JP6400399B2 - Composite structure of metal and reinforced fiber thermoplastic resin and method for producing the same - Google Patents

Description

  The present invention relates to a composite structure of a metal and a reinforced fiber thermoplastic resin obtained by integrating a metal and a reinforced fiber thermoplastic resin to achieve high strength and light weight, and a method for producing the same. More specifically, a metal in which a structural member made of a reinforced fiber thermoplastic resin molded into a desired shape and a metal structural member installed at a desired position of a structural member made of reinforced fiber thermoplastic resin are integrated. And a reinforced fiber thermoplastic resin composite structure and a method for producing the same.

  Carbon fiber reinforced thermosetting resin is a reinforced fiber resin (reinforced plastic) that uses carbon fiber as a reinforcing material, and is a material that has sufficient rigidity while being 1/4 to 1/5 that of iron. Are known. This carbon fiber reinforced thermosetting resin has been put to practical use from golf club shafts, fishing rods, and the like, and is also used in components such as aircraft that are required to be lightweight while being highly rigid. This component made of carbon fiber reinforced thermosetting resin is a high temperature and pressure increase in a kiln called autoclave that can pressurize a sheet (prepreg) in which carbon fiber is impregnated with thermosetting resin. Molded by the autoclave method, etc.

  However, since the resin material impregnated into the carbon fiber is a thermosetting resin, it is solidified by heating and does not soften even when reheated. In addition, the autoclave method, etc., often takes a long time to mold the components, so the productivity is low, and there are problems such as waste materials and defective products cannot be re-formed and recycled. It is expensive. Therefore, a constituent member made of carbon fiber reinforced thermosetting resin has not been adopted as a constituent member of an automobile such as a mass-produced car.

  Therefore, development of a carbon fiber reinforced thermoplastic resin using a thermoplastic resin as a matrix has been promoted as a material that can be used as a structural member of a mass-produced vehicle. This carbon fiber reinforced thermoplastic resin can be set in a die of a press machine after heating, and can be formed by a high-speed stamping molding by a clamping process, and the molding time can be shortened to a few minutes or less than before. . Further, it is possible to join and recycle parts by reheating.

  Depending on the application, structural members made of carbon fiber reinforced thermoplastic resin molded into various shapes are assembled and commercialized. That is, in order to be completed as a product, the structural members must be combined, fastened, and fixed in the same manner as the metallic structural members. For this reason, various researches and developments and various proposals have been made on techniques for joining carbon fiber reinforced thermoplastic resins. A conventional technique related to joining of carbon fiber reinforced thermoplastic resins will be described in accordance with patent literature.

  For example, a method of fusing a CFRTP material, which is a thermoplastic resin reinforced with carbon fiber, applying a voltage to the CFRTP material and applying pressure to partially melt, stopping the voltage application, A technique related to a method for cooling and fusing a joint portion of a CFRTP material is known (for example, see Patent Document 1). There is also known a technique related to a method of joining a pair of joined articles, at least one of which is a carbon fiber reinforced thermoplastic resin composite, using resistance welding (see, for example, Patent Document 2).

  Furthermore, a method of manufacturing a joining member formed by joining a carbon fiber composite material using a thermoplastic resin as a matrix (base material) and a metal, and forming a concavo-convex shape on the metal surface, and a thermoplastic resin layer And a technique relating to a joining method for joining a metal and a carbon fiber composite material by melting a thermoplastic resin layer is known (for example, see Patent Document 3). In addition, a technique relating to a joining method of joining members in which a carbon fiber reinforced composite material using a thermoplastic resin as a matrix is added to a metal member by insert molding is known (for example, see Patent Document 4).

  Furthermore, an adhesive structure member comprising a main structural material and a reinforcing member in which at least one fiber reinforcing material layer is laminated and bonded to the surface of the main structural material, and bonded to the main structure of the reinforcing member A technique relating to an adhesive structure member having a groove processing portion in which a groove is processed on a surface to be processed is known (for example, see Patent Document 5).

JP 2012-187903 A JP 2012-16867 A WO2013 / 146900 (A1) JP 2012-158142 A JP 2012-171221 A

However, the techniques of Patent Documents 1 and 2 are techniques for joining a joined product made of a carbon fiber reinforced thermoplastic resin composite or a similar material, and joining a carbon fiber reinforced thermoplastic resin composite and a metal. It is not possible. The technique of Patent Document 3 is a technique that needs to include a step of providing a thin layer of organic matter in order to enhance the bonding force between the thermoplastic resin layer and the metal surface. Moreover, there existed a possibility that rigidity may fall by having a thermoplastic resin layer. In the technology of Patent Document 4, when insert molding is performed with a carbon fiber composite material, the entire cavity formed in a complicated shape may not be filled with the carbon fiber composite material, and high precision and reliable injection molding is possible. There was a risk that it could not be performed. Moreover, the technique of patent document 5 requires the process of processing the groove processing part for expressing the outstanding adhesive strength, and the problem that productivity falls will arise.
As described above, the techniques of Patent Documents 1 to 5 still have problems in firmly and firmly fixing the structural member made of metal and the structural member made of reinforced fiber thermoplastic resin (carbon fiber reinforced thermoplastic resin). There was room for improvement.

