Vehicle structure comprising resin panel and metallic fastener having bolt insertion part

Abstract

To provide a vehicle structure capable of reducing a number of manufacturing steps by embedding a metal fastener in a resin panel by insert-molding when mounting the resin panel and another component such as a damper stay.SOLUTION: A vehicle structure comprises: a metallic fastener having a bolt insertion part; and a resin panel. The metallic fastener is embedded in the resin panel by insert-molding. The resin panel is provided with a hole h1 formed at a position corresponding to the bolt insertion part.SELECTED DRAWING: Figure 5

Description

[Technical field]

[0001] The present invention relates to a vehicle structure including a metal fastener having a bolt insertion portion and a resin panel, and to a method for manufacturing the same. [Background technology]

[0002] Composite materials that use reinforcing fibers as the reinforcement have high tensile strength and tensile modulus, and a small coefficient of linear expansion, resulting in excellent dimensional stability. They also have excellent heat resistance, chemical resistance, fatigue resistance, abrasion resistance, electromagnetic wave shielding properties, and X-ray transparency. Therefore, composite materials that use carbon fiber as the reinforcement are widely used in automobiles, sports and leisure, aerospace, and general industrial applications. Patent Document 1 describes a resin back door structure for a vehicle that enables the rear glass to be replaced without the load from the damper. Patent Document 2 describes a resin molded product in which a metal plate is embedded and integrated as an insert member, and a method for insert molding the molded product. It describes that the metal plate embedded as an insert member can suppress the occurrence of sink marks in the resin ribs. US Pat. No. 5,399,433 describes a hybrid tailgate or rear door for vehicles, particularly automobiles such as passenger cars, that includes a thermoplastic inner structure and composite reinforcements. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2014-76707 A [Patent Document 2] JP 2003-251633 A [Patent Document 3] Special Publication No. 2019-536688 Summary of the Invention [Problem to be solved by the invention]

[0004] However, in the invention described in Patent Document 1, when attaching the damper stay to the door panel, a bolt is inserted into a bracket on the door panel side, but the bracket is attached to the door panel with an adhesive, which requires too many manufacturing steps. Similarly, the door panels described in Patent Documents 2 and 3 also require separate fastening parts to be provided when attaching the damper stay to other parts, such as the door panel, which also requires too many manufacturing steps. Therefore, an object of the present invention is to provide a vehicle structure that can reduce manufacturing man-hours by embedding metal fasteners into a resin panel by insert molding when attaching the resin panel to other components such as damper stays. [Means for solving the problem]

[0005] In order to solve the above problems, the present invention provides the following means.

[0006] <1> A vehicle structure including a metal fastener having a bolt insertion portion and a resin panel, The metal fastener is embedded in the resin panel by insert molding, A vehicle structure, wherein a hole h1 is provided in the resin panel at a position corresponding to the bolt insertion portion. <2> The resin panel has a fiber reinforced resin member A and a fiber reinforced resin member B, The weight average fiber length of the reinforcing fibers a contained in the fiber reinforced resin member A is less than 3 mm, The weight average fiber length of the reinforcing fiber b contained in the fiber reinforced resin member B is 3 mm or more. <1> The vehicle structure according to claim 1. <3> A hole is provided in the fiber reinforced resin member A to define a hole h1 provided in the resin panel. <2> The vehicle structure according to claim 1. <4> The metal fastener is covered with a fiber reinforced resin member A. <2> or <3> The vehicle structure according to claim 1. <5> The fiber reinforced resin member B is in contact with the fiber reinforced resin member A. <2> ~ <4> 13. A vehicle structure according to any one of claims 1 to 12. <6> The fiber reinforced resin member B is not in contact with the metal fastener. <4> or <5> The vehicle structure according to claim 1. <7> The resin contained in the fiber reinforced resin member A is a thermoplastic resin or a thermosetting resin, The resin contained in the fiber reinforced resin member B is a thermoplastic resin or a thermosetting resin. <2> ~ <6> 13. A vehicle structure according to any one of claims 1 to 12. <8> Fiber-reinforced resin material A is a glass fiber-reinforced resin material A containing glass fibers. GF And, Fiber-reinforced resin component B is a carbon fiber-reinforced resin component B containing carbon fiber. CF , or glass fiber reinforced resin material B containing glass fiber GF That is, <2> ~ <7> 13. A vehicle structure according to any one of claims 1 to 12. <9> Reinforced fiber resin component B is carbon fiber reinforced resin component B CF , and glass fiber reinforced resin member B GF Equipped with Metal fasteners are made of glass fiber reinforced resin material A GF Covered by Glass fiber reinforced resin material A GF Carbon fiber reinforced resin component B CF In contact with <7> The vehicle structure according to claim 1. <10> Glass fiber reinforced resin material A GF , Carbon fiber reinforced resin material B CF , and glass fiber reinforced resin member B GF The resin contained in is a thermoplastic resin. <9> The vehicle structure according to claim 1. <11> Carbon fiber reinforced resin material B CF , and glass fiber reinforced resin member B GF is a molded body using a sheet molding compound, <9> The vehicle structure according to claim 1. <12> The resin panel has a fiber-reinforced resin member B, Fiber-reinforced resin component B is glass fiber-reinforced resin component B GF Including, Glass fiber reinforced resin material B GF is molded from sheet molding compound, <1> The vehicle structure according to claim 1. <13> Fiber-reinforced resin component B is carbon fiber-reinforced resin component B CF , and glass fiber reinforced resin member B GF Including, Carbon fiber reinforced resin material B CF is molded from sheet molding compound, Metal fasteners are made of glass fiber reinforced resin material B GF Or carbon fiber reinforced resin member B CF Covered by <12> The vehicle structure according to claim 1. <14> The metal fastener is L-shaped, corrugated, or I-shaped; <1> ~ <13> 13. A vehicle structure according to any one of claims 1 to 12. <15> The resin panel is a door panel constituting a vehicle back door, and the vehicle structure is a vehicle resin back door structure. <1> ~ <14> 13. A vehicle structure according to any one of claims 1 to 12. <16> The vehicle back door includes a damper stay, The door panel and the damper stay are fastened to each other by inserting a bolt into the bolt insertion portion. <15> The vehicle structure according to claim 1. <17> The door panel includes a rear glass. <15> or <16> The vehicle structure according to claim 1. <18> The resin panel has a rib within 30 mm of the metal fastener. <2> ~ <11> 13. A vehicle structure according to any one of claims 1 to 12. <19> The resin panel has a thickness deviation within 30 mm of the metal fastener. <2> ~ <18> 13. A vehicle structure according to any one of claims 1 to 12. <20> The material Bm for producing the fiber reinforced resin member B and the metal fastener are placed in a molding die in advance, and the material Am for producing the fiber reinforced resin member A is injected into the molding die, so that the fiber reinforced resin member A, the fiber reinforced resin member B, and the metal fastener are integrally molded, <2> ~ <11> 13. A method for manufacturing a vehicle structure according to any one of claims 1 to 12. <21> The hole h1 is provided by secondary processing after integral molding. <20> A method for manufacturing the vehicle structure according to claim 1. <22> The hole h1 was provided at the same time as the integral molding. <20> A method for manufacturing the vehicle structure according to claim 1. Effect of the Invention

