から、繊維基材５ｂに含浸させる樹脂と同種の樹脂が好ましい。接着剤４Ａの代わりに接着シートを用いてもよい。本実施形態では、金属板３は、アルミニウム合金からなるため、炭素繊維からなる強化繊維５ａが金属板３に直接接触しないように、接着剤４Ａを配置することが好ましい。これにより、アルミニウム合金と炭素との接触を回避し、アルミニウム合金のガルバニック腐食を抑えることができる。 Further, the adhesive 4A is a thermosetting adhesive, and from the viewpoint of the fiber reinforced resin material 5A, a resin of the same type as the resin impregnated in the fiber base material 5b is preferable. An adhesive sheet may be used instead of the adhesive 4A. In the present embodiment, since the metal plate 3 is made of an aluminum alloy, it is preferable to arrange the adhesive 4A so that the reinforcing fibers 5a made of carbon fibers do not come into direct contact with the metal plate 3. As a result, contact between the aluminum alloy and carbon can be avoided, and galvanic corrosion of the aluminum alloy can be suppressed.

なお、このような腐食が発生しないように、金属板３の材料と強化繊維５ａの材料とが選択され、金属板３に、繊維強化樹脂材５Ａを直接貼着することができるのであれば、接着剤４Ａを設けなくてもよい。たとえば、金属板３が鋼製である場合には、強化繊維５ａが炭素繊維であっても、このような腐食を回避することができる。 If the material of the metal plate 3 and the material of the reinforcing fiber 5a are selected so that such corrosion does not occur, and the fiber reinforced resin material 5A can be directly attached to the metal plate 3. It is not necessary to provide the adhesive 4A. For example, when the metal plate 3 is made of steel, such corrosion can be avoided even if the reinforcing fiber 5a is carbon fiber.

４．接合工程Ｓ４について
次に、接合工程Ｓ４を行う。この工程では、図５に示すように、金属部品２に補強材６を接合する。具体的には、金属部品２の開口部２５を覆うように、補強材６の金属板３を接合する。本実施形態では、補強材６の金属板３で外壁部２１及び２３の一部の表面を覆い、金属板３の周縁に沿って、連続的に金属板３と外壁部２１とにアーク溶接などの溶接を行う。 4. About the joining step S4 Next, the joining step S4 is performed. In this step, as shown in FIG. 5, the reinforcing member 6 is joined to the metal part 2. Specifically, the metal plate 3 of the reinforcing material 6 is joined so as to cover the opening 25 of the metal part 2. In the present embodiment, the metal plate 3 of the reinforcing material 6 covers a part of the surfaces of the outer wall portions 21 and 23, and arc welding or the like is continuously performed on the metal plate 3 and the outer wall portion 21 along the peripheral edge of the metal plate 3. Weld.

これにより、図５の下図に示すように、金属板３は、その周縁において、溶接部８を介して外壁部２１、２３に接合された複合部材１を得ることができる。複合部材１には、金属部品２と金属板３とにより、金属製の筒状体が形成され、この筒状体の表面に繊維強化樹脂材５が配置される。なお、本実施形態では、金属板３の周縁に沿って連続的に溶接したが、金属板３の周縁に沿ってスポット的に溶接してもよい。 As a result, as shown in the lower figure of FIG. 5, the metal plate 3 can obtain the composite member 1 joined to the outer wall portions 21 and 23 via the welded portion 8 at the peripheral edge thereof. A metal tubular body is formed in the composite member 1 by the metal component 2 and the metal plate 3, and the fiber reinforced resin material 5 is arranged on the surface of the tubular body. In the present embodiment, the metal plate 3 is continuously welded along the peripheral edge, but the metal plate 3 may be spot-welded along the peripheral edge.

本実施形態では、金属部品２に繊維強化樹脂材５を直接貼着するのではなく、平滑な表面を有した金属板３に繊維強化樹脂材５を貼り付けて熱硬化させるため、強化繊維５ａの配向性を保った状態の補強材６で、金属部品２を補強することができる。 In the present embodiment, the fiber reinforced resin material 5 is not directly attached to the metal part 2, but the fiber reinforced resin material 5 is attached to the metal plate 3 having a smooth surface and thermosetting, so that the reinforcing fibers 5a The metal part 2 can be reinforced with the reinforcing material 6 in a state where the orientation of the above is maintained.

したがって、金属部品２の長手方向に沿って、強化繊維５ａが蛇行することなく、配向性の高い強化繊維５ａを配置することができる。この結果、補強材６による金属部品２の補強効果を高めることができる。 Therefore, the reinforcing fibers 5a having high orientation can be arranged along the longitudinal direction of the metal component 2 without the reinforcing fibers 5a meandering. As a result, the reinforcing effect of the metal component 2 by the reinforcing member 6 can be enhanced.