The present invention has been made to solve such problems and achieves the following object.
The object of the present invention is to firmly fix a metal structural member and a structural member made of a reinforced fiber thermoplastic resin to reduce the weight and increase the rigidity, and facilitate the assembly work and the like with the metal and the reinforced fiber heat. The object is to provide a composite structure of a plastic resin and a method for producing the same.

In order to achieve the above object, the present invention employs the following means.
The composite structure of the metal of the present invention 1 and the reinforced fiber thermoplastic resin is
A first component member made of a fiber reinforced thermoplastic resin formed in a desired shape and containing a reinforcing fiber in a thermoplastic resin, and installed at a desired position of the first component member, and opened on one side One or more types of treatment selected from primer application, surface treatment by laser, surface treatment by mechanical treatment, and surface treatment by chemical treatment on the inner peripheral surface Is provided between the second component member made of metal, the first component member, and the second component member, and the other surface and side surface of the second component member is the second component member. The surface of the inner peripheral portion is integrally fixed, and one surface is composed of a bonding resin member made of a thermoplastic resin and fixed integrally with the thermoplastic resin of the first component member, The second component member has the side surface of the other surface. A slope more the one side expands, wherein the one having the inclination angle in a range of less than 15 ° or 90 ° to one side.

The method for producing a composite structure of a metal and a fiber reinforced thermoplastic resin of the present invention 2 ,
A first step of forming a first component member made of fiber reinforced thermoplastic resin, in which a reinforced fiber is contained in a thermoplastic resin, into a desired shape, and a second metal member having an opening formed on one side A second step of forming the constituent member into a desired shape, and a surface of the inner peripheral portion of the second constituent member by applying primer, surface treatment by laser, surface treatment by mechanical treatment, and surface by chemical treatment A third step of performing one or more treatments selected from the treatments, and injecting and filling the thermoplastic resin composition of the bonding resin member into the inner peripheral portion of the second component member inserted into the mold. A fourth step of manufacturing a metal resin member in which the other surface and the side surface of the bonding resin member are integrally fixed to the surface of the inner peripheral portion subjected to the treatment; and a desired position of the first component member The metal resin member is installed on the first component member. The metal resin member is thermocompression-bonded from the other side, and consists of a fifth step of fixing the thermoplastic resin of the first component member partially melted and one surface of the bonding resin member together, In the second component member, the side surface is an inclined surface whose one surface side is wider than the other surface side, and has an inclination angle within a range of 15 ° or more and less than 90 ° with respect to the one surface. The metal resin member is formed such that a predetermined amount of the bonding resin member protrudes from the one surface of the second component member, and protrudes when thermocompression bonding is performed in the fifth step. It is characterized in that the portion is a melting allowance.

The method for producing a composite structure of a metal and a fiber-reinforced thermoplastic resin of the present invention 3 ,
A first step of forming a first component member made of fiber reinforced thermoplastic resin, in which a reinforced fiber is contained in a thermoplastic resin, into a desired shape, and a second metal member having an opening formed on one side A second step of forming the constituent member into a desired shape, and a surface of the inner peripheral portion of the second constituent member by applying primer, surface treatment by laser, surface treatment by mechanical treatment, and surface by chemical treatment A third step of performing one or more processes selected from the processes; and bringing one surface of the second component member into contact with the first component member at a desired position of the first component member. The fourth step of setting in the mold, the mold is closed, and the space of the first constituent member and the inner peripheral portion of the second constituent member is heated in the bonding resin member. A plastic resin composition is injected and filled, and the thermoplastic resin composition is cooled. The one surface of the bonding resin member and the first component member, the other surface and side surface of the bonding resin member, and the inner peripheral portion of the second component member subjected to the treatment. And the second component member is a slope whose one surface side is wider than the other surface side, and is 15 ° or more with respect to the one surface. In addition to having an inclination angle within a range of less than 90 °, at least one hole for injecting the thermoplastic resin composition into the space is formed, and the fifth step is performed through the hole. And a step of injecting and filling the thermoplastic resin composition of the bonding resin member.

The method for producing a composite structure of a metal and a fiber-reinforced thermoplastic resin according to the fourth aspect of the present invention is the second or third aspect of the present invention, wherein the reinforcing fiber is a carbon fiber.