[0007] The vehicle structure of the present invention can easily provide fasteners for attaching the resin panel to other components such as damper stays by embedding metal fasteners in the resin panel by insert molding. [Brief description of the drawings]

[0008] [Figure 1] 1 is a schematic diagram showing a conventional plastic back door structure for a vehicle in which a reinforcing bracket is fastened to a plastic back door panel. [Diagram 2] 1 is a schematic diagram showing a conventional plastic back door structure for a vehicle in which a reinforcing bracket is fastened to a plastic back door panel. [Diagram 3] FIG. 5 is a schematic diagram showing the location of cross section AA in FIGS. 3 and 4 for illustrating the mounting position of the damper stay. [Figure 4] 4 is a cross-sectional view taken along the line AA in FIG. 3, showing a conventional vehicle structure. [Diagram 5](a) A cross-sectional view taken along the line AA in Fig. 3. A schematic diagram of a metal fastener embedded in a resin panel by insert molding before a bolt is attached. (b) A cross-sectional view taken along the line AA in Fig. 3. A schematic diagram of a metal fastener embedded in a resin panel by insert molding after a bolt is attached. [Figure 6] 1 is a schematic diagram of a vehicle structure of the present invention, including a metal fastener having a bolt insertion portion and a resin panel. The metal fastener is embedded in the resin panel by insert molding, and a hole h1 is provided in the resin panel at a position corresponding to the bolt insertion portion. The bolt is not yet inserted. [Figure 7] A schematic diagram of a preferred structure around the hole h1. The structure is designed to minimize the involvement of the resin panel in the fastening portion. [Figure 8] Schematic diagram depicting the molding of a metal fastener 801 by sandwiching it using material Bm (sheet molding compound, 802). DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] The present invention will be described in detail below. The present invention is a vehicle structure including a metal fastener having a bolt insertion portion and a resin panel, the metal fastener being embedded in the resin panel by insert molding, and the resin panel being provided with a hole h1 at a position corresponding to the bolt insertion portion. Preferably, the resin panel has a fiber reinforced resin member A and a fiber reinforced resin member B.

[0010] [Reinforced fiber] In the present specification, the reinforcing fiber is preferably at least one selected from the group consisting of carbon fiber, aramid fiber, and glass fiber, and more preferably, the reinforcing fiber is carbon fiber or glass fiber. More specifically, when the fiber reinforced resin member A is used, the reinforcing fibers contained therein are preferably carbon fibers or glass fibers. When the fiber reinforced resin member B is used, the reinforcing fibers contained therein are preferably carbon fibers or glass fibers.

[0011] [Carbon fiber] 1. Carbon fiber in general As the carbon fiber used in the present invention, generally known are polyacrylonitrile (PAN)-based carbon fiber, petroleum / coal pitch-based carbon fiber, rayon-based carbon fiber, cellulose-based carbon fiber, lignin-based carbon fiber, phenol-based carbon fiber, etc., and any of these carbon fibers can be suitably used in the present invention. Among them, it is preferable to use polyacrylonitrile (PAN)-based carbon fiber in the present invention because of its excellent tensile strength. As the PAN-based carbon fiber, for example, the carbon fiber "Tenax" (registered trademark) STS40-24KS (average fiber diameter 7 μm) manufactured by Teijin Limited can be used.

[0012] 2. Carbon fiber sizing agent The carbon fiber used in the present invention may have a sizing agent attached to its surface. When using carbon fiber with a sizing agent attached thereto, the type of the sizing agent can be appropriately selected depending on the type of carbon fiber and the type of thermoplastic resin used in the fiber reinforced resin member B or the fiber reinforced resin member A, and is not particularly limited.

[0013] 3. Carbon fiber fiber diameter The fiber diameter of the carbon fiber single yarn (generally, the single yarn may be called a filament) used in the present invention may be appropriately determined according to the type of carbon fiber, and is not particularly limited. The average fiber diameter is usually preferably within the range of 3 μm to 50 μm, more preferably within the range of 4 μm to 12 μm, and further preferably within the range of 5 μm to 8 μm. When the carbon fiber is in the form of a fiber bundle, it refers to the diameter of the carbon fiber (single yarn) constituting the fiber bundle, not the diameter of the fiber bundle. The average fiber diameter of the carbon fiber can be measured, for example, by the method described in JIS R7607:2000.

