WO2016035694A1 - エネルギー吸収部材 - Google Patents

エネルギー吸収部材 Download PDF

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Publication number
WO2016035694A1
WO2016035694A1 PCT/JP2015/074370 JP2015074370W WO2016035694A1 WO 2016035694 A1 WO2016035694 A1 WO 2016035694A1 JP 2015074370 W JP2015074370 W JP 2015074370W WO 2016035694 A1 WO2016035694 A1 WO 2016035694A1
Authority
WO
WIPO (PCT)
Prior art keywords
fiber
load
shape holding
trigger
fiber layer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/JP2015/074370
Other languages
English (en)
French (fr)
Inventor
宏匡 富岡
亜矢 牧
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Toyota Industries Corp
Original Assignee
Toyota Industries Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Toyota Industries Corp filed Critical Toyota Industries Corp
Priority to EP15838901.5A priority Critical patent/EP3190307B1/en
Priority to CN201580046899.3A priority patent/CN106605079B/zh
Priority to US15/507,980 priority patent/US10023141B2/en
Publication of WO2016035694A1 publication Critical patent/WO2016035694A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D3/00—Woven fabrics characterised by their shape
    • D03D3/02—Tubular fabrics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R19/00—Wheel guards; Radiator guards, e.g. grilles; Obstruction removers; Fittings damping bouncing force in collisions
    • B60R19/02—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects
    • B60R19/24—Arrangements for mounting bumpers on vehicles
    • B60R19/26—Arrangements for mounting bumpers on vehicles comprising yieldable mounting means
    • B60R19/30—Elastomeric material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B1/00—Layered products having a non-planar shape
    • B32B1/08—Tubular products
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/08—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts
    • B32B3/085—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts spaced apart pieces on the surface of a layer
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    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
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    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/06—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
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    • B32B5/14—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by a layer differing constitutionally or physically in different parts, e.g. denser near its faces
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    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/28—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer impregnated with or embedded in a plastic substance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R19/00—Wheel guards; Radiator guards, e.g. grilles; Obstruction removers; Fittings damping bouncing force in collisions
    • B60R19/02—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects
    • B60R19/24—Arrangements for mounting bumpers on vehicles
    • B60R19/26—Arrangements for mounting bumpers on vehicles comprising yieldable mounting means
    • B60R19/34—Arrangements for mounting bumpers on vehicles comprising yieldable mounting means destroyed upon impact, e.g. one-shot type
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D1/00—Woven fabrics designed to make specified articles
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D11/00—Double or multi-ply fabrics not otherwise provided for
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04C—BRAIDING OR MANUFACTURE OF LACE, INCLUDING BOBBIN-NET OR CARBONISED LACE; BRAIDING MACHINES; BRAID; LACE
    • D04C1/00—Braid or lace, e.g. pillow-lace; Processes for the manufacture thereof
    • D04C1/06—Braid or lace serving particular purposes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16F—SPRINGS; SHOCK-ABSORBERS; MEANS FOR DAMPING VIBRATION
    • F16F1/00—Springs
    • F16F1/36—Springs made of rubber or other material having high internal friction, e.g. thermoplastic elastomers
    • F16F1/366—Springs made of rubber or other material having high internal friction, e.g. thermoplastic elastomers made of fibre-reinforced plastics, i.e. characterised by their special construction from such materials
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16F—SPRINGS; SHOCK-ABSORBERS; MEANS FOR DAMPING VIBRATION
    • F16F7/00—Vibration-dampers; Shock-absorbers
    • F16F7/12—Vibration-dampers; Shock-absorbers using plastic deformation of members
    • F16F7/124—Vibration-dampers; Shock-absorbers using plastic deformation of members characterised by their special construction from fibre-reinforced plastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
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    • B60R19/00—Wheel guards; Radiator guards, e.g. grilles; Obstruction removers; Fittings damping bouncing force in collisions
    • B60R19/02—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects
    • B60R19/03—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects characterised by material, e.g. composite
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    • B60R19/24—Arrangements for mounting bumpers on vehicles
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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Definitions

  • the present invention relates to an energy absorbing member that includes a fiber structure having an impregnated resin and absorbs impact energy when subjected to an impact load.
  • an energy absorbing member is disposed between the bumper and the body frame.
  • This energy absorbing member absorbs impact energy due to its own destruction when receiving an excessive impact load.
  • a fiber reinforced composite material having an excellent energy absorbing ability is known.
  • the energy absorbing member has a trigger portion that becomes a starting point of destruction when receiving an excessive impact load.
  • the shock absorbing composite material structure 80 disclosed in Patent Document 1 includes a fiber laminate having an impregnated resin.
  • the fiber laminate has a plurality of laminated reinforcing fibers.
  • the shock absorbing composite structure 80 has a trigger portion 82 in a range from a tip in a direction in which a load is applied (hereinafter referred to as a load direction) to a predetermined position along the load direction.
  • the trigger part 82 is provided so as not to improve the interlayer bonding force of the fiber laminate.
  • the portion beyond the predetermined position, that is, the portion excluding the trigger portion 82 is an interlayer reinforcement region 81 in which the interlayer coupling force is improved by the need ring 83.
  • the trigger portion 82 when an excessive impact load is applied, the trigger portion 82 is locally destroyed prior to the interlayer reinforcement region 81 to absorb energy, and the progress of the fracture in the interlayer reinforcement region 81 is achieved. Suppress.