  The composite structure of the metal and the reinforced fiber thermoplastic resin of the present invention is a lightweight, high-rigidity first structural member made of reinforced fiber thermoplastic resin that can be easily molded, and other composite structures. The metal second structural member for facilitating the process can be easily and firmly fixed. In other words, the composite structure has a main portion made of the first structural member made of the reinforced fiber thermoplastic resin, and can be a lightweight and highly rigid structure. Further, the second structural member is a metallic structural member, and a part (part) for performing connection, coupling, or the like can be easily formed by machining or the like in order to assemble and commercialize the second structural member. That is, this composite structural member can be reduced in weight as compared with a conventional structural member made of metal, and a product can be assembled and manufactured in substantially the same manner as the conventional structural member made of metal.

  Furthermore, the first structural member is made of a fiber reinforced thermoplastic resin in which a reinforced fiber is contained in a thermoplastic resin, and the time for molding into a desired shape can be reduced and the productivity can be improved. It is also easy to re-mold and recycle defective products. Further, in this composite structure, the second structural member made of metal is integrally fixed to the first structural member, so that the composite structure is bonded to the same structure as the conventional metal structure. It can be fastened with a fastening member such as a bolt, and the assembly work is easy. For example, it can also be used in low-priced products such as automobiles such as mass-produced vehicles, so that vehicle weight can be reduced and fuel consumption can be reduced.

  In the method for producing a composite structure of a metal and a reinforced fiber thermoplastic resin of the present invention, a first structural member made of reinforced fiber thermoplastic resin and a second structural member made of metal are bonded via a bonding resin member. It is firmly fixed as a unit. The second structural member has been subjected to at least one treatment selected from primer coating, laser surface treatment, surface treatment by mechanical treatment, and surface treatment by chemical treatment. It adheres firmly. In the thermoplastic resin that is the matrix (base material) of the first structural member, the heated bonding resin member or the portion (portion) that comes into contact with the thermoplastic resin composition of the injected bonding resin member is partially melted. In the process of post-cooling, the thermoplastic resin and the bonding resin member of the first structural member are integrated and firmly fixed. Further, the first structural member can be easily formed and can be manufactured at low cost. By such a manufacturing method, a composite structure of a metal and a fiber reinforced thermoplastic resin, which can be reduced in weight and increased in rigidity, can be manufactured with improved productivity.

FIG. 1 is a view showing a composite structure of a metal and a reinforced fiber thermoplastic resin of the present invention, where (a) is an external view, and (b) is a cross-sectional view taken along line BB. is there. FIG. 2 is an explanatory view schematically showing a process in which a composite structure of a metal and a reinforced fiber thermoplastic resin is manufactured in the first embodiment of the present invention. FIG. 3 is an explanatory view showing a state before the first structural member made of a reinforced fiber thermoplastic resin and the metal resin member are fixed. FIG. 4 is an explanatory view schematically showing a state in which the first structural member and the metal resin member are firmly fixed by thermocompression bonding. FIG. 5 is an explanatory view schematically showing a process in which a composite structure of a metal and a reinforced fiber thermoplastic resin is manufactured in the second embodiment. FIG. 6 is an explanatory view showing a state in which the mold is closed in the second embodiment. FIG. 7 shows the thermoplastic resin of the bonding resin member in the space formed between the first structural member made of reinforced fiber thermoplastic resin and the second structural member made of metal in the second embodiment. It is explanatory drawing which shows the state which has injected the composition.

  Next, an embodiment of a composite structure of a metal and a reinforced fiber thermoplastic resin of the present invention and a manufacturing method thereof will be described with reference to the drawings.

  FIG. 1 is a view showing a composite structure of a metal and a reinforced fiber thermoplastic resin of the present invention, where (a) is an external view, and (b) is a cross-sectional view taken along line BB. is there. FIG. 2 is an explanatory view schematically showing a process (step) in which a composite structure of a metal and a reinforced fiber thermoplastic resin is manufactured in the first embodiment of the present invention, and FIG. FIG. 4 is an explanatory view showing a state before the first structural member made of a plastic resin and the metal resin member are fixed, and FIG. 4 is a diagram in which the first structural member and the metal resin member are firmly fixed by thermocompression bonding. It is explanatory drawing which showed typically the state which is. In the description of this embodiment, the reinforced fiber thermoplastic resin will be described by taking a carbon fiber reinforced thermoplastic resin as an example.

[First Embodiment]
Based on FIG. 1, the composite structure of a metal and a carbon fiber reinforced thermoplastic resin will be described.
A composite structure of a metal and a carbon fiber reinforced thermoplastic resin (hereinafter referred to as CFRTP) in which carbon fiber is contained in a thermoplastic resin (hereinafter referred to as a composite structure). Reference numeral 1 denotes a structural member (structural component) for constituting an automobile, an aircraft, or the like. For example, it corresponds to a metallic structural member (structural component) that is currently made of metal, and is a structural member that is required to have substantially the same strength and rigidity as the metallic structural member.