[0014] [Glass fiber] The case where the reinforcing fiber used in the present invention is glass fiber will be described. 1. Glass fiber in general The glass fiber used in the present invention may be any glass fiber that is generally called a glass fiber. The glass composition is not particularly limited, and may be A-glass, C-glass, E-glass, or the like. In some cases, TiO 2 , S.O. 3 , P 2 O 5 It may also contain other components. As the glass fiber, for example, E-glass RS240QR-483 (count: 2400 g / 1000 m) glass fiber manufactured by Nitto Boseki Co., Ltd. can be used.

[0015] 2. Glass fiber sizing agent The glass fiber used in the present invention may have a sizing agent attached to its surface. When using glass fiber with a sizing agent attached, the type of sizing agent can be appropriately selected according to the type of glass fiber and the type of resin contained in the resin panel, and is not particularly limited. Glass fiber that has been previously treated with a conventionally known coupling agent such as an organic silane compound, an organic titanium compound, an organic borane compound, and an epoxy compound can be preferably used.

[0016] 3. Fiber diameter of glass fiber The average fiber diameter of the glass fibers is preferably 1 μm to 50 μm, and more preferably 5 μm to 20 μm. If the average fiber diameter is too small, it becomes difficult to impregnate the fibers with the thermoplastic resin, and if it is too large, it has an adverse effect on moldability and processability.

[0017] [Fiber length of reinforcing fibers contained in fiber-reinforced resin material A] The weight average fiber length of the reinforcing fibers a contained in the fiber reinforced resin member A is preferably less than 3 mm. The weight average fiber length of the reinforcing fibers contained in the fiber reinforced resin member A is more preferably 0.01 mm or more and less than 3 mm. There is no particular limitation on the weight average fiber length Lwa of the reinforcing fiber a, but the lower limit is preferably 0.01 mm or more, more preferably 0.05 mm or more, and even more preferably 0.1 mm or more. When the weight average fiber length Lwa of the reinforcing fiber a is 0.01 mm or more, mechanical strength is ensured. On the other hand, the upper limit of the weight average fiber length Lwa of the reinforcing fiber a is preferably less than 3 mm, more preferably less than 2 mm, and even more preferably less than 1 mm. If Lwa is 1.0 mm or less, it is easy to manufacture the fiber reinforced resin member A by injection. In the case of injection, a kneading process is included, and the weight average fiber length of the carbon fibers that have been thoroughly kneaded generally becomes less than 1 mm. The weight average fiber length Lwa of the reinforcing fiber a is calculated by the formulas (1) and (2) described later. The weight average fiber length of the reinforcing fiber a is preferably shorter than the weight average fiber length of the reinforcing fiber b.

[0018] [Fiber length of reinforcing fibers contained in fiber-reinforced resin material B] The weight average fiber length of the reinforcing fibers b contained in the fiber reinforced resin member B is preferably 3 mm or more. The weight average fiber length of the reinforcing fibers b contained in the fiber reinforced resin member B is more preferably 3 mm or more and 100 mm or less. The weight average fiber length of the reinforcing fibers b is preferably longer than the weight average fiber length of the reinforcing fibers a. Reinforcing fibers b having different fiber lengths may be used in combination. In other words, the reinforcing fibers b used in the present invention may have a single peak in the weight average fiber length distribution, or may have multiple peaks. The weight average fiber length Lwb of the reinforcing fiber b is more preferably 3 mm or more and 80 mm or less, and even more preferably 5 mm or more and 60 mm or less. If Lwb is 100 mm or less, the fluidity of the material is less likely to decrease when the fiber reinforced resin member B is produced by press molding, and it is easy to produce the fiber reinforced resin member in the desired shape. In addition, if Lwb is 1 mm or more, the mechanical strength of the obtained fiber reinforced resin member is less likely to decrease, which is preferable. The weight average fiber length and number average fiber length of the reinforcing fibers b can be measured in the same manner as in the formulas (1) and (2) described later.

[0019] [Number average fiber length Ln and weight average fiber length Lw] In general, when the fiber length of each reinforcing fiber is Li, the number average fiber length Ln and the weight average fiber length Lw can be calculated by the following formulas (1) and (2). The units of the number average fiber length Ln and the weight average fiber length Lw are mm. Ln = ΣLi / I Equation (1) Lw = (ΣLi 2 ) / (ΣLi)...Equation (2) Here, "I" indicates the number of reinforcing fibers measured. When the fiber length is constant, the number average fiber length and the weight average fiber length are the same value. Reinforcing fibers can be extracted from resin panels, for example, by performing a heat treatment at 500°C for about 1 hour and removing the resin in a furnace. The average fiber length can be calculated, for example, by measuring the fiber lengths of 100 fibers randomly extracted from a resin panel to the nearest 1 mm using a caliper or the like, and then calculating the average fiber length based on formula (1). If the fiber contains short fibers that cannot be measured with a caliper, the resin is removed, and the resulting reinforcing fiber is placed in water containing a surfactant and thoroughly stirred with ultrasonic vibration. The stirred dispersion is randomly sampled with a measuring spoon to obtain an evaluation sample, and the lengths of 3,000 fibers are measured using Nireco's Luzex AP image analyzer. Using the measured fiber length, the number average fiber length Ln and weight average fiber length Lw can be calculated in the same manner as in the above formulas (1) and (2).

