Metal-prepreg composite

Abstract

This invention provides a metal-prepreg composite for manufacturing metal-fiber reinforced resin molded articles, which reduces manufacturing costs and provides high adhesion, and a metal-fiber reinforced resin molded article obtained by pressing the metal-prepreg composite. A metal-prepreg composite comprising a fiber reinforced resin prepreg layer, an adhesive reinforcing layer composed of metal having multiple through holes disposed on the fiber reinforced resin prepreg layer, an adhesive sheet disposed on the adhesive reinforcing layer, and a metal body disposed on the adhesive sheet is fabricated. A metal-fiber reinforced resin composite molded article can be manufactured by heating and pressing this metal-prepreg composite, i.e., a composite material of metal and fiber reinforced resin.

Description

Technical Field

[0001] This invention relates to metal-prepreg composites and metal-fiber reinforced resin composites obtained therefrom. Background Technology

[0002] Fiber-reinforced resins, such as those made of carbon fiber, are materials that combine high strength and lightweight, and are therefore used in a variety of applications. For example, in the automotive industry, they are highly anticipated as a new material to replace steel. However, fiber-reinforced resins are currently more expensive than steel, making it difficult to use them in large quantities when the goal is to reduce product prices. Therefore, composites of metals such as steel and fiber-reinforced resins are used, thereby achieving material lightweighting and cost reduction.

[0003] Regarding metal-resin composites, for example, Patent Document 1 discloses a method for manufacturing a composite of resin and metal parts, which involves surface treatment of the metal parts using chemical etching, followed by bonding the resin to the treated parts using an injection method (Patent Document 1).

[0004] In addition, for example, Patent Document 2 discloses a method for surface treatment of metals that exhibits excellent adhesion when bonding metals and organic polymers, which involves chemical etching of the metal surface with the formation of a film, followed by treatment using a silane coupling agent or coating-type chromate treatment (Patent Document 2).

[0005] In addition, for example, Patent Document 3 discloses a method in which an adhesive layer having a modified polypropylene resin with polar groups introduced is formed on a substrate treatment film provided on the surface of a substrate formed of aluminum alloy, so as to bond with the polypropylene through compatibility and anchoring effect (Patent Document 3).

[0006] In the aforementioned prior art, in order to improve the adhesion, the metal surface is roughened by utilizing the anchoring effect brought about by the unevenness, and the adhesion is improved when bonding the metal and resin. However, these treatments are difficult to control or involve many steps, thus consuming time and costs.

[0007] Existing technical documents Patent documents Patent Document 1: Japanese Patent Application Publication No. 2001-225352 Patent Document 2: Japanese Patent Application Publication No. 11-293476 Patent Document 3: Japanese Patent Application Publication No. 2016-016584 Summary of the Invention

[0008] Therefore, the object of the present invention is to provide a metal-prepreg composite that reduces manufacturing costs and has high adhesion.

[0009] The inventors of this invention conducted in-depth research and, as a result, discovered a heat-pressed metal-prepreg composite that reduces manufacturing costs and provides high adhesive strength by configuring an adhesive reinforcement layer composed of metal with multiple through holes between the metal and the prepreg. That is, this invention includes the following solution.

[0010] [1] A metal-prepreg composite comprising: Prepreg layer of fiber-reinforced resin; An adhesive reinforcement layer is disposed on the prepreg layer; An adhesive sheet disposed on the adhesive reinforcement layer; and A metal body disposed on the adhesive sheet. Furthermore, the metal-prepreg composite is obtained by integrating the fiber-reinforced resin prepreg layer, the adhesive reinforcement layer, the adhesive sheet, and the metal body. The metal-prepreg composite is characterized in that... The adhesive reinforcement layer is made of metal with multiple through holes. The adhesive component of the adhesive sheet passes through the through-hole of the adhesive reinforcement layer and contacts the metal body, thereby improving the adhesion between the prepreg layer and the metal body.

[0011] [2] The metal-prepreg composite according to [1] is characterized in that, The prepreg in the prepreg layer is a carbon fiber reinforced resin prepreg.

[0012] [3] The metal-prepreg composite according to [1] or [2] is characterized in that, The adhesive reinforcement layer is a perforated metal, a mesh metal, or an expanded metal.

[0013] [4] A method for improving the bonding strength between the prepreg layer of the fiber-reinforced resin constituting the metal-prepreg composite and the metal body, characterized in that it comprises: The process of overlapping an adhesive sheet and an adhesive reinforcement layer made of metal with multiple through holes between the prepreg layer and the metal body, and the process of distributing an adhesive sheet and an adhesive reinforcement layer between the prepreg layer and the metal body. The process of integrating the prepreg layer, the metal body, the adhesive sheet, and the adhesive reinforcement layer.