  The composite structure 1 includes a first structural member made of CFRTP (hereinafter referred to as a CFRTP member) 11 formed into a desired shape and a metal provided at a desired position of the CFRTP member 11. The second structural member (hereinafter referred to as a metal member) 12 and a bonding resin member 13 made of a thermoplastic resin for fixing the CFRTP member 11 and the metal member 12 together. ing.

The metal member 12 of the composite structure 1 is fastened to another composite structure by a known fastening member such as a bolt so that the composite structures can be easily assembled to each other, and is not shown. However, for example, a fastening portion, a coupling portion, or the like including a screw hole, a mounting portion, a bolt hole, or the like is formed. By doing in this way, the composite structure 1 formed in various shapes and other composite structures are easily and firmly fastened, and the productivity is not lowered.
Based on FIGS. 2 to 4, a method for producing a composite structure of a metal and a carbon fiber reinforced thermoplastic resin in the first embodiment will be described.

[CFRTP members]
The CFRTP member 11 is formed in a desired shape by forming the CFRTP material 11a into a predetermined size. The CFRTP material 11a may be a thermoplastic resin [for example, PP (polypropylene), PA (polyamide)] containing 60% or less carbon fiber. In order to form the CFRTP material 11a in a desired shape, the CFRTP material 11a is heated to a predetermined temperature, and then the CFRTP material 11a is inserted into a mold formed in the desired shape, and press-molded with the mold. A hot pressing method (for example, a stamping molding method) for producing a CFRTP molded member having a predetermined shape is often employed. The technology related to the stamping molding is a known technology (for example, see Japanese Patent Application Laid-Open No. 2012-213946), and detailed description thereof is omitted in the description of this embodiment. Thereafter, the CFRTP molded member is trimmed on the outer peripheral surface and the like to be manufactured into a CFRTP member 11 having a desired shape [steps (a) and (b) in FIG. 2].

[Metal parts]
The metal member 12 targeted by the present invention is mainly a light alloy such as an aluminum alloy, a magnesium alloy, a titanium alloy, or a copper alloy, a steel material, and stainless steel. A plate-shaped metal material having a predetermined thickness is cut into a desired size. A metal material cut into a desired size is formed into a desired shape. The metal member 12 has a larger area on the bottom surface (one surface 12a located on one side) side fixed to the CFRTP member 11 than on the upper surface (the other surface 12b located on the other side) side. An opening is formed on the bottom surface (one surface 12a) side. The metal member 12 has a side surface that is wider on the bottom surface (one surface 12a) side than the upper surface (the other surface 12b) side and has a slope having a predetermined inclination angle α with respect to the bottom surface. For example, the slope has an inclination angle α in the range of 15 ° or more and less than 90 ° with respect to the bottom surface (one surface 12a) of the metal member 12 joined to the CFRTP member 11. Such molding can be easily performed by press molding, and the metal member 12 of this embodiment has a substantially trapezoidal shape when viewed in cross-section and has an open bottom surface [step of FIG. (C), (d)]. The metal member may be, for example, a truncated cone-shaped or substantially truncated cone-shaped structural member, a truncated pyramid-shaped or generally truncated pyramid-shaped structural member, or the like. That is, the metal member only needs to have a substantially trapezoidal shape in sectional view having the side surface having the inclination angle α described above.

  The metal member 12 is subjected to a treatment capable of being easily joined to a thermoplastic resin on the surface of the inner peripheral portion 12c having a substantially trapezoidal shape in a cross-sectional view [step (e) in FIG. 2]. Even if the thermoplastic resin composition is injection-molded in a state where no treatment is applied to the surface of the inner peripheral portion 12c of the metal member 12, a sufficient bonding force cannot be obtained in many cases. In particular, it is insufficient when high reliability is required. Therefore, in the present invention, the surface of the inner peripheral portion 12c of the metal member 12 is subjected to an etching process, thereby increasing the bonding force. The present inventors have developed an etching technique for integrating a metal alloy and a resin with a strong bonding force, and some of these techniques are disclosed. [For example, refer to JP 2007-301972 A, WO 2004/041532 (A1), Japanese Patent No. 3954379, etc.].

[Example of aluminum alloy]
The outline will be described by taking an aluminum alloy as an example. A standardized aluminum alloy is used, but in order to produce a product, it is pressed from a plate-shaped material and formed into a desired shape. There is a possibility that oils and fats and fine dust may adhere to the surface of the processed shape, and the surface is washed with an aluminum degreasing agent.