[0020] [Volume ratio of reinforcing fibers in fiber-reinforced resin member A and fiber-reinforced resin member B] For each of the fiber reinforced resin member A and the fiber reinforced resin member B, the reinforcing fiber volume fraction (Vf) can be calculated by the following formula (3). There is no particular limitation on the reinforcing fiber volume fraction, but the reinforcing fiber volume fraction (Vf) is preferably 10 to 60 Vol%, more preferably 20 to 50 Vol%, and even more preferably 25 to 45 Vol%. Reinforcing fiber volume ratio (Vf) = 100 × reinforcing fiber volume / (reinforcing fiber volume + resin volume) Equation (3)

[0021] In the present invention, it is preferable in terms of the manufacturing process that the reinforcing fiber volume fraction Vfa of the fiber reinforced resin member A and the carbon fiber volume fraction Vfb of the fiber reinforced resin member B satisfy the relationship Vfb ≧ Vfa. For example, when a material obtained by crushing scraps recovered from a manufacturing process or a product is used as the fiber reinforced resin member A, and the scraps are crushed and then a thermoplastic resin is further added to manufacture the fiber reinforced resin member A, Vfb>Vfa is often satisfied. In other words, if a manufacturing method that satisfies Vfb ≧ Vfa is adopted, the scraps remaining after cutting out the fiber reinforced resin member B can be efficiently used, and the product can be easily recycled. Vfb is preferably 20 to 45 Vol %, and more preferably 25 to 40 Vol %. Vfa is preferably 1 to 40 Vol %, more preferably 5 to 30 Vol %, and further preferably 10 to 25 Vol %.

[0022] [Analysis of reinforcing fiber volume fraction (Vf)] Although there is no limitation on the analysis of the reinforcing fiber volume fraction, it is recommended to measure it as follows. A sample is cut out from the resin panel, and the resin is burned off in a furnace at 500°C for 1 hour. The mass of the sample is calculated by weighing it before and after the treatment. Next, the volume ratio of the reinforcing fiber and the resin is calculated using the specific gravity of each component. Vf = 100 x reinforcing fiber volume / (reinforcing fiber volume + resin volume)

[0023] [resin] The resin used in the resin panel may be either thermosetting or thermoplastic. 1.Thermoplastic resin 1.1 Overview When the resin used is a thermoplastic resin, the type is not particularly limited, and a resin having a desired softening point or melting point can be appropriately selected and used. As the above-mentioned thermoplastic resin, one having a softening point in the range of 180°C to 350°C is usually used, but is not limited thereto. Examples of thermoplastic resins include polyolefin resins, polystyrene resins, polyamide resins, polyester resins, polyacetal resins (polyoxymethylene resins), polycarbonate resins, (meth)acrylic resins, polyarylate resins, polyphenylene ether resins, polyimide resins, polyether nitrile resins, phenoxy resins, polyphenylene sulfide resins, polysulfone resins, polyketone resins, polyether ketone resins, thermoplastic urethane resins, fluorine-based resins, and thermoplastic polybenzimidazole resins. The thermoplastic resin used in the resin panel of the present invention may be one type or two or more types. Examples of the use of two or more types of thermoplastic resins in combination include, but are not limited to, the use of thermoplastic resins having different softening points or melting points, or the use of thermoplastic resins having different average molecular weights. When a thermoplastic resin is used, it is more preferable to use a polyolefin resin, and even more preferable to use a polypropylene resin.

[0024] 1.2 Resins of fiber-reinforced resin member A and fiber-reinforced resin member B The resin contained in the fiber reinforced resin member A is preferably a thermoplastic resin. When the resin contained in the fiber reinforced resin member B is a thermoplastic resin, it is more preferable that the resins contained in the fiber reinforced resin members A and B are the same type of thermoplastic resin. 2.Thermosetting resin The resin contained in the fiber reinforced resin member B may be a thermosetting resin. In this case, the fiber reinforced resin member B is preferably a molded sheet molding compound (sometimes called SMC) using reinforced fibers. The sheet molding compound has high moldability, so it can be easily molded even into complex shapes. The sheet molding compound has higher fluidity and shapeability than continuous fibers, so ribs and bosses can be easily created.

[0025] [Material Am, Material Bm] In this specification, the material before molding of the fiber reinforced resin member A used in the vehicle structural body may be referred to as material Am, and the material before molding of the fiber reinforced resin member B may be referred to as material Bm.

[0026] [Other agents] The resin used for the resin panel may contain additives such as various fibrous or non-fibrous fillers of organic or inorganic fibers, flame retardants, UV resistance agents, stabilizers, release agents, pigments, softeners, plasticizers, surfactants, etc., as long as the object of the present invention is not impaired.

[0027] [Types and structures of metal fasteners] The metal fasteners used in the present invention are fasteners made of metal. There is no particular limitation on the shape of the metal fastener used in the present invention, and it may be, for example, L-shaped, corrugated, or I-shaped. The metal fastener has a bolt insertion portion. An example of the vehicle structure of the present invention is shown in Figures 5(a) and (b). In Figure 5(a), a metal fastener (503) is embedded in a resin panel 504 by insert molding. In Figure 5(b), a bolt 505 fastens the metal fastener 503 to a bracket 502. This makes it possible to join, for example, a damper stay to a resin panel. Note that 506 is a hinge for fastening the bolt. As shown in Figure 5(b), it is preferable to insert and fasten the bolt 505 from the outside of the resin panel.

[0028] [Metal fasteners embedded in plastic panels by insert molding] The metal fastener is embedded in the resin panel by insert molding. Insert molding is a molding method in which resin is poured around the metal fastener inserted in a mold to integrate the metal fastener and the resin. There is no particular limitation on the insert molding method.

[0029] 1.Insert molding using injection As described below, it is preferable that material Bm and the metal fasteners are placed in the mold in advance, and material Am is injected into the mold.

[0030] 1.1 Location of metal fasteners The metal fastener is preferably covered with the fiber reinforced resin member A. In this case, the metal fastener is placed in a mold in advance, and material Am is injected into the mold to cover the metal fastener with material Am, so that the metal fastener is covered with the fiber reinforced resin member A. At this time, the fiber reinforced resin member A, the fiber reinforced resin member B, and the metal fastener are integrally molded.