  • the trigger portion 82 in the state of the fiber laminate before impregnating the resin, the trigger portion 82 is easily torn or bent in the load direction from the tip. For this reason, in order to impregnate the fiber laminate, for example, during the operation of enclosing the fiber laminate in a mold, as shown in FIG. Will bend. Therefore, handling of the fiber laminate is very bad, and the productivity of the impact-absorbing composite structure 80 may be reduced.
  • An object of the present invention is to provide an energy absorbing member that can suppress a decrease in productivity.
  • an energy absorbing member configured to absorb impact energy when subjected to an impact load.
  • the energy absorbing member includes a fiber structure having an impregnated resin.
  • the said fiber structure has a some fiber layer laminated
  • Each fiber layer is formed by arranging a plurality of load direction yarns extending in a direction in which a load is applied.
  • the fiber structure has an interlayer bonding force due to the bonding of the plurality of fiber layers.
  • the fiber structure has a first end surface configured to be loaded first, and a second end surface located on the opposite side of the first end surface in the direction in which the load is applied.
  • the fiber structure includes a shape holding portion including the first end surface, a main body portion including the second end surface, and suppressing progress of destruction of the fiber structure, and between the shape holding portion and the main body portion. And a trigger portion that becomes a starting point of destruction when receiving an impact load.
  • Each of the shape holding part and the main body part has a higher interlayer bonding force than the trigger part due to the woven structure.
  • (A) is a perspective view which shows the energy absorption member of 1st Embodiment
  • (b) is a plane sectional view which shows a shape holding
  • (c) is a plane sectional view which shows a trigger part.
  • (A) is a perspective view which shows the energy absorption member of 2nd Embodiment
  • (b) is a plane sectional view which shows a shape holding
  • (c) is a plane sectional view which shows a trigger part.
  • (A) is a perspective view which shows the energy absorption member of 3rd Embodiment
  • (b) is a plane sectional view which shows a shape holding
  • (c) is a plane sectional view which shows a trigger part.
  • the plane sectional view showing another example of the trigger part in a 3rd embodiment.
  • the energy absorption member 10 is a fiber reinforced composite material.
  • the energy absorbing member 10 is configured by impregnating a cylindrical fiber structure 11 with a thermosetting resin 15 as a matrix resin. That is, the energy absorbing member 10 includes a fiber structure 11 having an impregnated thermosetting resin 15.
  • the energy absorbing member 10 receives an excessive impact load along the axial direction of the cylindrical body, the energy absorbing member 10 absorbs energy by its own destruction.
  • the load direction Z for example, an epoxy resin is used as the thermosetting resin 15.
  • the fiber structure 11 has two end faces located on opposite sides in the load direction Z. Specifically, the fiber structure 11 has a first end surface 11a configured such that a load is applied first, and has a second end surface 11b located on the opposite side of the first end surface 11a in the load direction Z.
  • the fiber structure 11 includes a shape holding portion 22 including the first end surface 11a, a second end surface 11b, and a main body portion 24 that suppresses the progress of destruction of the fiber structure 11, and the shape holding portion 22 and the main body portion 24. And a trigger portion 23 which becomes a starting point of destruction when receiving an impact load.
  • the fiber structure 11 is configured to receive a load in the order of the shape holding portion 22, the trigger portion 23, and the main body portion 24.
  • the fiber structure 11 has a trigger portion 23 in the middle of the load direction Z.
  • the trigger portion 23 is provided at a position closer to the first end surface 11a than the second end surface 11b in the load direction Z. In other words, when the intermediate position of the fiber structure 11 is defined between the first end surface 11a and the second end surface 11b in the load direction Z, the trigger portion 23 is disposed between the first end surface 11a and the intermediate position. Has been.
  • the main body part 24 is located in a position closer to the second end face 11b than the trigger part 23 in the load direction Z.
  • the shape holding part 22 is located at a position closer to the first end surface 11 a than the trigger part 23 in the load direction Z.
  • the trigger portion 23 is disposed between the shape holding portion 22 and the main body portion 24 in the load direction Z.
  • the main body portion 24 In the length along the load direction Z, the main body portion 24 is the longest, and then the trigger portion 23 is long. And in the length along the load direction Z, the shape holding
  • the fiber structure 11 has a plurality of fiber layers 13 laminated in a direction orthogonal to the load direction Z (lamination direction X). Each fiber layer 13 is formed by arranging a plurality of load direction yarns 12 extending in the entire load direction Z. In the tubular fiber structure 11, the plurality of fiber layers 13 are stacked concentrically around the central axis extending in the load direction Z. In the present embodiment, the fiber structure 11 has five fiber layers 13. The five fiber layers 13 include a first fiber layer 13a, a second fiber layer 13b, a third fiber layer 13c, a fourth fiber layer 13d, and a fifth fiber layer 13e arranged in the stacking direction X, that is, in the radial direction. .
  • the fiber layer 13 located at one end in the laminating direction X, that is, the outer end is the first fiber layer 13a
  • the second layer is sequentially arranged along the laminating direction X toward the other end, that is, the inner end.
  • the fiber layer 13b, the third fiber layer 13c, the fourth fiber layer 13d, and the fifth fiber layer 13e are arranged.
  • the two fiber layers 13 adjacent in the stacking direction X are coupled to each other by the first entangled yarn 14a and the second entangled yarn 14b as entangled yarns. That is, the first fiber layer 13a and the second fiber layer 13b are bonded to each other, the second fiber layer 13b and the third fiber layer 13c are bonded to each other, and the third fiber layer 13c and the fourth fiber layer 13d are bonded to each other. The fourth fiber layer 13d and the fifth fiber layer 13e are bonded to each other.
  • the fiber structure 11 has an interlayer bonding force due to the bonding of the plurality of fiber layers 13.
