JP5952990B2 - Metal resin composite - Google Patents

Description

  The present invention relates to a metal resin composite using a metal plate and a fiber reinforced resin.

  In transportation equipment such as automobiles and airplanes, electrical and electronic equipment, furniture, buildings, etc., since it is lightweight, it has high strength and excellent durability, so a composite of fiber reinforced resin and metal is their body material, It is used as a frame material, a housing material, and the like.

  In Patent Document 1, a metal plate and a fiber reinforced resin composition are mainly composed of an epoxy resin, carbon fiber or glass fiber, a thermally activated curing agent, a thermally activated curing catalyst, a thermally decomposable organic foaming agent, an inorganic material. It is disclosed that a system filler and a foaming resin containing a predetermined amount of an anti-bubble agent are joined together and used as a vehicle body material for an automobile. Thereby, generation | occurrence | production of the curvature after heat-hardening is suppressed rather than the case where a metal plate and a fiber reinforced resin composition are joined using a thermosetting adhesive agent, and it is supposed that it can manufacture in a shorter period of time.

  Patent Document 2 discloses a metal resin composite in which a fiber reinforced resin layer containing a crosslinked product of cycloolefin polymer and carbon fiber and a metal plate are integrated. According to this structure, it is said that it is excellent in the adhesiveness of a metal layer and a fiber reinforced resin layer, impact resistance, etc., and can be used conveniently in a motor vehicle, an aircraft, etc.

JP 2007-196545 A JP 2011-37002 A

  However, in any case, the above-described structure is merely a structure in which a metal plate and a fiber reinforced resin layer are laminated. In other words, the fiber reinforced resin layer is only fixed and supported on the entire surface of the metal plate. When concentrated load is applied, the tensile strength and compression at the load point are larger, like the behavior of a static definite beam. Power is generated. The ones disclosed in Patent Document 1 and Patent Document 2 are devised to increase adhesion, durability, etc., such as delamination between the metal plate and the fiber reinforced resin layer compared to the previous ones. Although the occurrence is considered to be suppressed, it depends on the bonding force between the two, and there is no change in the basic structure that a large tensile force around the load point is likely to occur.

  The present invention has been made in view of the above, and in a structure in which a metal plate and a fiber reinforced resin layer are laminated, while maintaining the characteristics of lightness, the rigidity is enhanced and the damping property is enhanced, and the impact resistance is improved. It is an object of the present invention to provide a metal resin composite excellent in the above.

  In order to solve the above problems, the metal resin composite of the present invention is a metal resin composite in which a metal plate and a fiber reinforced resin layer are laminated, and the metal plate is provided on each of both surfaces of the fiber reinforced resin layer. Are stacked, and at least one edge of the metal plate is bent, and the edge of the fiber reinforced resin layer is overlapped with the edge of the bent metal plate in a plan view. At least a part is fixed to at least one of the metal plates.

At least a part of the opposing edges of each metal plate is integrally bent, and among the edges of the fiber reinforced resin layer, the edges of the bent metal plates are viewed in plan view. It is preferable that at least a part of the overlapping range is fixed to each metal plate. In each of the metal plates, it is preferable that a portion not overlapping with the fiber reinforced resin layer is a mounting portion with another member. It is preferable that at least a part of the edge of the fiber reinforced resin layer is bent together with the edge of the metal plate.
The fiber reinforced resin layer is preferably composed of a fiber reinforced resin or a laminate of two or more thereof. The fiber reinforced resin layer is preferably composed of a laminate of fiber reinforced resin and metal foil. The fiber reinforced resin layer is preferably composed of a laminate in which fibers and metal foil are laminated and integrated by sewing and then impregnated with a matrix resin. The sewing thread used for the sewing is preferably a high-strength thread containing at least one of aramid fiber, PTT, and PET. It is preferable that the bending process of the edge of the metal plate is formed by any one of a bending process including a hemming process and a double winding process. The metal foil constituting the fiber reinforced resin layer is preferably a stainless steel foil having a thickness of 0.01 to 0.1 mm. It is preferable that the reinforcing fiber constituting the fiber reinforced resin layer is a continuous fiber. The continuous fiber is preferably a carbon fiber. The metal plate is preferably a high Young's modulus thin plate material having a thickness of 0.2 to 1.5 mm.