[0031] Also, it is preferable that the fiber reinforced resin member B is not in contact with the metal fastener. In this case, when insert molding, the material Bm and the metal fastener are placed in a mold in advance without contacting each other, and then the material Am is injected into the mold and placed in the mold. The resin of the fiber reinforced resin member A is a thermoplastic resin, and the metal fastener is covered by the fiber reinforced resin member A by injecting the material Am. This manufacturing method leads to a reduction in manufacturing man-hours. Furthermore, by designing the metal fastener to be covered by the fiber reinforced resin member A and not in contact with the fiber reinforced resin member B, the welds generated by the contact between the material Am and the material Bm do not exist around the metal fastener. In other words, it is more preferable that the metal fastener is covered by the fiber reinforced resin member A, and there is no weld generated by the fiber reinforced resin member A on the contact surface with the metal fastener. In addition, when the fiber reinforced resin member B is not in contact with the metal fastener, it is preferable that the fiber reinforced resin member B is in contact with the fiber reinforced resin member A.

[0032] 1.2 Preferred embodiment 1 Fiber-reinforced material A is a glass fiber-reinforced material A containing glass fibers. GF The fiber reinforced member B is a carbon fiber reinforced member B containing carbon fibers. CF or glass fiber reinforced member B containing glass fiber GF It is preferable that: More preferably, the reinforcing fiber member B is a carbon fiber reinforced resin member B CF , and glass fiber reinforced resin member B GF The metal fastener is a glass fiber reinforced resin member A GF and glass fiber reinforced resin member A. GF Carbon fiber reinforced resin component B CF Carbon fiber reinforced member B CF and glass fiber reinforced member B GF By using both, the carbon fiber reinforced resin material B is partially CF It is possible to use a carbon fiber reinforced resin member B. CF The location where it is used is preferably the periphery of the hole h1, and it is preferably used to reinforce the fastening.

[0033] 1.3 Resin of Preferred Embodiment 1 It is preferable that the resin contained in the fiber reinforced resin member A is a thermoplastic resin or a thermosetting resin, and the resin contained in the fiber reinforced resin member B is a thermoplastic resin or a thermosetting resin. Glass fiber reinforced resin material A GF , Carbon fiber reinforced resin material B CF , Glass fiber reinforced resin material B GF The resin contained in may be a thermoplastic resin. Glass fiber reinforced resin material A GF is a thermoplastic resin, while carbon fiber reinforced resin component B CF , Glass fiber reinforced resin material B GF The molded article may be a molded article made using a sheet molding compound.

[0034] 2. Insert molding using SMC As another method of insert molding, a sheet molding compound containing carbon fiber may be used as the material Bm, and the metal fastener may be covered at the same time as molding the material Bm. In this case, it is not necessarily necessary to use the fiber-reinforced resin member A.

[0035] 2.2 Preferred form 2 The resin panel of the vehicle structure has a fiber-reinforced resin member B, and the fiber-reinforced resin member B is a glass fiber-reinforced resin member B GF Glass fiber reinforced resin member B GF is preferably molded from a sheet molding compound. More preferably, the fiber reinforced resin member B is a carbon fiber reinforced resin member B CF , and glass fiber reinforced resin member B GF Carbon fiber reinforced resin member B CF is molded from sheet molding compound, and the metal fastener is made of glass fiber reinforced resin material B. GF Or carbon fiber reinforced resin member B CF It is preferable that the metal fastener is covered with a carbon fiber reinforced resin member B. CF and the other areas are covered with glass fiber reinforced resin material B. GF If created, it would be possible to reinforce the metal fastener and the area around hole h1.

[0036] [Resin panel] 1.Shape The shape of the resin panel is not particularly limited. The resin panel preferably has at least one flat surface having at least one thickness (plate thickness), and may have a cross-sectional shape of a T-shape, an L-shape, a U-shape, a hat shape, or a three-dimensional shape including these, and may further have an uneven shape (for example, a rib, a boss, etc.). The resin panel preferably has a shape including a part having a cross-sectional shape of a hat shape.

[0037] 2. Uneven thickness structure The resin panel may include a thickness-varying portion, that is, the resin panel may include a thickness-varying structure. It is preferable that the uneven thickness portion of the resin panel is located within 30 mm from the metal fastener. Naturally, the uneven thickness portion may be located outside 30 mm from the metal fastener. In other words, the periphery of the metal fastener may have an uneven thickness structure. Furthermore, when the metal fastener is covered with fiber reinforced resin member A, it is preferable that the uneven thickness structure is provided within 30 mm from the metal fastener depending on the thickness of fiber reinforced resin member B and the thickness of fiber reinforced resin member A. It is more preferable that the uneven thickness portion of the resin panel is located within 20 mm from the metal fastener.

[0038] 2.1 When using insert molding using injection When a resin panel has an uneven thickness structure (a portion with an uneven thickness), it is preferable that the fiber reinforced resin member A contributes to the uneven thickness structure. This is because the material Bm for producing the fiber reinforced resin member B is preferably plate-shaped, and the material Am for producing the fiber reinforced resin member A is preferably an injection material. By using the material Am, it is easy to manufacture a resin panel with an uneven thickness structure. For example, when manufacturing a resin panel having a thickness deviation structure in which the thickness gradually decreases from 2 mm to 3 mm, a 1 mm thick material Bm is placed in a molding die, and the remaining 1 mm to 2 mm thickness deviation region is formed by adding material Am, which is made of fiber reinforced resin member A.

[0039] 2.2 When using insert molding with SMC When a sheet molding compound containing carbon fiber is used as the material Bm and the metal fastener is covered at the same time as the material Bm is molded, the fiber reinforced resin member B can contribute to the uneven thickness structure.