  • the first entangled yarn 14a and the second entangled yarn 14b penetrate the two fiber layers 13 adjacent to each other in the stacking direction X, and are folded back by the load direction yarns 12 of the respective fiber layers 13. Looking at the traveling direction of the first entangled yarn 14a and the second entangled yarn 14b in one direction, the first entangled yarn 14a is one load direction yarn 12 with respect to the two load direction yarns 12 adjacent in the stacking direction X. The second entangled yarn 14b is folded back with the other load direction yarn 12. Therefore, the first entangled yarn 14a and the second entangled yarn 14b are entangled with each load direction yarn 12 so as to sandwich the two load direction yarns 12 adjacent to each other in the stacking direction X from opposite directions.
  • the five fiber layers 13 are formed by the entanglement of the first entangled yarn 14a and the second entangled yarn 14b with the load direction yarn 12 so that the adjacent fiber layers 13 in the laminating direction X are Bonded to each other, the interlayer bonding force in the stacking direction X is enhanced.
  • the main body portion 24 has the same structure as the shape holding portion 22 and has the same interlayer coupling force.
  • Each of the main body portion 24 and the shape holding portion 22 has a higher interlayer bonding force than the trigger portion 23 due to the woven structure.
  • the shape holding part 22 is provided only by one layer of the interlaced yarns 14a and 14b from the first end surface 11a in the load direction Z.
  • the main body 24 includes a plurality of layers of entangled yarns 14a and 14b stacked along the load direction Z.
  • the trigger part 23 contains the same five fiber layers 13 as the shape holding
  • the first fiber layer 13a and the second fiber layer 13b adjacent to each other in the stacking direction X are coupled by the first entangled yarn 14a and the second entangled yarn 14b, and the fourth fiber layer 13d and the fifth fiber layer. 13e is connected by the first entangled yarn 14a and the second entangled yarn 14b.
  • the 2nd fiber layer 13b and the 3rd fiber layer 13c, and the 3rd fiber layer 13c and the 4th fiber layer 13d are the 1st entangled yarn 14a and the 2nd entangled yarn 14b of each layer.
  • the load direction yarn 12 is not entangled. That is, the first entangled yarn 14a and the second entangled yarn 14b are not entangled with the load direction yarn 12 of the third fiber layer 13c, and the fiber layer 13 is coupled to the trigger portion 23 in the stacking direction.
  • the shape holding unit 22 uses the first entangled yarn 14 a and the second entangled yarn 14 b to bond the plurality of fiber layers 13, so that the interlayer bonding force is greater than the trigger unit 23 due to the woven structure. Has been increased.
  • the load direction yarn 12, the first entangled yarn 14a and the second entangled yarn 14b are all composed of untwisted fiber bundles made of the same kind of material.
  • untwisted fiber bundles made of carbon fibers are used for the load direction yarn 12 and the entangled yarns 14a and 14b.
  • the carbon fiber bundle hundreds to tens of thousands of thin fibers are bundled to form one fiber bundle.
  • a fiber bundle having the number of fibers suitable for the required performance is selected.
  • the energy absorption member 10 which made the fiber structure 11 which has the shape holding
  • the manufacturing method of the energy absorbing member 10 will be described together with the operation.
  • the fiber structure 11 having the shape holding part 22, the trigger part 23, and the main body part 24 is manufactured.
  • the fiber structure 11 is impregnated with the thermosetting resin 15 and cured.
  • the resin 15 is impregnated and cured by an RTM (resin transfer molding) method. Specifically, when the fiber structure 11 is enclosed in a mold configured with irregularities, the thermosetting resin 15 is injected into the mold, and the thermosetting resin 15 is cured, the energy absorbing member 10 is manufactured. Is done.
  • the shape holding part 22 is provided at a position closer to the first end surface 11 a of the fiber structure 11 than the trigger part 23.
  • the shape holding part 22 is provided at a position where a load is first applied.
  • the shape holding unit 22 is configured by joining the fiber layers 13 adjacent in the stacking direction X with the first entangled yarn 14a and the second entangled yarn 14b, and has a structure that is not easily frayed. Therefore, when encapsulating the fiber structure 11 in the mold for the production of the energy absorbing member 10, the shape holding portion 22 causes the first end surface 11 a of the fiber structure 11 to split between the fiber layers 13, It can suppress that it bends. As a result, the fiber structure 11 can be easily handled when the fiber structure 11 is sealed in the mold, and the productivity of the energy absorbing member 10 can be prevented from being lowered.
  • the trigger part 23 can suppress tearing and bending at the first end surface 11 a of the fiber structure 11, and the stacking direction X at the trigger part 23
  • the bias of the load direction yarn 12 in the arrangement direction of the load direction yarns 12 can be suppressed.
  • the manufactured energy absorbing member 10 it is possible to suppress the occurrence of unevenness of the resin density due to the bias of the load direction yarn 12 and the bias of the load direction yarn 12.
  • the shape holding part 22 is provided with only one layer from the first end face 11a. That is, it is provided in the minimum region that can be formed using the first entangled yarn 14a and the second entangled yarn 14b. Therefore, the shape holding part 22 can hold the shape while suppressing an excessive increase in the interlayer coupling force of the first end surface 11a of the fiber structure 11.
  • the shape holding part 22 and the main body part 24 and the trigger part 23 have different functions by changing the woven structure of the fiber structure 11. For this reason, for example, after manufacturing a fiber structure having the same woven structure, an adhesive is applied to the tip of the fiber structure in the load direction Z to form a shape holding portion, or the thickness of the fiber structure is reduced. As compared with the case where the trigger part and the shape holding part are formed by processing as described above, the fiber structure 11 can be easily manufactured.