[0014] [5] A method for manufacturing a metal-fiber reinforced resin composite molded article, characterized in that it includes: The process of stacking and integrating a fiber-reinforced resin prepreg layer, an adhesive reinforcing layer made of metal with multiple through holes, an adhesive sheet, and a metal body in this sequence to form a metal-prepreg composite, and The process of manufacturing a metal-fiber reinforced resin composite by heating and pressing the metal-prepreg composite.

[0015] Invention Effects By using the metal-prepreg composite of the present invention, heating and pressing are performed simultaneously (heat pressing method), which can reduce manufacturing costs and produce lightweight metal-fiber reinforced resin composite molded articles in a short time.

[0016] The metal-prepreg composite of the present invention includes an adhesive reinforcement layer made of metal with multiple through holes. The adhesive component of the adhesive sheet disposed between the adhesive reinforcement layer and the metal body passes through the through holes of the adhesive reinforcement layer. Therefore, the bonding area is large, which improves the adhesion between the metal body and the adhesive reinforcement layer. Furthermore, a portion of the prepreg is also embedded in the through holes; thus, similar to the convex-concave design, the through holes generate an anchoring effect, thereby increasing the adhesion between the metal body and the prepreg layer.

[0017] The metal-prepreg composite of the present invention does not require surface treatment and roughening of the metal to improve adhesion, thereby enabling the manufacture of metal-fiber reinforced resin composite molded articles with high adhesion between the metal and the fiber reinforced resin and low cost. Attached Figure Description

[0018] Figure 1 middle, Figure 1 The above figure is a diagram showing the layers of the metal-prepreg composite A constituting the embodiment. 1 is the prepreg of carbon fiber reinforced resin, 2 is the mesh aluminum (adhesive reinforcement layer), 3 is the adhesive sheet, and 4 is the metal plate (metal body). Figure 1 The following diagram represents metal-prepreg composite A. Detailed Implementation

[0019] The present invention will now be described in detail using examples. It should be noted that the present invention is not limited to the examples, and appropriate design changes can be made within the scope known to those skilled in the art. Example

[0020] [Metal-Prepreg Composite] like Figure 1As shown in the figure below, the embodiment described in this specification, namely the metal-prepreg composite A, is a composite consisting of a carbon fiber reinforced resin prepreg 1, a mesh aluminum (a bonding reinforcement layer composed of metal having multiple through holes 21) 2, an adhesive sheet 3, and a metal plate (metal body) 4. The prepreg 1, the bonding reinforcement layer, and the metal plate 4 are bonded together by means of the adhesive sheet 3. By heating and pressing the metal-prepreg composite A, a metal-fiber reinforced resin composite molded body can be obtained.

[0021] (Metallic body) The metal plate 4 constituting the metal body can be any material that can be formed by the pressing molding of the present invention, and there is no particular limitation. Various metals such as aluminum, stainless steel, iron, steel, titanium, and high-strength steel can be used.

[0022] The thickness of the metal sheet 4 is not limited. It can be 0.05 mm or more to facilitate molding into the desired shape. There is no upper limit to the thickness. The metal sheet 4 can be a relatively thin metal (e.g., less than 50 mm) or very thick relative to the prepreg 1. However, from the viewpoint of ease of heat pressing, a metal sheet with a thickness of about 0.05 to 50 mm is preferred.

[0023] (Prepreg) The prepreg constituting prepreg 1 is a carbon fiber reinforced resin prepreg; however, this invention is not limited to this, and can be a substance obtained by only semi-curing the resin, or a substance that is semi-cured by uniformly impregnating the resin with a fibrous reinforcing material such as glass cloth or carbon fiber and then heating or drying it. For example, fabric prepregs, unidirectional prepregs, etc., can be used.

[0024] The resin constituting prepreg 1 is not particularly limited, and thermosetting resins, thermoplastic resins, and resin compositions comprising one of them can be used. Examples of thermosetting resins include epoxy resins, vinyl ester resins, unsaturated polyester resins, polyurethane resins, phenolic resins, etc., and these thermosetting resins can be used in combination. Examples of thermoplastic resins include acrylic resins, polyester resins, polycarbonate resins, polypropylene resins, polyethylene resins, polystyrene resins, vinyl chloride resins, polyamide resins, etc. These thermoplastic resins can be used alone or in combination.

[0025] The fibers that can be contained in prepreg 1 include glass fibers, carbon fibers, metal fibers, etc. As the fiber matrix in the fiber-reinforced resin prepreg, carbon fiber material with a thickness of 0.03 mm to 0.5 mm is preferred, but not limited to this. Furthermore, the carbon fibers constituting prepreg 1 can be PAN-based carbon fibers made from polyacrylonitrile, pitch-based carbon fibers made from pitch, etc. PAN-based carbon fibers are preferred as the carbon fibers constituting prepreg 1, but not limited to this. In addition, the fibers constituting the prepreg may also include composites such as SMC (Sheet Molding Compound).