[0040] 3. Ribs 3.1 When using insert molding using injection The resin panel preferably has a rib made of the fiber reinforced resin member A located within 30 mm from the metal fastener. Naturally, a rib may be present outside more than 30 mm from the metal fastener.

[0041] 3.2 When using insert molding with SMC When a sheet molding compound containing carbon fiber is used as the material Bm and the metal fastener is covered at the same time as the material Bm is molded, the ribs can be provided using a fiber-reinforced resin member.

[0042] 4. Figure 6 shows a schematic diagram of a vehicle structure of the present invention, which includes a metal fastener having a bolt insertion portion and a resin panel. The metal fastener 603 is embedded in the resin panel by insert molding, and the resin panel is provided with a hole h1 (601) at a position corresponding to the bolt insertion portion. Figure 6 shows the state before the bolt is inserted. In Figure 6, a rib 602 is provided around the metal fastener 603.

[0043] [hole h1] The resin panel is provided with a hole h1 at a position corresponding to the bolt insertion portion. 1. Hole h1 is created during molding It is preferable to form the hole h1 at the same time as molding. For example, it is preferable to make the hole h1 provided in the resin panel by providing a hole in the fiber reinforced resin member A. In the case of insert molding in which a material Am is injected into a molding die, if a protrusion corresponding to the hole h1 to be created is provided in the molding die in advance, the hole h1 can be created in the fiber reinforced resin member A when the material Am is poured in and molding is completed. On the other hand, in the case of insert molding using SMC, a protrusion corresponding to the hole h1 to be created is provided in advance on the mold, and a hole h0 is created in the material Bm at a position corresponding to the protrusion of the mold, and the hole h0 is fitted into the protrusion of the mold and pressed to create the hole h1 in the fiber reinforced resin member B. For more details, the methods described in International Publication No. 2017 / 043186 and JP-A-10-100175 can be referred to. In either case, the hole h1 can be easily formed since it is formed simultaneously with integral molding. If the hole h1 is formed by integral molding, the manufacturing process can be simplified.

[0044] 2. Hole h1 is created by secondary processing Also, the hole h1 may be provided by secondary machining. For example, the hole h1 may be provided by secondary processing after integral molding described later.

[0045] 3. Structure of the hole h1 The preferred structure of the hole h1 will be described with reference to FIG. 7. FIG. 7 is a schematic diagram showing a structure in which the resin panel is not involved in the fastening part as much as possible. That is, it is preferable that the metal fastener (for example, 701 in FIG. 7) embedded in the resin panel by insert molding and the fastener (for example, 704 in FIG. 7) used for connection with the vehicle body side are in contact. More preferably, it is preferable that the metal fastener (for example, 701 in FIG. 7) embedded in the resin panel by insert molding and the fastener (for example, 704 in FIG. 7) used for connection with the vehicle body side are in surface contact. The fastener (for example, 704 in FIG. 7) used for connection with the vehicle body side is preferably a bracket and is preferably used for connection with the damper stay. As shown in FIG. 7, by making the bolt fixing locations where the load is applied in surface contact with each other between metals (701 and 704 in FIG. 7), the fastening stability is improved. In other words, regarding the shape of the hole h1, the relationship between the area S1 of the hole h1 (for example, the area of the hole h1 seen from the left side in FIG. 7) as seen from the side of the metal fastener embedded in the resin panel by insert molding and the area S2 of the hole h1 (for example, the area of the hole h1 seen from the right side in FIG. 7) as seen from the side of the fastener used for connection with the vehicle body side is preferably S1 < S2. When S1 < S2, the fastener (for example, 704 in FIG. 7) used for connection with the vehicle body side can be embedded in the resin panel. Thereby, the fastening strength is stabilized.

[0046] [Door panel constituting the back door] 1. Door panel It is preferable that the resin panel is a door panel constituting the vehicle rear door, and the vehicle structure is a vehicle resin rear door structure. The door panel may be provided with a rear glass.

[0047] 2. Damper stay It is preferable that the vehicle back door is provided with a damper stay, and the door panel and the damper stay are fastened and fixed by inserting a bolt into the bolt insertion part. The damper stay is a fastener for a damper, and a damper is a member that prevents unintentional closure of the back door when a door, lid, or drawer is closed or opened by using an orifice structure or a shear structure.

[0048] [Manufacturing method: Insert molding using injection] The following describes the case where material Am is injected into a molding die. 1. Overview The vehicle structure of the present invention is preferably manufactured in such a manner that material Bm for producing fiber reinforced resin member B and metal fasteners are placed in a molding die in advance, material Am for producing fiber reinforced resin member A is injected into the molding die, and fiber reinforced resin member A, fiber reinforced resin member B, and metal fasteners are integrally molded.

[0049] 2. When using cold press molding When the resin contained in the fiber reinforced resin member A and the fiber reinforced resin member B is a thermoplastic resin, the vehicle structure is preferably manufactured by cold pressing.

[0050] 2.1. A process of placing the material Bm for producing the fiber-reinforced resin member B and the metal fasteners in the mold in advance

[0051] 2.1.1 Arrangement of material Bm for creating fiber-reinforced resin part B The step of placing the material Bm for producing the fiber reinforced resin member B in the present invention in a molding die can be carried out by using a conventionally known method. In this case, the material Bm is preferably placed in the mold in a preheated state. If the thermoplastic resin contained in the fiber reinforced resin member B is crystalline, it is preferably heated to a temperature between the melting point and the decomposition temperature, and if it is amorphous, it is preferably heated to a temperature between the glass transition temperature and the decomposition temperature. In addition, the temperature of the mold is preferably adjusted to a temperature below the melting point if the thermoplastic resin contained in the fiber reinforced resin member B is crystalline, and below the glass transition temperature if it is amorphous. In this way, by adjusting the temperatures of the material Bm and the mold, cold pressing can be performed suitably. It is preferable that the material Bm is pre-shaped before the pressing is started.