  • the shape holding part 22 and the main body part 24 have the same woven structure and the same interlayer bonding force. Therefore, compared with the case where all of the shape holding part 22, the trigger part 23, and the main body part 24 are formed with different woven structures, it is possible to simplify the manufacture of the fiber structure 11, and thus the energy absorbing member 10. it can.
  • the energy absorbing member 30 of the second embodiment has a cylindrical fiber structure 31 similar to the energy absorbing member 10 of the first embodiment, and its fiber structure.
  • the body 31 includes a shape holding portion 32, a trigger portion 33, and a main body portion 34 that are arranged in parallel along the load direction Z.
  • the fiber structure 31 of the second embodiment is different from the first embodiment in the method of increasing the interlayer bonding force in the shape holding part 32 and the main body part 34.
  • the fiber structure 31 is manufactured by a three-dimensional braiding apparatus. Further, the fiber structure 31 has a first end surface 31a configured such that a load is first applied in the load direction Z, and a second end surface 31b located on the opposite side of the first end surface 31a in the load direction Z. .
  • the fiber structure 31 is a braided tissue.
  • Each of the shape holding part 32 and the main body part 34 includes a plurality of fiber layers 36, and first and second penetrating threads 37 a and 37 b that are structured to penetrate the fiber layer 36.
  • Each fiber layer 36 is formed by arranging a plurality of load direction threads 35.
  • the load direction yarn 35, the first penetration yarn 37a, and the second penetration yarn 37b are untwisted fiber bundles made of carbon fibers.
  • the direction orthogonal to the stacking direction X and the load direction yarns 35 is arranged is defined as an arrangement direction Y.
  • the fiber structure 31 has five fiber layers 36.
  • the five fiber layers 36 include a first fiber layer 36a, a second fiber layer 36b, a third fiber layer 36c, a fourth fiber layer 36d, and a fifth fiber layer 36e arranged in the stacking direction X, that is, in the radial direction. .
  • the fiber layer 36 at one end in the stacking direction X, that is, the outer end is the first fiber layer 36a.
  • the second fiber layer is sequentially along the stacking direction X toward the other end, that is, the inner end.
  • 36b, the 3rd fiber layer 36c, and the 4th fiber layer 36d are located in a line.
  • the first penetrating thread 37 a penetrates the two fiber layers 36 adjacent to each other in the stacking direction X and the load direction thread 35 of each fiber layer 36 that penetrates. It is folded at. That is, two of the first penetrating yarns 37a pass through the first fiber layer 36a and the second fiber layer 36b, and are folded back by the load direction yarns 35 of the penetrating fiber layers 36a and 36b. Another two of the first penetrating yarns 37a pass through the second fiber layer 36b and the third fiber layer 36c, and are folded back by the load direction yarns 35 of the penetrating fiber layers 36b and 36c. Another two of the first penetrating yarns 37a pass through the third fiber layer 36c and the fourth fiber layer 36d, and are folded back by the load direction yarns 35 of the penetrating fiber layers 36c and 36d.
  • the first penetrating thread 37 a is folded back by the load direction thread 35 of one fiber layer 36, and then one fiber thread 36 along the arrangement direction Y in the other fiber layer 36.
  • the load direction yarn 35 extends toward the next load direction yarn 35.
  • the first penetration thread 37 a penetrates the two fiber layers 36 and is folded back by the load direction thread 35 of the latter fiber layer 36. Therefore, the first penetration yarn 37a is folded back by the load direction yarns 35 so as to sandwich the two fiber layers 36 adjacent to each other in the stacking direction X from opposite directions via the different load direction yarns 35 in the arrangement direction Y. Yes.
  • the first penetrating thread 37a joins two adjacent fiber layers 36 together.
  • the second penetrating yarn 37b is structured so as to pass through only the first fiber layer 36a at one end in the stacking direction and the fourth fiber layer 36d at the other end in the stacking direction. And each load direction thread
  • the shape holding part 32 and the main body part 34 have the same structure and the same interlayer coupling force. Note that only one layer of the shape holding portion 32 is provided from the first end surface 31a in the load direction Z.
  • the trigger part 33 it has comprised so that the 2nd penetration thread 37b may fold through each of the four fiber layers 36, and may be turned back.
  • the first penetrating thread 37a penetrates the first fiber layer 36a and the second fiber layer 36b, and is structured to be folded along the load direction thread 35 of each fiber layer 36, and the third fiber layer 36c It is structured so as to penetrate the fourth fiber layer 36 d and to be folded along the load direction thread 35 of each fiber layer 36.
  • the 1st penetration thread 37a is not penetrated so that the 2nd fiber layer 36b and the 3rd fiber layer 36c may be straddled, and the 2nd fiber layer 36b and the 3rd fiber layer 36c are the 1st They are not joined by the penetrating thread 37a. That is, in the trigger part 33, the 1st penetration thread 37a is not couple
  • each of the shape holding part 32 and the main body part 34 is connected to the plurality of fiber layers 36 using the first penetrating thread 37a and the second penetrating thread 37b, so that the trigger part is formed by the woven structure. It has an interlayer bonding strength higher than 33.
  • the energy absorbing member 30 of the present embodiment is manufactured by impregnating and curing the thermosetting resin 15 on the fiber structure 31 manufactured by the three-dimensional braiding apparatus.
  • the resin impregnation and curing is performed by RTM (resin transfer). ⁇ Molding method is used.
  • the fiber structure 31 can be manufactured by a three-dimensional braiding device, and the cylindrical energy absorbing member 30 can be easily manufactured.