[0026] Prepreg 1 is preferably a fabric prepreg made of epoxy resin and carbon fiber, but is not limited thereto. Prepreg 1 can be composed of a single piece of prepreg or multiple pieces of the same or different types of prepreg.

[0027] (Adhesive sheet) The adhesive sheet 3 used in the metal-prepreg composite A of the present invention can be any adhesive sheet 3 capable of bonding the metal plate 4 and the prepreg 1, and is not particularly limited. Examples of adhesive components include epoxy resin, acrylic resin, polyurethane resin, neoprene rubber, cyanoacrylate, modified silicone, etc., preferably having adhesive properties before curing. These adhesive components can be used alone or in combination. In addition, adhesive sheets 3 with different adhesive components can be stacked.

[0028] (Adhesive reinforcement layer) The mesh aluminum 2, serving as an adhesive reinforcement layer, is inserted between the adhesive sheet 3 and the prepreg 1, which are positioned between the metal plate 4 and the prepreg 1. The mesh aluminum 2 is made of metal and has multiple through holes 21.

[0029] The metal used for the mesh aluminum 2 can be any material that can be formed by the pressing and molding process of this invention. There are no particular limitations, and various metals such as aluminum, stainless steel, iron, steel, titanium, and high-strength steel can be used.

[0030] The thickness of the mesh aluminum 2 is not limited, but it is preferably about 0.05 to 3 mm in order to be easily formed into the desired shape by pressing.

[0031] Mesh aluminum 2 is composed of perforated metal, mesh metal, or expanded metal. Perforated metal is a material obtained by processing a metal sheet with holes created using a punching die. Mesh metal is a material obtained by weaving in metal wire or by weaving metal wire into a mesh. Expanded metal is a material obtained by using machinery to create houndstooth-like cuts in a metal sheet and expanding the cuts to form diamond or tortoise-shell shaped meshes.

[0032] The main purpose of the mesh aluminum 2 is to improve the adhesion between the metal plate 4 and the prepreg 1, and to improve the adhesion between the fiber-reinforced resin and the metal body of the metal-fiber-reinforced resin composite molded body after the metal-prepreg composite A has been heated and pressed. The mesh aluminum 2 is preferably in a state close to the roughening of the metal surface, which is also used in the prior art to improve adhesion; therefore, the plurality of through holes 21 are preferably 0.01 to 500 mm. 2 The through holes have an area of ​​approximately 100 mm to 5 cm. Furthermore, the distance between adjacent through holes 21 (here, distance refers to the shortest distance between the edge of one through hole and the edge of an adjacent through hole) is approximately 0.5 mm to 5 cm. If it is a mesh, a mesh size of 1 to 100 mesh is preferred. Therefore, since the metal portion is small and the thickness is thin, the strength of the mesh aluminum 2 itself may not be high; however, it effectively improves the adhesion between the metal plate 4 and the prepreg 1.

[0033] The metal-prepreg composite A is obtained by layering and pressing together carbon fiber reinforced resin prepreg 1, a mesh aluminum 2 composed of metal with multiple through holes 21, an adhesive sheet 3, and a metal plate 4 to achieve integration. At this point, the pressing pressure does not need to be large; a pressure similar to that applied by hand is sufficient.

[0034] When pressed, the adhesive component of the adhesive sheet 3 enters the through hole 21 of the mesh aluminum 2 and reaches the prepreg 1 on the opposite side of the mesh aluminum 2. The metal plate 4, the mesh aluminum 2 and the prepreg 1 are integrated by means of the adhesive sheet 3.

[0035] [Metal-Fiber Reinforced Resin Composite Molded Body] The metal-fiber reinforced resin composite molded body of the present invention is manufactured by heating and pressurizing a metal-prepreg composite A.

[0036] In the metal-fiber reinforced resin composite molded body, through heating and pressurization, the adhesive components of the adhesive sheet 3, the mesh aluminum 2, and the prepreg 1 are integrated into a composite adhesive reinforcing layer 5, and the metal plate 4 and the composite adhesive reinforcing layer 5 are bonded together with high adhesive strength. At this time, the prepreg 1 is cooled after pressurization and heating to form the composite adhesive reinforcing layer 5. In the metal-fiber reinforced resin composite molded body constructed in this way, high-strength metal and high-strength fiber reinforced resin are bonded together with high adhesive strength, and it can be used as a substitute for composite materials of metal-fiber reinforced resin that have undergone conventional adhesive strength enhancement treatments.