[0052] 2.1.2 Metallic fastener placement It is preferable to fix the metal fastener to the lower die so that it does not move during the pressing process. It is preferable to design it so that it is clamped to the lower die in advance and the molded body (finished product) can be removed from the die at the same time as molding is completed using a slide core.

[0053] 2.2 The process of closing the mold, injecting material Am into the mold after pressure begins to be applied to a part of material Bm. In the manufacturing method of the vehicle structure of the present invention, after the material Bm is placed in the mold, the mold is closed, and after the mold is closed (typically by lowering the upper mold), the material Am is injected into the mold (preferably by pouring it into the mold by an injection device). The timing of injection of material Am may be immediately before or immediately after pressure begins to be applied to a portion of material Bm. If material Bm is prone to misalignment within the molding die, it is preferable to inject material Am immediately after pressure begins to be applied to at least a portion of material Bm. The fact that pressure has begun to be applied to a part of the material Bm can usually be confirmed by a pressure gauge installed in the press molding machine. More specifically, it can be confirmed by the pressure being output to the pressure gauge of the press molding machine after the upper die (upper molding die) of the molding die descends and comes into contact with the material Bm. The method of injecting the material Am into the mold is not particularly limited, and may be any method known in the art. For example, a gate is provided in the mold, and the material Am is injected from outside the mold by an injection device. The number of gates for injecting the material Am and the position of the gate are not particularly limited. In the present invention, it is preferable that the volume Va of the material Am used and the volume Vb of the material Bm used satisfy the relationship Vb≧Va. The ratio Va:Vb is preferably 10:90 to 50:50, and more preferably 20:80 to 40:60. When Va:Vb is 10:90 to 50:50, for example, the main part of the press-molded body can be formed using the material Bm, and only the necessary parts (such as the edges and details) can be formed using the highly fluid material Am. The pressure when injecting the material Am is preferably 30 to 200 kgf / m 2 More preferably, it is 40 to 150 kgf / m 2 Although there is no particular limitation on the heating temperature of the material Am, for example, when nylon 6 is used as the thermoplastic resin, the heating temperature is preferably 200 to 300°C.

[0054] 2.3 The process of cold pressing materials Am and Bm in a mold to form an integrated body Cold pressing can be performed using a conventionally known method. In general, in the cold pressing method, for example, a fiber-reinforced thermoplastic resin material (material Am when a thermoplastic resin is used and material Bm when a thermoplastic resin is used may be collectively called "fiber-reinforced thermoplastic resin material") heated to a first predetermined temperature is placed in a mold set to a second predetermined temperature, and then pressurized and cooled. Specifically, when the thermoplastic resin contained in the fiber reinforced thermoplastic resin material is crystalline, the first predetermined temperature is equal to or higher than the melting point, and the second predetermined temperature is lower than the melting point. When the thermoplastic resin is amorphous, the first predetermined temperature is equal to or higher than the glass transition temperature, and the second predetermined temperature is lower than the glass transition temperature. That is, the cold press method includes at least the following steps A-1) to A-2). Step A-1) A step of heating a fiber-reinforced thermoplastic resin material to a temperature between the melting point and the decomposition temperature if the thermoplastic resin is crystalline, or between the glass transition temperature and the decomposition temperature if the thermoplastic resin is amorphous. Step A-2) The fiber-reinforced thermoplastic resin material heated in step A-1) is placed in a mold whose temperature is adjusted to below the melting point if the thermoplastic resin is crystalline, or below the glass transition temperature if the thermoplastic resin is amorphous, and then pressurized. By carrying out these steps, the molding of the fiber reinforced thermoplastic resin material can be completed (a press molded body can be produced). The above steps must be performed in the above order, but other steps may be included between each step. For example, the other steps include a shaping step in which a molding die other than the molding die used in step A-2) is used to pre-shape the molded body into the shape of the mold cavity before step A-2). Step A-2) is a step in which pressure is applied to the fiber-reinforced thermoplastic resin material to obtain a molded body of a desired shape. The molding pressure at this time is not particularly limited, but is preferably less than 20 MPa relative to the mold cavity projected area, and more preferably 10 MPa or less. Of course, various steps may be inserted between the above steps during press molding, and for example, vacuum press molding may be used in which press molding is performed while being evacuated. Since the material Am is injected into the mold, when it is injected into the mold, it is generally heated to a temperature above the melting point and below the decomposition temperature if the thermoplastic resin is crystalline, or above the glass transition temperature and below the decomposition temperature if the thermoplastic resin is amorphous. In the present invention, it is preferable that the material Bm is plate-shaped, and the material Am is caused to flow in the in-plane direction of the material Bm to extend the surface, thereby producing a resin panel.

[0055] 3. Molding methods other than cold pressing Although the above description has focused on "cold press molding," integral molding may also be performed using hot press molding.

[0056] 4. Benefits of one-piece molding In a preferred manufacturing method for a vehicle structure of the present invention, the material Bm and the metal fasteners are placed in a molding die in advance, and the material Am is injected into the molding die to integrally mold the fiber reinforced resin member A, the fiber reinforced resin member B, and the metal fasteners. This makes it possible to manufacture a resin panel integrated with the metal fasteners in a single molding process, resulting in excellent productivity. Moreover, in the preferred manufacturing method, the joining strength between the fiber reinforced resin member A and the fiber reinforced resin member B in the resin panel is also excellent. Furthermore, in the present invention, the easily flowing material Am can be injected only in the necessary areas and pressed, making it possible to produce molded bodies with more complex shapes (for example, molded bodies having ribs or bosses).