  • the energy absorption member 40 of 3rd Embodiment has the cylindrical fiber structure 41 similarly to the energy absorption member 10 of 1st Embodiment,
  • the body 41 includes a shape holding portion 42, a trigger portion 43, and a main body portion 44 that are arranged in parallel along the load direction Z. Further, the fiber structure 41 has a first end face 41a configured so that a load is applied first, and has a second end face 41b located on the opposite side of the first end face 41a in the load direction Z.
  • the fiber structure 41 of the third embodiment has a plurality of fiber layers 46 stacked.
  • the fiber layer 46 is formed of a plain weave (woven fabric) in which warp yarns 45a as a plurality of load direction yarns and a plurality of weft yarns 45b are alternately combined one by one.
  • the fiber layer 46 is a plain weave, but may be formed of a satin weave or a twill weave in addition to the plain weave.
  • each fiber layer 46 the direction perpendicular to the stacking direction X and in which the warp yarns 45a are arranged is defined as an arrangement direction Y.
  • the fiber structure 11 has five fiber layers 46.
  • the five fiber layers 46 include a first fiber layer 46a, a second fiber layer 46b, a third fiber layer 46c, a fourth fiber layer 46d, and a fifth fiber layer 46e arranged in the stacking direction X, that is, in the radial direction. .
  • the fiber layer 46 positioned at one end in the stacking direction X, that is, the outer end, is the first fiber layer 46a, and the second layer in the order of the other end along the stacking direction X, that is, the inner end.
  • the fiber layer 46b, the third fiber layer 46c, and the fourth fiber layer 46d are arranged.
  • a plurality of fiber layers 46 are coupled by a plurality of in-plane threads 47 and a retaining thread 48.
  • the above-described warp yarn 45a and weft yarn 45b are untwisted fiber bundles made of carbon fibers.
  • a plurality of retaining yarns 48 are provided on the surface of the first fiber layer 46a at one end in the stacking direction at intervals in the arrangement direction Y of the warp yarns 45a.
  • Each of the plurality of in-plane threads 47 is inserted into the laminated body of the four fiber layers 46 from the surface of the fourth fiber layer 46d at the other end in the lamination direction, and penetrates the four fiber layers 46 in the lamination direction X.
  • the first fiber layer 46a is folded back through the outside of the retaining thread 48 on the surface.
  • the in-plane thread 47 is inserted from the surface of the first fiber layer 46a into the laminated body of the four fiber layers 46, penetrates the four fiber layers 46 in the lamination direction X, and then the surface of the fourth fiber layer 46d. Has been drawn to.
  • the in-plane yarn 47 is repeatedly folded back on the surfaces of the first fiber layer 46a and the fourth fiber layer 46d, and the four fiber layers 46 are joined at a plurality of locations by the in-plane yarn 47.
  • the trigger portion 43 has a configuration in which the fiber layers 46 are simply laminated, and the fiber layers 46 are joined together by the in-plane yarn 47 and the retaining yarn 48. Not. Therefore, in the trigger portion 43, the interlayer coupling force is lower than that of the shape holding portion 42 and the main body portion 44. That is, each of the shape holding part 42 and the main body part 44 has a higher interlayer bonding force than the trigger part 43 due to the woven structure.
  • the fiber layers 46 are coupled to each other by the in-plane thread 47 and the retaining thread 48, whereas the trigger part In 43, the fiber layers 46 are not joined together by the in-plane yarn 47 and the retaining yarn 48.
  • the four fiber layers 46 may be joined by the in-plane yarn 47 and the retaining yarn 48 only at the shape holding portion 42 and the main body portion 44. Therefore, the fiber structure 41 having the shape holding part 42, the trigger part 43, and the main body part 44 can be easily manufactured.
  • first entangled yarn 14a and the second entangled yarn 14b, the first penetrating yarn 37a and the first entangled yarn 14a are also formed in all the fiber layers in the trigger portions 23 and 33. Bonding in the stacking direction X may be performed by the two penetrating yarn 37b.
  • the number of entanglements by the first entangled yarn 14a and the second entangled yarn 14b at the trigger portions 23 and 33 and the number of entanglements by the first and second penetrating yarns 37a and 37b are determined by the shape holding portion and the main body portion.
  • the interlayer coupling force at the trigger portion may be lower than that of the shape holding portion and the main body portion by being less than the number of entanglements and the number of penetrations.
  • the thicknesses of the first entangled yarn 14a and the second entangled yarn 14b in the trigger portions 23 and 33 and the thicknesses of the first penetrating yarn 37a and the second penetrating yarn 37b are determined based on the thicknesses of the shape holding portion and the main body portion. It is made thinner so that the interlayer coupling force at the trigger portion is lower than that of the shape holding portion and the main body portion.
  • an in-plane thread 47 and a retaining thread 48 may also be used for the trigger unit 43.
  • the number of in-plane threads 47 and retaining threads 48 used in the trigger unit 43 is less than the number used in the shape holding unit 42 and the main body unit 44, and
  • the interlayer coupling force may be lower than the interlayer coupling force of the shape holding part 42 and the main body part 44.
  • the thickness of the in-plane thread 47 used in the trigger unit 43 is made thinner than the shape holding unit 42 and the main body unit 44. May be. Even if the number of in-plane threads 47 and retaining threads 48 used is the same in the trigger portion 43, the shape holding portion 42, and the main body portion 44, the interlayer coupling in the trigger portion 43 is caused by the difference in thickness. The force may be lower than the interlayer bonding force of the shape holding portion 42 and the main body portion 44.