  In the present invention, a fiber reinforced resin layer is sandwiched between a metal plate and a metal plate, the edge of at least one metal plate is bent, and the edge of the fiber reinforced resin layer is bent. In this structure, at least a part of the range overlapping the edge of the metal plate in plan view is fixed to at least one metal plate. Preferably, at least part of the edge of the fiber reinforced resin layer is bent together with the edge of the metal plate. Therefore, the fiber reinforced resin layer has a both-end fixed structure in which a bent end edge is a fixed end, exhibits a behavior similar to that of an indefinite beam, and generates a tension. In other words, compared to the conventional structure that shows the behavior of static beams, the vicinity of the fixed end is hard to be deformed and it is difficult to stretch.When the same material with the same thickness is used, deformation at the load point in concentrated load is not possible. It is more suppressed and the rigidity is increased. As a result, it is possible to adopt a thinner metal plate, which contributes to further weight reduction. Further, in the case where the end edge of the fiber reinforced resin layer is exposed, it is necessary to perform end processing (trimming) for preventing the fiber from protruding outward. Since the edge of the layer is covered with a bent metal plate, such end treatment is not required, the yield of fibers is improved, and the processing cost is reduced.

  As the fiber reinforced resin layer, it is possible to use only a fiber reinforced resin, a laminated body of fiber reinforced resins, a laminated body of metal foil to the fiber reinforced resin, etc. It is more preferable to use a laminate comprising a matrix resin impregnated after being integrated by sewing. The fiber reinforced resin layer itself sandwiched between the metal plates also has a laminated structure of fibers and metal foils, so that the rigidity can be further increased. Is also impregnated, so that the adhesion between the fiber and the metal foil becomes higher, delamination hardly occurs, and durability is improved.

FIG. 1 is a cross-sectional view showing an example of a metal resin composite according to an embodiment of the present invention. FIG. 2 is a cross-sectional view showing another example of the metal resin composite according to the embodiment. FIG. 3 is a cross-sectional view showing still another example of the metal resin composite according to the embodiment. FIG. 4 is a cross-sectional view showing still another example of the metal resin composite according to the embodiment. Fig.5 (a) is sectional drawing which showed the preferable example of the fiber reinforced resin layer, (b) is a top view. FIG. 6 is a cross-sectional view showing an example of a metal-resin composite in which an attachment portion with another member is formed on the outer periphery of the metal plate. FIG. 7A is a diagram for explaining the measurement method of the test example, FIG. 7B is a diagram showing the measurement result of the compression property of the test example, and FIG. 7C is the measurement of the tensile property of the test example. It is the figure which showed the result.

  Hereinafter, the present invention will be described in more detail based on the embodiments shown in the drawings. FIG. 1 is a cross-sectional view of a metal resin composite 1 according to an embodiment of the present invention. As shown in this figure, the metal resin composite 1 is configured to have two metal plates 10 and 20 and a fiber reinforced resin layer 30 disposed therebetween.

  The metal plates 10 and 20 may be any of ferrous metals and non-ferrous metals, and steel, stainless steel, aluminum and the like can be used. Depending on the application, when used as a frame or panel of a seat structure of an automobile, it is preferable to use a thin plate material having a thickness of 0.2 to 1.5 mm in consideration of lightness. A high Young's modulus having a Young's modulus of about 70 to about 210 GPa is preferable.

  The fiber reinforced resin layer 30 is formed by impregnating a matrix resin only after fiber reinforced resin, a fiber reinforced resin laminate, a fiber reinforced resin and metal foil laminate, and a fiber and metal foil laminated and integrated by sewing. Any of the laminated bodies can be used. Here, the laminated body of fiber reinforced resin and the laminated body of fiber reinforced resin and metal foil can also be laminated | stacked by well-known means, such as adhesion | attachment.

As the fiber reinforced resin layer 30, as shown in FIG. 5, it is preferable to use a laminate in which fibers 31 and metal foils 32 and 33 are laminated and integrated by sewing and then impregnated with a matrix resin 34. As the sewing means, for example, a sewing machine can be employed. Since the strength of the sewing thread 35 is added and the matrix resin 34 is impregnated even when passing through the sewing thread 35, a relatively high strength portion is formed along the seam, and the fiber 31 and the metal foils 32, 33 are formed. Adhesion strength with is further increased. In particular, since the sewing needle passes through the metal foils 32 and 33, a cylindrical flange as in the case of burring the through holes of the sewing needles in the metal foils 32 and 33 is formed. The matrix resin 34 easily enters from the through holes, and the adhesion between the fibers 31 and the metal foils 32 and 33 can be increased. In addition, since the rounded portion is formed at the periphery of the through hole, the function of preventing thread breakage of the sewing thread 35 is also achieved. Furthermore, by using a needle having a round tip as the sewing needle, cutting of the fiber 31 can be prevented. Here, as the form of the fiber 31, a form such as a woven fabric, a nonwoven fabric, a knitted fabric, or the like can be used. Moreover, not only a two-dimensional thing but a three-dimensional fabric and knitted fabric can also be used.
As the sewing thread 35, a high-strength thread containing at least one of aramid fiber, PTT, and PET can be used. If higher strength and incombustibility are required, a thread mainly composed of aramid fiber. Preferably, a thread containing PTT or PET is preferable in the case where elasticity or more rigidity is given during sewing.