[0057] [Manufacturing method: Molding method using sheet molding compound to cover metal fasteners] Glass fiber reinforced resin component B using sheet molding compound GF、 Or carbon fiber reinforced resin member B CF The metal fastener is made of glass fiber reinforced resin material B. GF Or carbon fiber reinforced resin member B CF In this case, it is not always necessary to use the injected material. FIG. 8 shows the molding process of sandwiching a metal fastener 801 using a material Bm (sheet molding compound, 802). The metal fastener 801 is supported by a slide core 803 so that it does not move due to the material Bm or the like. By arranging the metal fastener as shown in FIG. 8, the glass fiber reinforced resin member B GF Or carbon fiber reinforced resin member B CF It is possible to manufacture a vehicle structure covered with [Explanation of symbols]

[0058] 401 Bracket 1 402 Bracket 2 403 Bracket 3 404 Inner Panel 501, 602 Ribs 502 Bracket 503, 603 Metal fasteners embedded in plastic panels by insert molding 601 hole h1 504, 702 Resin Panel 505, 703 Volts 506 Nut 701, 801 Metal fasteners 704 Bracket for connecting to the vehicle body 802 Material Bm (preferably sheet molding compound) 803 Slide core (supporting metal fasteners) 804 Upper mold 805 Lower mold

Claims

1. A vehicle structure including a metal fastener having a bolt insertion portion and a resin panel, The metal fastener is embedded in the resin panel by insert molding, The resin panel has a hole h1 at a position corresponding to the bolt insertion portion.

2. The resin panel has a fiber reinforced resin member A and a fiber reinforced resin member B, The weight average fiber length of the reinforcing fibers a contained in the fiber reinforced resin member A is less than 3 mm, The weight average fiber length of the reinforcing fibers b contained in the fiber reinforced resin member B is 3 mm or more. The vehicle structure of claim 1 .

3. 3. The vehicle structure according to claim 2, wherein the fiber reinforced resin member A is provided with a hole h1 formed in the resin panel.

4. 4. The vehicle structure according to claim 2, wherein the metal fastener is covered with a fiber-reinforced resin member (A).

5. The vehicle structure according to any one of claims 2 to 4, wherein the fiber reinforced resin member B is in contact with the fiber reinforced resin member A.

6. 6. The vehicle structure according to claim 4, wherein the fiber reinforced resin member (B) is not in contact with a metal fastener.

7. The resin contained in the fiber reinforced resin member A is a thermoplastic resin or a thermosetting resin, The vehicle structure according to any one of claims 2 to 6, wherein the resin contained in the fiber reinforced resin member B is a thermoplastic resin or a thermosetting resin.

8. The fiber-reinforced resin member A is a glass fiber-reinforced resin member A containing glass fibers. ＧＦ And, The fiber-reinforced resin member B is a carbon fiber-reinforced resin member B containing carbon fibers. ＣＦ Or glass fiber reinforced resin member B containing glass fiber ＧＦ That is, The vehicle structure according to any one of claims 2 to 7.

9. The reinforced fiber resin member B is a carbon fiber reinforced resin member B. ＣＦ , and glass fiber reinforced resin member B ＧＦ Equipped with The metal fastener is a glass fiber reinforced resin member A. ＧＦ Covered by Glass fiber reinforced resin member A ＧＦ Carbon fiber reinforced resin member B ＣＦ In contact with 8. A vehicle structure according to claim 7.

10. Glass fiber reinforced resin member A ＧＦ , carbon fiber reinforced resin member B ＣＦ , and glass fiber reinforced resin member B ＧＦ 10. The vehicle structure according to claim 9, wherein the resin contained in the first layer is a thermoplastic resin.

11. Carbon fiber reinforced resin member B ＣＦ , and glass fiber reinforced resin member B ＧＦ The vehicle structure according to claim 9, which is a molded article made using a sheet molding compound.

12. The resin panel has a fiber reinforced resin member B, Fiber reinforced resin member B is a glass fiber reinforced resin member B ＧＦ Including, Glass fiber reinforced resin member B ＧＦ 2. The vehicle structure of claim 1, wherein the sheet molding compound is molded.

13. Fiber-reinforced resin member B is a carbon fiber-reinforced resin member B ＣＦ , and glass fiber reinforced resin member B ＧＦ Including, Carbon fiber reinforced resin member B ＣＦ is molded from sheet molding compound, Metal fastener is glass fiber reinforced resin member B ＧＦ Or carbon fiber reinforced resin member B ＣＦ 13. The vehicle structure of claim 12, wherein the vehicle structure is covered by

14. The vehicle structure according to any one of claims 1 to 13, wherein the metal fastener is L-shaped, corrugated, or I-shaped.

15. The resin panel is a door panel constituting a vehicle back door, and the vehicle structure is a vehicle resin back door structure. The vehicle structure according to any one of claims 1 to 14.

16. The vehicle back door includes a damper stay, The door panel and the damper stay are fastened to each other by inserting a bolt into the bolt insertion portion.

16. A vehicle structure as claimed in claim 15.

17. 17. A vehicle structure as claimed in claim 15 or 16, wherein the door panel comprises a rear glass.

18. The vehicle structure according to any one of claims 2 to 11, wherein the resin panel has a rib located within 30 mm from a metal fastener.

19. The vehicle structure according to any one of claims 2 to 18, wherein the resin panel has a thickness deviation portion within 30 mm from a metal fastener.

20. A method for manufacturing a vehicle structure according to any one of claims 2 to 11, in which a material Bm for producing the fiber reinforced resin member B and the metal fasteners are placed in a molding die in advance, and a material Am for producing the fiber reinforced resin member A is injected into the molding die, so that the fiber reinforced resin member A, the fiber reinforced resin member B, and the metal fasteners are integrally molded.

21. The method for manufacturing a vehicle structure according to claim 20, wherein the hole h1 is provided by a secondary process after integral molding.

22. The method for manufacturing a vehicle structure according to claim 20, wherein the hole h1 is provided at the same time as the integral molding.

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