  • the way of joining the fiber layers 36 by the first penetrating thread 37a and the second penetrating thread 37b may be appropriately changed. Further, the fiber layers 36 may be bonded to each other with only one type of penetrating yarn without using two types of penetrating yarns of the first penetrating yarn 37a and the second penetrating yarn 37b.
  • the fiber layer 13 in which the first entangled yarn 14a and the second entangled yarn 14b are entangled may be three or more layers.
  • the load direction yarn 12 to be sandwiched is There are three or more adjacent in the stacking direction X.
  • the interlayer coupling force of the shape holding parts 22, 32, 42 is higher than the interlayer coupling force of the trigger parts 23, 33, 43, it may be lower than the interlayer coupling force of the main body parts 24, 34, 44. It can be good or expensive.
  • the interlayer coupling force of the shape holding portions 22, 32, 42 is higher than the interlayer coupling force of the trigger portions 23, 33, 43, the shape holding portions 22, 32, 42 and the main body portions 24, 34, 44 And the woven structure may be different.
  • thermosetting resin 15 is used as the matrix resin, but other types of resins may be used.
  • the number of fiber layers 13, 36, and 46 to be laminated may be arbitrarily changed.
  • ⁇ Load direction yarns 12, 35, first entangled yarn 14a, second entangled yarn 14b, first penetrating yarn 37a, second penetrating yarn 37b, warp yarn 45a, weft yarn 45b, in-plane yarn 47, and retaining yarn 48 are Not limited to carbon fiber.
  • each yarn may be changed as appropriate in accordance with physical properties required for the energy absorbing members 10, 30, and 40.
  • the yarn that can be used include an aramid fiber, a poly-p-phenylenebenzobisoxazole fiber, an ultrahigh molecular weight polyethylene fiber, an arbitrary fiber such as a glass fiber and a ceramic fiber.
  • the shape of the fiber structures 11, 31, and 41 may not be cylindrical, but may be a columnar shape or a plate shape in which a load direction thread extends in the load direction Z.

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Abstract

エネルギー吸収部材は、繊維構造体を備える。繊維構造体は、荷重が最初に加わるように構成された第１端面と、荷重が加わる方向において該第１端面と反対側に位置する第２端面とを有する。繊維構造体は、第１端面を含む形状保持部と、第２端面を含み、繊維構造体の破壊の進行を抑制する本体部と、形状保持部と本体部との間に配置され、衝撃荷重を受けた際に破壊の起点となるトリガ部とを備える。形状保持部及び本体部の各々は、織組織によってトリガ部よりも高い層間結合力を有する。

Description

エネルギー吸収部材
　本発明は、含浸された樹脂を有する繊維構造体を備え、衝撃荷重を受けた際の衝撃エネルギーを吸収するエネルギー吸収部材に関する。
　例えば、バンパーと車体フレームの間には、エネルギー吸収部材が配置されている。このエネルギー吸収部材は、過大な衝撃荷重を受けた場合に、自身の破壊により衝撃エネルギーを吸収する。エネルギー吸収部材としては、優れたエネルギー吸収能力を有する繊維強化複合材料が知られている。また、エネルギー吸収部材は、過大な衝撃荷重を受けた際の破壊の起点となるトリガ部を有している。