[Chemical etching]
Next, a chemical etching process is performed on the surface of the inner peripheral portion 12c of the aluminum alloy. This is not an essential treatment in the present invention, but by performing this, the bonding between the aluminum alloy shaped article and the thermoplastic resin composition becomes more effective. Specifically, the aluminum alloy is immersed in a basic aqueous solution (pH> 7) and then washed with water. Examples of the base used in the basic aqueous solution include sodium hydroxide, potassium hydroxide, soda ash, and ammonia. By performing this treatment, the surface of the aluminum alloy is dissolved as aluminate ions while releasing hydrogen, and the surface of the aluminum alloy is shaved and etched to form a new surface.

[Chemical conversion treatment]
Next, chemical conversion (inner surface treatment) is performed on the chemically etched aluminum alloy surface [step (e) in FIG. 2]. This is an essential process in the present invention. Specifically, the aluminum alloy is immersed in an aqueous solution of ammonia, hydrazine and / or a water-soluble amine compound. By performing this treatment, the surface of the aluminum alloy is finely immersed to form fine irregularities, and the nitrogen-containing compound is adsorbed. A method in which a 3 to 10% hydrazine monohydrate aqueous solution is set to 40 ° C. to 70 ° C. and the aluminum alloy is immersed in the solution for several minutes and then washed with water is preferable. This is because it has no odor and is easy to handle.

  In addition, the metal member 12 may be obtained by applying an inner surface treatment for applying a primer (undercoat material) to the surface of the inner peripheral portion 12c. Further, the metal member 12 may be subjected to surface treatment (inner surface treatment) by laser processing so that the surface of the inner peripheral portion 12c becomes an uneven surface having a desired surface roughness. Further, the metal member 12 is subjected to a surface treatment (inner surface treatment) so that the surface of the inner peripheral portion 12c becomes an uneven surface having a desired surface roughness by mechanical processing such as cutting and grinding. It may be a thing. Further, the metal member 12 may be a member in which the surface of the inner peripheral portion 12c is subjected to a surface treatment (an inner surface treatment) by a chemical treatment. Further, one or more treatments selected from these surface treatments may be performed. That is, the metal member 12 only needs to be subjected to a surface treatment for strengthening the bonding with the bonding resin member 13 on the surface of the inner peripheral portion 12c.

[Bonding of metal members and bonding resin members]
Next, a crystalline thermoplastic resin composition (hereinafter referred to as a bonding resin composition) that is a composition of the bonding resin member 13 is injection-molded on the surface of the aluminum alloy subjected to the chemical conversion treatment in this way. As the bonding resin composition, a resin composition mainly composed of poniphenylene sphere (hereinafter referred to as “PPS”) or polybutylene terephthalate (hereinafter referred to as “PBT”) is used. Further, the inclusion of the filler is very important from the viewpoint of improving the mechanical properties and making the linear expansion coefficients of the aluminum alloy shaped product and the bonding resin composition coincide. As the fiber filler, one or more selected from glass fiber, carbon fiber, and aramid fiber may be used. As the powder filler, selected from calcium carbonate, magnesium carbonate, silica, talc, glass, and clay. One or more types may be used.

  The metal member 12 is inserted into a mold (not shown) after chemical conversion treatment of the surface of the inner peripheral portion 12c. A bonding resin composition heated to a predetermined temperature and pressurized to a predetermined pressure is injected and filled into the cavity of the mold. In the process in which the filled bonding resin composition is cooled to become the bonding resin member 13, the surface of the inner peripheral portion 12c of the metal member 12 and the other surface and side surfaces of the bonding resin member 13 are firmly bonded to each other. A metal resin member 14 in which the member 12 and the bonding resin member 13 are integrated is manufactured [step (f) in FIG. 2]. The metal resin member 14 is formed so that the bonding resin member 13 protrudes downward by a predetermined amount a (for example, 0.3 mm) from the end surface (opening side end surface) of the bottom surface of the metal member 12. . The part (part) formed so as to protrude is a melting margin of the bonding resin member 13 when the CFRTP member 11 and the metal resin member 14 are integrally fixed by thermocompression bonding by the thermocompression bonding apparatus 20. is there.

[Fixing of CFRTP member and metal resin member]
A metal resin member 14 is integrally fixed to a predetermined position on the CFRTP member 11 formed in a desired shape. This predetermined position corresponds to a coupling position when the composite structure 1 is assembled.