  When the fiber reinforced resin layer 30 has a laminated structure with the metal foils 32 and 33, the metal foil to be used has a thickness of 0.01 to 0.1 mm because a predetermined rigidity can be obtained even if it is light and thin. It is preferable to use a stainless steel foil.

  As the fibers 31 forming the fiber reinforced resin layer 30, it is preferable to use continuous fibers such as carbon fibers, silicon carbide fibers, alumina fibers, and glass fibers. Among these, carbon fibers are used when strength is required. It is preferable.

  As the matrix resin 34 of the fiber reinforced resin layer 30, thermosetting resins such as epoxy resin, phenol resin, urethane resin, unsaturated polyester resin, polyethylene resin, polypropylene resin, nylon, polyamide resin, polystyrene, ABS resin, methacrylic resin , Thermoplastic resins such as polyethylene terephthalate and polyamideimide can be used. Therefore, the fiber reinforced resin layer 30 is preferably in the form of CFRP using a thermosetting resin for carbon fibers and CFRTP using a thermoplastic resin for carbon fibers.

  At least one of the two metal plates 10 and 20 sandwiching the fiber reinforced resin layer 30 therebetween, in the example of FIG. 1, the edge 10a of the metal plate 10 is bent. As bending means, hemming or the like can be used in addition to bending or curling only by bending at a predetermined angle. Especially, hemming is preferable for fixing the edge of the fiber reinforced resin layer 30 because the edge of the metal plate 10 or 20 is bent 180 degrees and overlapped. In addition, as a bending method, double winding is also preferable for fixing the edge of the fiber reinforced resin layer 30 because an overlapping portion is formed at the edges of the metal plates 10 and 20 (see FIG. 4). Caulking can also be applied.

As shown in FIG. 1, in the edge 30 a of the fiber reinforced resin layer 30, a range that overlaps the edge 10 a of one metal plate 10 that is bent in a plan view (“A” shown in FIG. 1). And “B” range is fixed to each of the metal plates 10 and 20 located on both surfaces of the end edge 30a of the fiber reinforced resin layer 30. The fixing means is arbitrary, such as adhesion and welding. Means can be used, and laser welding, spot welding, CO ₂ welding, or the like can be used as the welding means.

  As shown in FIG. 2, the edge 30 a of the fiber reinforced resin layer 30 is bent together with the edge 10 a of one metal plate 10, and the edge 30 a is bent with the edge 10 a of one bent metal plate 10. It can also fix as a structure pinched | interposed between the edge 20a of the other metal plate 10 which is not bent.

  As shown in FIG. 3, the edge 30 a of the fiber reinforced resin layer 30 is positioned and fixed in the range of the bent edges 10 a and 20 a of the edges 10 a and 20 a of the opposing metal plates 10 and 20. It is preferable. Even within the bent edges 10a and 20a, the edge 30a of the fiber reinforced resin layer 30 is fixed by adhesion or welding, or by caulking from the surface of one of the metal plates 10 and 20. It is preferable that the edge 30a of the fiber reinforced resin layer 30 is fixed more reliably. In addition, when bending the edge 30a of the fiber reinforced resin layer 30, if it is a thermoplastic resin, it can be bent by heating from the outer surface of the edge 10a, 20a of the metal plates 10 and 20, for example. In the case of the above-mentioned double winding process, it can be heated and bent similarly. Further, the fiber reinforced resin layer 30 is processed in a state where the end edge 30a is bent in advance, and in this state, the metal plates 10 and 20 are laminated as shown in FIGS. 1 and 2, and one of the metal plates 10a is bent. It can also be processed.

  According to this embodiment, since the fiber reinforced resin layer 30 has a both-end fixed structure in which the end edges 10a and 20a of the metal plates 10 and 20 are fixed ends, the vicinity of the fixed ends is difficult to be deformed and hardly stretched. . Therefore, when the same material having the same thickness is used, the deformation at the load point in the concentrated load is further suppressed and the rigidity is increased as compared with the conventional simple laminated structure of the metal plate and the fiber reinforced resin layer. As a result, it is possible to adopt metal plates 10 and 20 having a smaller thickness, which contributes to weight reduction.