[0037] In addition, in the case of a metal plate 4 with a very thick thickness, a composite adhesive reinforcement layer 5 can be provided on the metal plate 4 to further enhance the strength of the metal plate 4.

[0038] [Compression molding] In this invention, when the metal plate 4 is a relatively thin metal (e.g., a metal sheet), a metal-fiber reinforced resin composite molded body with a predetermined shape can be manufactured by heating and pressing. Press molding is performed using an upper mold and a lower mold, sandwiched between the two molds. The upper and lower molds can have predetermined shapes to form the molded article. For example, a protrusion can be provided on one of the pressing surfaces of the upper and lower molds, and a recess corresponding to the protrusion (which can be inserted) can be provided on the other. Accordingly, the metal-prepreg composite is held between the protrusion and the recess, thus the metal-fiber reinforced resin composite molded body can have a three-dimensional shape.

[0039] In the manufacture of the metal-fiber reinforced resin composite molded article of the present invention, the pressing temperature is typically 100–350°C. When the prepreg resin is a thermosetting resin, the temperature can be 120–160°C; when the prepreg resin is a thermoplastic resin, the temperature can be 230–350°C.

[0040] There is no particular limitation on the pressure for pressing the metal-fiber reinforced resin molded articles, which is usually 0.1 to 15 MPa.

[0041] The resulting metal-fiber reinforced resin composite is formed by molding the fiber reinforced resin according to its intended use or shape, and can be used for parts of aircraft, automobiles, etc., such as the casing of automobile batteries.

[0042] [Confirmation of bond strength] A metal-prepreg composite A was manufactured using a carbon fiber-containing epoxy resin prepreg (prepreg 1), a mesh aluminum 2 (0.6 mm thick, 10 mesh) as the adhesive reinforcement layer, an epoxy resin-containing sheet as the adhesive sheet 3, and high-strength steel as the metal plate 4, enabling it to undergo shear fracture test. Conversely, a metal-prepreg composite B of the same shape was manufactured using the same method without the mesh aluminum 2. Both metal-prepreg composites A and B were subjected to heat pressing under the same conditions, and the shear fracture force of the resulting metal-fiber reinforced resin molded body was measured using a tensile testing machine at a tensile speed of 10 mm / min. The results showed that the bonding strength was increased by approximately 1.05 to 1.3 times.

[0043] Symbol Explanation 1. Prepreg 2··· Mesh Aluminum 3··· Adhesive sheet 4. Metal plate 5. Composite adhesive reinforcement layer

Claims

1. A metal-prepreg composite, comprising: Prepreg layer of fiber-reinforced resin; An adhesive reinforcement layer is disposed on the prepreg layer; An adhesive sheet disposed on the adhesive reinforcement layer; as well as A metal body disposed on the adhesive sheet. Furthermore, the metal-prepreg composite is obtained by integrating the fiber-reinforced resin prepreg layer, the adhesive reinforcement layer, the adhesive sheet, and the metal body through heating and pressing. The metal-prepreg composite is characterized in that... The adhesive reinforcement layer is made of metal with multiple through holes. The adhesive component of the adhesive sheet passes through the through holes of the adhesive reinforcement layer and contacts the metal body, thereby improving the adhesion between the prepreg layer and the metal body. The prepreg in the prepreg layer is a fabric prepreg composed of epoxy resin and carbon fiber.

2. The metal-prepreg composite according to claim 1, characterized in that, The adhesive reinforcement layer is a perforated metal, a mesh metal, or an expanded metal.

3. A method for improving the bond strength between the prepreg layer of a fiber-reinforced resin constituting a metal-prepreg composite and the metal body, characterized in that, include: The process of overlapping an adhesive sheet and an adhesive reinforcement layer made of metal with multiple through holes between the prepreg layer and the metal body, and the process of distributing an adhesive sheet and an adhesive reinforcement layer between the prepreg layer and the metal body. The process of integrating the prepreg layer, the metal body, the adhesive sheet, and the adhesive reinforcement layer by heating and pressing simultaneously. The prepreg in the prepreg layer is a fabric prepreg composed of epoxy resin and carbon fiber.

4. A method for manufacturing a metal-fiber reinforced resin composite molded article, characterized in that, include: The process of forming a metal-prepreg composite by stacking a fiber-reinforced resin prepreg layer, an adhesive reinforcing layer made of metal with multiple through holes, an adhesive sheet, and a metal body in this sequence, and The process of manufacturing a metal-fiber reinforced resin composite by heating and pressing the metal-prepreg composite simultaneously. The prepreg in the prepreg layer is a fabric prepreg composed of epoxy resin and carbon fiber.

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