  The CFRTP member 11 is placed and fixed on the base 25. The metal resin member 14 is placed at a desired position of the CFRTP member 11 and the thermocompression bonding head 21 is covered. A heater 24 is built in the thermocompression bonding head 21. The thermocompression bonding head 21 heats the bonding resin member 13 to a predetermined temperature (for example, a temperature higher by +20 to 30 ° C. than the melting point of the thermoplastic resin of the bonding resin member), A predetermined pressure P is applied so that the thermoplastic resin that is the matrix (base material) of the CFRTP member 11 that has been melted is integrated in the course of cooling [step (g) in FIG. 2]. These controls are performed by the thermocompression controller 22. The bonding resin member 13 heated to a predetermined temperature enters a molten state and conducts this heat to the CFRTP member 11 side. The portion of the thermoplastic resin of the CFRTP member 11 that is in contact with the heated bonding resin member 13 and its vicinity are partially melted. When the heating by the heater 24 is stopped and cooled, the bonding resin member 13 in a molten state and the partially melted portion of the thermoplastic resin of the CFRTP member 11 are integrally solidified to form a CFRTP member. The thermoplastic resin 11 and one surface of the bonding resin member 13 are integrated and firmly fixed. That is, the CFRTP member 11 and the metal member 12 are firmly and firmly fixed together through the bonding resin member 13. Also, the bottom surface of the metal member 12 is fixed so as to contact the top surface of the CFRTP member 11, the metal member 12 is in a solid state by the bonding resin member 13, and the metal resin member 14 is the bottom surface. (The one surface 12a located on one side of the metal member 12 to be the fixing surface of the metal resin member 14) is formed so that the area on the side is increased, and the side surface of the metal member 12 is at a predetermined angle It is firmly fixed because it is formed on the slope having the. In other words, the CFRTP member 11 and the metal member 12 are firmly integrated through the bonding resin member 13. By adopting such a configuration, even when a load is applied from the side of a fastening portion (not shown) formed on the metal member 12 and fastened to another structural member by a fastening member such as a bolt, the joining resin member Thus, no problem occurs in the portion that is integrally fixed via 13.

  The thermocompression bonding head 21 and the CFRTP member 11 are configured such that they can be relatively moved and positioned in the three-dimensional direction. For example, the thermocompression bonding head 21 is provided with an axis moving device that can be easily moved and positioned (not shown), and the thermocompression bonding head 21 is relative to the CFRTP member 11 in a three-dimensional direction. Therefore, it can be moved and positioned. That is, the metal member 12 can be positioned and fixed to the CFRTP member 11 at a desired position.

  This composite structure 1 is made of a CFRTP member 11 that is lightweight, highly rigid, and easy to mold, and a metal member 12 for facilitating assembly with other composite structures. It can be fixed. In other words, the composite structure 1 is mainly composed of the CFRTP member 11 and can be a lightweight and highly rigid structure. Further, the metal member 12 is a metal member that can be easily processed by metal, etc., and can be easily formed by machining or the like in order to be assembled and commercialized. . In other words, the composite structure member 1 can be reduced in weight as compared with the conventional structure member made of metal, and can be assembled and manufactured in the same manner as the conventional structure member made of metal. .

  Furthermore, the CFRTP member 11 is made of a fiber reinforced thermoplastic resin in which a reinforced fiber is contained in a thermoplastic resin, so that the time required for forming into a desired shape can be shortened and productivity can be improved, and waste materials and defective products can be obtained. It is also easy to remold and recycle. Further, in this composite structure 1, the metal member 12 is integrally fixed to the CFRTP member 11, so that the composite structures 1 can be coupled to each other like a conventional metal structure, such as a bolt. It can be fastened with a fastening member, and assembly work is easy. For example, it can also be used for low-priced products such as automobiles such as mass-produced vehicles. When this composite structure is adopted, the vehicle weight can be reduced and the amount of fuel used can be reduced.

  In the method for manufacturing the composite structure 1, the CFRTP member 11 and the metal member 12 are firmly and firmly bonded together through the bonding resin member 13. The metal member 12 is subjected to at least one treatment selected from primer application, laser surface treatment, mechanical treatment surface treatment, and chemical treatment surface treatment. It adheres firmly. The thermoplastic resin of the CFRTP member 11 is in the process of being cooled after the contact portion (part) with the heated bonding resin member 13 is partially melted, and the thermoplastic resin of the CFRTP member 11 and the bonding resin member 13. Are united and firmly fixed. Further, the first structural member can be easily formed and can be manufactured at low cost. By such a manufacturing method, a composite structure of a metal and a fiber reinforced thermoplastic resin, which can be reduced in weight and increased in rigidity, can be manufactured with improved productivity, and the spread can be promoted.

[Second Embodiment]
The composite structure of a metal and a carbon fiber reinforced thermoplastic resin and the manufacturing method thereof in the second embodiment will be described with reference to FIGS. FIG. 5 is an explanatory view schematically showing a process (step) in which a composite structure of a metal and a reinforced fiber thermoplastic resin is manufactured in the second embodiment, and FIG. 6 is a diagram showing the second embodiment. FIG. 7 is an explanatory view showing a state in which the mold is closed, and FIG. 7 is a view between the first structural member made of reinforced fiber thermoplastic resin and the second structural member made of metal in the second embodiment. It is explanatory drawing which shows the state which has inject | poured the thermoplastic resin composition of the joining resin member to the formed cavity (space part).