　例えば、図５に示すように、特許文献１に開示の衝撃吸収複合材構造８０は、含浸された樹脂を有する繊維積層体を備えている。繊維積層体は、積層された複数の補強繊維を有する。衝撃吸収複合材構造８０は、荷重が加わる方向（以下、荷重方向と記載する）における先端から、荷重方向に沿って所定位置に至るまでの範囲に、トリガ部８２を有する。トリガ部８２は、繊維積層体の層間結合力を向上させないようにするために設けられている。衝撃吸収複合材構造８０において、前記所定位置から先の部分、即ちトリガ部８２を除いた部分は、ニードリング８３によって層間結合力を向上させた層間補強領域８１である。このような衝撃吸収複合材構造８０では、過大な衝撃荷重を受けた場合、層間補強領域８１に先立ってトリガ部８２に局部破壊を生じさせてエネルギーを吸収し、層間補強領域８１で破壊の進行を抑制する。
特開２００４－３２４８１４号公報
　ところが、特許文献１の衝撃吸収複合材構造８０において、樹脂を含浸させる前の繊維積層体の状態では、トリガ部８２が先端から荷重方向に裂けたり、撓んだりしやすい。このため、繊維積層体を樹脂含浸させるため、例えば、繊維積層体を金型内に封入する作業を行う最中、図５に示すように、トリガ部８２が先端から裂けたり、トリガ部８２全体が撓んだりする。そのため、繊維積層体の取り扱いが非常に悪く、衝撃吸収複合材構造８０の生産性が低下してしまう虞がある。
　本発明の目的は、生産性の低下を抑制することができるエネルギー吸収部材を提供することにある。
　上記目的を達成するために、衝撃荷重を受けた際の衝撃エネルギーを吸収するように構成されたエネルギー吸収部材を提供する。エネルギー吸収部材は、含浸された樹脂を有する繊維構造体を備える。前記繊維構造体は、荷重が加わる方向と直交する方向に積層された複数の繊維層を有する。各繊維層は、荷重が加わる方向に延びる複数の荷重方向糸を配列してなる。前記繊維構造体は、前記複数の繊維層の結合により層間結合力を有する。前記繊維構造体は、荷重が最初に加わるように構成された第１端面と、荷重が加わる方向において該第１端面と反対側に位置する第２端面とを有する。前記繊維構造体は、前記第１端面を含む形状保持部と、前記第２端面を含み、前記繊維構造体の破壊の進行を抑制する本体部と、前記形状保持部と前記本体部との間に配置され、衝撃荷重を受けた際に破壊の起点となるトリガ部とを備える。前記形状保持部及び前記本体部の各々は、織組織によって前記トリガ部よりも高い層間結合力を有する。
（ａ）は第１の実施形態のエネルギー吸収部材を示す斜視図、（ｂ）は形状保持部及び本体部を示す平断面図、（ｃ）はトリガ部を示す平断面図。 （ａ）は第２の実施形態のエネルギー吸収部材を示す斜視図、（ｂ）は形状保持部及び本体部を示す平断面図、（ｃ）はトリガ部を示す平断面図。 （ａ）は第３の実施形態のエネルギー吸収部材を示す斜視図、（ｂ）は形状保持部及び本体部を示す平断面図、（ｃ）はトリガ部を示す平断面図。 第３の実施形態におけるトリガ部の別例を示す平断面図。 背景技術を示す図。
　（第１の実施形態）
　以下、エネルギー吸収部材を具体化した第１の実施形態を図１にしたがって説明する。
　図１（ａ）に示すように、エネルギー吸収部材１０は繊維強化複合材料である。エネルギー吸収部材１０は、筒状の繊維構造体１１にマトリックス樹脂としての熱硬化性樹脂１５を含浸させて構成されたものである。即ち、エネルギー吸収部材１０は、含浸された熱硬化性樹脂１５を有する繊維構造体１１を備える。エネルギー吸収部材１０は、筒体の軸方向に沿って過大な衝撃荷重を受けた場合に、自身の破壊によりエネルギーを吸収する。以下、エネルギー吸収部材１０に対し荷重が加わる方向（筒体の軸方向）を荷重方向Ｚと定義する。熱硬化性樹脂１５としては、例えば、エポキシ樹脂が使用される。
　繊維構造体１１は、荷重方向Ｚにおいて互いに反対側に位置する二つの端面を有する。詳しくは、繊維構造体１１は、荷重が最初に加わるように構成された第１端面１１ａを有し、荷重方向Ｚにおいて第１端面１１ａと反対側に位置する第２端面１１ｂを有する。
　繊維構造体１１は、第１端面１１ａを含む形状保持部２２と、第２端面１１ｂを含み、繊維構造体１１の破壊の進行を抑制する本体部２４と、形状保持部２２と本体部２４との間に配置され、衝撃荷重を受けた際に破壊の起点となるトリガ部２３とを備える。繊維構造体１１は、形状保持部２２、トリガ部２３、及び本体部２４の順に荷重を受けるように構成されている。
　即ち、繊維構造体１１は、荷重方向Ｚの途中にトリガ部２３を有する。トリガ部２３は、荷重方向Ｚにおける第２端面１１ｂよりも第１端面１１ａに近い位置に設けられている。換言すれば、荷重方向Ｚにおいて第１端面１１ａと第２端面１１ｂとの間に繊維構造体１１の中間位置を定義した場合、トリガ部２３は、第１端面１１ａと中間位置との間に配置されている。
　本体部２４は、荷重方向Ｚにおいて、トリガ部２３よりも第２端面１１ｂに近い位置に位置する。形状保持部２２は、荷重方向Ｚにおいて、トリガ部２３より第１端面１１ａに近い位置に位置する。
　そして、トリガ部２３は、荷重方向Ｚにおいて、形状保持部２２と本体部２４の間に配置されている。荷重方向Ｚに沿った長さでは、本体部２４が最も長く、その次に、トリガ部２３が長い。そして、荷重方向Ｚに沿った長さでは、形状保持部２２が最も短い。
　図１（ｂ）に示すように、繊維構造体１１は、荷重方向Ｚに直交する方向（積層方向Ｘ）に積層された複数の繊維層１３を有する。各繊維層１３は、荷重方向Ｚ全体に延びる複数の荷重方向糸１２を配列して形成されている。そして、筒状の繊維構造体１１では、複数の繊維層１３は、荷重方向Ｚに延びる中心軸を中心とした同心円状に積層されている。本実施形態では、繊維構造体１１は、５つの繊維層１３を有している。５つの繊維層１３は、積層方向Ｘ、即ち径方向に配置された第１繊維層１３ａ、第２繊維層１３ｂ、第３繊維層１３ｃ、第４繊維層１３ｄ、及び第５繊維層１３ｅを含む。具体的には、積層方向Ｘの一端、即ち外端に位置する繊維層１３が第１繊維層１３ａであり、以下、積層方向Ｘに沿って他端、即ち内端に向けて順に、第２繊維層１３ｂ、第３繊維層１３ｃ、第４繊維層１３ｄ、第５繊維層１３ｅが並んでいる。
