JP6947074B2 - Manufacturing method of composite member - Google Patents

Description

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.

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.

Japanese Unexamined Patent Publication No. 2003-129611

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.

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.

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. ..

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.

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.

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.

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.

It is a flow chart for demonstrating the manufacturing method of the composite member which concerns on embodiment of this invention. It is a schematic conceptual diagram for demonstrating the metal part manufacturing process shown in FIG. It is a schematic perspective view for demonstrating the metal plate manufacturing process shown in FIG. It is a schematic conceptual diagram for demonstrating the reinforcing material manufacturing process shown in FIG. It is a schematic conceptual diagram for demonstrating the joining process shown in FIG. 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.

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. 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.

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.

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.

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.

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. 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.

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.

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. 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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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. 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.

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.

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.

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.

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.

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.

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.

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.

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: 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)

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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