  The composite structure of metal and carbon fiber reinforced thermoplastic resin and the manufacturing method thereof according to the second embodiment is a composite structure of metal and carbon fiber reinforced thermoplastic resin compared to the first embodiment described above. A part of the manufacturing process for manufacturing is different, and the composite structure of metal and carbon fiber reinforced thermoplastic resin is the same or almost the same. The second embodiment will be described with a focus on the different steps of the manufacturing method. In the description of the second embodiment, the same parts as those in the first embodiment are denoted by the same reference numerals, and detailed description thereof is omitted.

  A CFRTP member 11 is manufactured by forming the CFRTP material 11a into a desired shape by stamping. Trimming or the like is performed on the CFRTP member 11 [steps (a) and (b) in FIG. 5]. After the metal material is cut into a desired size, the cut metal material is formed into a desired shape by press molding to produce the metal member 12 [steps (c) and (d) in FIG. 5]. An inner surface treatment is applied to the surface of the inner peripheral portion 12c of the metal member 12 [step (e) in FIG. 5]. Each of these steps is the same as in the first embodiment. The metal member 12 has at least one hole 16 (see FIG. 6) for injecting and filling the cavity (space portion) 15 with the thermoplastic resin composition of the bonding resin member 13.

  A CFRTP member 11 and a metal member 12 are set in a mold 30 composed of one mold 31 and the other mold 32, and the mold 30 is closed. A bonding resin composition (a thermoplastic resin composition of the bonding resin member 13) is injected and filled from a nozzle 33 into a cavity 15 formed between the CFRTP member 11 and the metal member 12, and so-called insert molding is performed. Is called. At this time, the bonding resin composition is heated to a predetermined temperature (for example, a temperature +20 to 30 ° C. higher than the melting point of the thermoplastic resin of the bonding resin member), and injected and filled into the cavity 15 with a predetermined injection pressure. It will be. Therefore, the other surface and side surface of the bonding resin member 13 and the surface of the inner peripheral portion 12c on which the surface treatment of the metal member 12 is performed cool the filled bonding resin composition to become the bonding resin member 13. It adheres firmly in the process. Further, when the bonding resin composition is filled with the CFRTP member 11, a portion where the thermoplastic resin as a matrix (base material) is in contact with the filled bonding resin composition and its vicinity are partially Melt. In the process where the filled bonding resin composition is cooled to become the bonding resin member 13, the bonding resin composition and the thermoplastic resin of the partially melted CFRTP member are solidified integrally. In other words, one surface of the bonding resin member 13 and the CFRTP member 11 are firmly and firmly fixed together in the process in which the filled bonding resin composition and the partially melted thermoplastic resin are cooled and solidified. [Step (h) in FIG. 5]. That is, the CFRTP member 11 and the metal member 12 are firmly and firmly fixed together through the bonding resin member 13.

  Further, the bottom surface (one surface 12a) of the metal member 12 is in contact with and firmly fixed to the top surface of the CFRTP member 11, the metal member 12 is in a solid state by the bonding resin member 13, The resin member 13 and the metal member 12 are formed so that the area on the bottom surface (one surface 12a) side to be fixed is increased, and the side surface of the metal member 12 is formed on an inclined surface having a predetermined angle. It is firmly fixed by being. In other words, the CFRTP member 11 and the metal member 12 are firmly integrated through the bonding resin member 13. By adopting such a configuration, even when a load is applied from the side of a fastening portion (not shown) formed on the metal member 12 and fastened to another structural member by a fastening member such as a bolt, the joining resin member Thus, no problem occurs in the portion that is fixed integrally with the connector 13.

  The mold 30 is opened and the composite structure 1 fixed integrally is taken out. If the composite structure 1 is small, this mold can manufacture the composite structure 1 in which a plurality of metal members 12 are integrally formed on a CFRTP member 11 by one injection molding. Good. Further, when the CFRTP member 11 is large, the CFRTP member 11 and the mold 30 are configured to be relatively movable, and the CFRTP member 11 is moved to the CFRTP member 11 while the mold 30 and the CFRTP member 11 are relatively moved. One or more metal members 12 may be secured. For example, the composite structure 1 may be manufactured by mounting and fixing the CFRTP member 11 on the moving table and performing the fixing operation described above while moving the CFRTP member 11 relative to the mold 30. The composite structure 1 and the manufacturing method thereof according to the second embodiment exhibit substantially the same effects as those of the first embodiment described above.

  As mentioned above, although embodiment of this invention was described, it cannot be overemphasized that this invention is not limited to this embodiment, and can be changed within the range which does not deviate from the objective of this invention, and the meaning. . For example, a fiber reinforced thermoplastic resin structural member is described as a carbon fiber reinforced thermoplastic resin structural member, but a thermoplastic resin containing other types of fibers (for example, glass fiber reinforced thermoplastic resin). Resin structural member).