さらに、補強材６の作製の際に、熱硬化性樹脂を熱硬化させるので、熱硬化時の熱影響を金属部品２が受けることはない。したがって、金属部品２が、アルミニウム合金からなる場合、この熱硬化時の熱によりアルミニウム合金が過時効により、強度低下することはない。 Further, since the thermosetting resin is heat-cured during the production of the reinforcing material 6, the metal component 2 is not affected by the heat during the heat-curing. Therefore, when the metal part 2 is made of an aluminum alloy, the strength of the aluminum alloy does not decrease due to overaging due to the heat during the heat curing.

さらに、補強材６の金属板３と、金属部品２とを溶接により接合するため、金属材料同士の接合になり、金属板３と外壁部２１、２３との接合強度を高めることができる。なお、本実施形態では、金属板３と、金属部品２とを溶接により接合したが、たとえば、リベット、ネジ、またはボルトなどの部材を介してこれらを接合してもよい。 Further, since the metal plate 3 of the reinforcing material 6 and the metal component 2 are joined by welding, the metal materials are joined to each other, and the joining strength between the metal plate 3 and the outer wall portions 21 and 23 can be increased. In the present embodiment, the metal plate 3 and the metal part 2 are joined by welding, but they may be joined via members such as rivets, screws, or bolts.

また、通常、金属部品に繊維強化樹脂材を直接貼着する場合、金属部品のアルミニウム合金と炭素繊維の炭素とが接触すると、アルミニウム合金のガルバニック腐食が懸念されるため、金属部品の表面に、電着塗装などの塗装を行わなければならない。しかしながら、本実施形態では、金属板３を介して繊維強化樹脂材５を金属部品２に接合するため、このような塗装をしなくてもよい。特に、金属部品に電着塗装を行うと、金属部品のアルミニウム合金も加熱され、過時効による金属部品の強度低下が懸念されるところ、本実施形態では、このような強度低下を防止することができる。 In addition, when a fiber-reinforced resin material is normally attached directly to a metal part, if the aluminum alloy of the metal part and the carbon of the carbon fiber come into contact with each other, there is a concern about galvanic corrosion of the aluminum alloy. Painting such as electrodeposition painting must be performed. However, in the present embodiment, since the fiber reinforced resin material 5 is joined to the metal part 2 via the metal plate 3, such coating is not necessary. In particular, when electrodeposition coating is applied to a metal part, the aluminum alloy of the metal part is also heated, and there is a concern that the strength of the metal part may decrease due to aging. In this embodiment, it is possible to prevent such a decrease in strength. can.

実施形態で得られた複合部材１は、たとえば、自動車のバンパーリインフォースメントやドアのインパクトビームに用いることができる。 The composite member 1 obtained in the embodiment can be used, for example, for a bumper reinforcement of an automobile or an impact beam of a door.

以上、本発明の一実施形態について詳述したが、本発明は、前記の実施形態に限定されるものではなく、特許請求の範囲に記載された本発明の精神を逸脱しない範囲で、種々の設計変更を行うことができるものである。 Although one embodiment of the present invention has been described in detail above, the present invention is not limited to the above-described embodiment, and various types are described within the scope of the claims as long as the spirit of the present invention is not deviated. It is possible to make design changes.

１：複合部材、２：金属部品、２Ａ：金属部材、３：金属板、４：接着層、４Ａ：接着剤、５：（熱硬化後の）繊維強化樹脂材、５Ａ：（熱硬化前の）繊維強化樹脂材、６：補強材、８：溶接部 1: Composite member, 2: Metal part, 2A: Metal member, 3: Metal plate, 4: Adhesive layer, 4A: Adhesive, 5: Fiber reinforced resin material (after thermosetting), 5A: (Before thermosetting) ) Fiber reinforced resin material, 6: Reinforcing material, 8: Welded part

Claims (1)

金属部品と、前記金属部品を補強する繊維強化樹脂材とを備えた筒状の複合部材の製造方法であって、
長手方向に沿って凹部が形成された金属部材を、前記凹部の開口部側に屈曲するように曲げ加工することにより、前記金属部品を作製する工程と、
前記金属部品の凹部の開口部を覆う形状の金属板の表面に、一方向に配向した強化繊維を含む繊維基材に未硬化の熱硬化性樹脂を含浸した繊維強化樹脂材を貼着した後、前記熱硬化性樹脂を熱硬化させて、補強材を作製する工程と、
前記金属部品の前記開口部を覆うように、前記補強材の前記金属板を接合する工程と、を含むことを特徴とする複合部材の製造方法。 A method for manufacturing a tubular composite member including a metal part and a fiber-reinforced resin material for reinforcing the metal part.
A step of manufacturing the metal part by bending a metal member having a recess formed along the longitudinal direction so as to bend toward the opening side of the recess.
After attaching a fiber reinforced resin material impregnated with an uncured thermosetting resin to a fiber base material containing unidirectionally oriented reinforcing fibers on the surface of a metal plate having a shape covering the opening of the recess of the metal part. , The process of producing a reinforcing material by thermosetting the thermosetting resin,
A method for manufacturing a composite member, which comprises a step of joining the metal plate of the reinforcing material so as to cover the opening of the metal part.
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