  Further, as shown in FIG. 6, the metal plates 10 and 20 that have end edges 10 a and 20 a projecting outward from the fiber reinforced resin layer 30 are used. It is preferable to bend the edges 10 a and 20 a of the metal plates 10 and 20 and provide the attachment portion 40 in a range that does not overlap the fiber reinforced resin layer 30. When this attachment portion 40 is attached to another member with, for example, a bolt or the like, there is no need to make a hole in the fiber reinforced resin layer 30, so that the problem that the strength of the fiber reinforced resin layer 30 is lowered after the attachment is eliminated. Note that the method of forming the attachment portion 40 is not limited to that shown in FIG. 6, and various means can be adopted.

(Test example)
7 is a view of FIG. 2 in which SPFC 440 having a thickness of 0.6 mm is laminated as metal plates 10 and 20 on both sides of one CFRTP having a thickness of 1.0 mm constituting the fiber reinforced resin layer 30 and hemming processing is performed on the edge. For the metal resin composite 1 having the same cross-sectional shape, along the surface direction (FIG. 7A), compression characteristics (FIG. 7B) measured by compression or tension, tensile characteristics (FIG. 7C) )). The measurement result of the metal resin composite 1 according to the test example is shown as “Total”. In addition, the surface of the metal plates 10 and 20 of the metal resin composite 1 of the test example was further subjected to heat treatment by rapid heating and quenching treatment (“Total + heat treatment”). For comparison, the same measurement was performed for a CFRTP simple substance having a thickness of 1.0 mm and a SPFC 440 simple substance having a thickness of 0.6 mm (indicated by “Steel”).

  As is clear from FIG. 7, CFRTP alone has higher tensile properties than compression properties and a poor balance, but in the case of the metal resin composite 1 of the test example, both compression properties and tensile properties are high. You can see that it is balanced.

  The metal resin composite 1 of the present invention can be used for the body of a transport device such as an automobile or an aircraft, a building, or the like, as in the past. Further, in transportation equipment such as automobiles, it is desired to reduce the weight of a seat structure to be mounted for further weight reduction. Therefore, in a seat structure including a seat back portion and a seat cushion portion, it is preferable to use as a member of at least a part of either a back frame constituting the seat back portion or a cushion frame constituting the seat cushion portion. For example, it can be used for a portion requiring high strength, such as a corner portion of a back frame or a bracket, or a back panel. It can also be used as a housing material of various electronic devices, a frame of a machine, or a surface material of furniture such as a table.

DESCRIPTION OF SYMBOLS 1 Metal resin composite 10 Metal plate 10a Edge 20 Metal plate 20a Edge 30 Fiber reinforced resin layer 30a Edge 31 Fiber 32,33 Metal foil 34 Matrix resin 35 Sewing thread 40 Attachment part

Claims (7)

A metal resin composite comprising a metal plate and a fiber reinforced resin layer laminated,
The metal plate is laminated on each of both surfaces of the fiber reinforced resin layer,
With at least one edge is bent of the metal plate,
Of the edge of the fiber reinforced resin layer, at least a part of the range overlapping the edge of the bent metal plate in plan view is fixed to at least one of the metal plates , and ,
The said fiber reinforced resin layer is comprised from the laminated body of fiber reinforced resin and metal foil, The metal resin composite characterized by the above-mentioned. A metal resin composite comprising a metal plate and a fiber reinforced resin layer laminated,
The metal plate is laminated on each of both surfaces of the fiber reinforced resin layer,
And at least one edge of the metal plate is bent ,
Of the edge of the fiber reinforced resin layer, at least a part of the range overlapping the edge of the bent metal plate in plan view is fixed to at least one of the metal plates, and ,
The fiber-reinforced resin layer is composed of a laminated body impregnated with a matrix resin, in which a woven fabric, a nonwoven fabric, or a knitted fabric and a metal foil are laminated and integrated by sewing. body. At least a part of the opposing edges of each metal plate is integrally bent, and among the edges of the fiber reinforced resin layer, the edges of the bent metal plates are viewed in plan view. The metal resin composite according to claim 1 or 2 , wherein at least a part of the overlapping range is fixed to each of the metal plates . The metal resin composite according to any one of claims 1 to 3, wherein in each of the metal plates, a portion not overlapping with the fiber reinforced resin layer is an attachment portion with another member . The metal resin composite according to any one of claims 1 to 4 , wherein at least a part of an edge of the fiber reinforced resin layer is bent together with an edge of the metal plate . The metal resin composite according to claim 2, wherein the sewing thread used for the sewing is a high-strength thread containing at least one of aramid fiber, PTT, and PET . The metal resin composite according to any one of claims 1 to 6 , wherein the metal foil constituting the fiber reinforced resin layer is a stainless steel foil having a thickness of 0.01 to 0.1 mm .

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