DESCRIPTION OF SYMBOLS 1 ... Composite structure 11 of a metal and a reinforced fiber thermoplastic resin 11 ... The 1st structural member made from a reinforced fiber thermoplastic resin (The 1st structural member made from a carbon fiber reinforced thermoplastic resin, a CFRTP member)
12 ... Metal second structural member (metal member)
DESCRIPTION OF SYMBOLS 13 ... Bonding resin member 14 ... Metal resin member 20 ... Thermocompression bonding apparatus 21 ... Thermocompression bonding head 22 ... Thermocompression-bonding control apparatus 30 ... Mold 31 ... One metal mold 32 ... Other metal mold

Claims (4)

A first component member made of a fiber reinforced thermoplastic resin formed into a desired shape and containing a reinforced fiber in a thermoplastic resin;
A structural member that is installed at a desired position of the first component member and has an opening formed on one side thereof, the surface of the inner peripheral portion being coated with primer, surface treatment with laser, surface by mechanical treatment A second component member made of metal that has been subjected to at least one treatment selected from a treatment and a surface treatment by chemical treatment;
It is provided between the first component member and the second component member, and the other surface and side surface are integrally fixed to the surface of the inner peripheral portion where the treatment of the second component member is performed. And one surface is made of a thermoplastic resin bonding resin member fixed integrally with the thermoplastic resin of the first component member,
In the second component member, the side surface is an inclined surface whose one surface side is wider than the other surface side, and has an inclination angle within a range of 15 ° or more and less than 90 ° with respect to the one surface. A composite structure of a metal and a fiber-reinforced thermoplastic resin characterized by being a thing. A first step of forming a first component member made of a fiber reinforced thermoplastic resin in which a reinforced fiber is contained in a thermoplastic resin into a desired shape;
A second step of forming a second metal component having an opening on one side into a desired shape;
Thirdly, the surface of the inner peripheral portion of the second component member is subjected to at least one process selected from primer application, laser surface treatment, surface treatment by mechanical treatment, and surface treatment by chemical treatment. Process,
The thermoplastic resin composition of the bonding resin member is injected and filled into the inner peripheral portion of the second component member inserted into the mold, and the bonding resin is applied to the surface of the inner peripheral portion subjected to the treatment. A fourth step of manufacturing a metal resin member in which the other surface and side surfaces of the member are integrally fixed;
The metal component member is installed at a desired position of the first component member, the metal component member is thermocompression-bonded to the first component member from the other side, and the first component member is partially melted. And a fifth step of integrally fixing the thermoplastic resin and one surface of the bonding resin member,
In the second component member, the side surface is an inclined surface whose one surface side is wider than the other surface side, and has an inclination angle within a range of 15 ° or more and less than 90 ° with respect to the one surface. Is,
The metal resin member is formed such that a predetermined amount of the bonding resin member protrudes from the one surface of the second component member, and when the thermocompression bonding is performed in the fifth step, the protruding portion is a melting allowance. A method for producing a composite structure of a metal and a fiber-reinforced thermoplastic resin, characterized in that: A first step of forming a first component member made of a fiber reinforced thermoplastic resin in which a reinforced fiber is contained in a thermoplastic resin into a desired shape;
A second step of forming a second metal component having an opening on one side into a desired shape;
Thirdly, the surface of the inner peripheral portion of the second component member is subjected to at least one process selected from primer application, laser surface treatment, surface treatment by mechanical treatment, and surface treatment by chemical treatment. Process,
A fourth step of bringing one surface of the second component member into contact with the first component member at a desired position of the first component member and setting the mold in a mold;
The mold is closed, and a thermoplastic resin composition of a bonding resin member is injected and filled into a space formed by the inner peripheral portion of the first component member and the second component member, and the heat In the process of cooling the plastic resin composition, one surface of the bonding resin member and the first component member, and the other surface and side surface of the bonding resin member and the second surface subjected to the treatment. The fifth step of integrally fixing the inner peripheral portion of the component member,
In the second component member, the side surface is an inclined surface whose one surface side is wider than the other surface side, and has an inclination angle within a range of 15 ° or more and less than 90 ° with respect to the one surface. And at least one hole for injecting the thermoplastic resin composition into the space is formed,
The fifth step is a step of injecting and filling the thermoplastic resin composition of the bonding resin member through the hole. A method for producing a composite structure of metal and fiber reinforced thermoplastic resin. In the manufacturing method of the composite structure of the metal and fiber reinforced thermoplastic resin as described in Claim 2 or 3 ,
The method for producing a composite structure of a metal and a fiber-reinforced thermoplastic resin, wherein the reinforcing fiber is a carbon fiber.

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