　形状保持部２２及び本体部２４の各々では、積層方向Ｘに隣り合う２つの繊維層１３は、交絡糸としての第１交絡糸１４ａ及び第２交絡糸１４ｂによって互いに結合されている。即ち、第１繊維層１３ａと第２繊維層１３ｂとが互いに結合され、第２繊維層１３ｂと第３繊維層１３ｃとが互いに結合され、第３繊維層１３ｃと第４繊維層１３ｄとが互いに結合され、第４繊維層１３ｄと第５繊維層１３ｅとが互いに結合されている。繊維構造体１１は、複数の繊維層１３の結合により層間結合力を有する。
　第１交絡糸１４ａ及び第２交絡糸１４ｂは、積層方向Ｘに隣り合う２つの繊維層１３を貫通し、かつ各繊維層１３の荷重方向糸１２で折り返されている。一方向への第１交絡糸１４ａと第２交絡糸１４ｂの進行方向を見ると、積層方向Ｘに隣り合う２つ荷重方向糸１２に対し、第１交絡糸１４ａは、一方の荷重方向糸１２で折り返され、第２交絡糸１４ｂは、他方の荷重方向糸１２で折り返されている。よって、第１交絡糸１４ａと第２交絡糸１４ｂは、積層方向Ｘに隣り合う２つの荷重方向糸１２を相反する方向から挟むように各荷重方向糸１２に交絡している。
　そして、形状保持部２２と本体部２４において、５つの繊維層１３は、第１交絡糸１４ａと第２交絡糸１４ｂの荷重方向糸１２に対する交絡によって、積層方向Ｘに隣り合う繊維層１３同士が互いに結合され、積層方向Ｘへの層間結合力が高められている。本体部２４は形状保持部２２と同じ構造を有し、同じ層間結合力を有する。本体部２４及び形状保持部２２の各々は、織組織によってトリガ部２３よりも高い層間結合力を有する。なお、形状保持部２２は、荷重方向Ｚの第１端面１１ａから１層の交絡糸１４ａ，１４ｂだけ設けられている。これに対して、本体部２４は、荷重方向Ｚに沿って積層された複数の層の交絡糸１４ａ，１４ｂを含む。
　図１（ｃ）に示すように、トリガ部２３は、形状保持部２２及び本体部２４と同じ５つの繊維層１３と、第１交絡糸１４ａ及び第２交絡糸１４ｂとを含む。しかし、トリガ部２３は、形状保持部２２及び本体部２４に比べて低い層間結合力を有する。トリガ部２３では、積層方向Ｘに隣り合う第１繊維層１３ａと第２繊維層１３ｂが第１交絡糸１４ａ及び第２交絡糸１４ｂによって結合されるとともに、第４繊維層１３ｄと第５繊維層１３ｅが第１交絡糸１４ａ及び第２交絡糸１４ｂによって結合されている。
　その一方で、トリガ部２３では、第２繊維層１３ｂと第３繊維層１３ｃ、及び第３繊維層１３ｃと第４繊維層１３ｄとは、第１交絡糸１４ａ及び第２交絡糸１４ｂが各層の荷重方向糸１２には交絡していない。すなわち、第３繊維層１３ｃの荷重方向糸１２に対しては、第１交絡糸１４ａ及び第２交絡糸１４ｂが交絡しておらず、トリガ部２３には、繊維層１３同士を積層方向に結合していない部位が存在する。すなわち、５つの繊維層１３のうち、積層方向Ｘの両側の２つだけで層間結合力が高められている。
　よって、５つの繊維層１３の全てが、隣り合う繊維層１３同士で層間結合力が高められた形状保持部２２及び本体部２４と比べると、トリガ部２３では層間結合力が低くなっている。したがって、繊維構造体１１において、形状保持部２２では、第１交絡糸１４ａ及び第２交絡糸１４ｂを用いて複数の繊維層１３を結合することで、織組織によってトリガ部２３よりも層間結合力が高められている。
　荷重方向糸１２、第１交絡糸１４ａ及び第２交絡糸１４ｂは全て同種の材質製の無撚りの繊維束で構成されている。この実施形態では荷重方向糸１２及び各交絡糸１４ａ，１４ｂには炭素繊維からなる無撚りの繊維束が使用されている。炭素繊維束は細い繊維が数百～数万本束ねられて１本の繊維束が構成されている。要求性能に適した繊維の本数の繊維束が選択される。
　そして、形状保持部２２、トリガ部２３、及び本体部２４を有する繊維構造体１１を強化繊維としたエネルギー吸収部材１０においては、荷重方向Ｚに沿って第１端面１１ａに過大な衝撃荷重を受けた場合、トリガ部２３に局部破壊を生じさせてエネルギーを吸収する。その後、本体部２４で破壊の進行を抑制する。
　次に、エネルギー吸収部材１０の製造方法を作用とともに説明する。
　まず、形状保持部２２、トリガ部２３、及び本体部２４を有する繊維構造体１１を製造する。次に、繊維構造体１１に、熱硬化性樹脂１５を含浸して硬化させる。樹脂１５の含浸及び硬化はＲＴＭ（レジン・トランスファー・モールディング）法で行われる。具体的には、凹凸で構成された金型に繊維構造体１１を封入し、金型内に熱硬化性樹脂１５を注入し、熱硬化性樹脂１５を硬化させると、エネルギー吸収部材１０が製造される。
　上記実施形態によれば、以下のような効果を得ることができる。
　（１）トリガ部２３を有するエネルギー吸収部材１０において、トリガ部２３よりも繊維構造体１１の第１端面１１ａに近い位置に形状保持部２２を設けた。形状保持部２２は、荷重が最初に加わる位置に設けられている。形状保持部２２は、積層方向Ｘに隣り合う繊維層１３同士を第１交絡糸１４ａ及び第２交絡糸１４ｂで結合して構成されており、ほつれにくい構造を有する。よって、エネルギー吸収部材１０の製造のため、繊維構造体１１を金型内に封入する際、形状保持部２２によって、繊維構造体１１の第１端面１１ａで繊維層１３同士の間が裂けたり、撓んだりすることを抑制することができる。その結果、金型に繊維構造体１１を封入する際の、繊維構造体１１の取り扱いが容易となりエネルギー吸収部材１０の生産性の低下が抑制できる。
　（２）繊維構造体１１に形状保持部２２を設けることで、トリガ部２３より繊維構造体１１の第１端面１１ａでの裂けや撓みを抑制することができ、トリガ部２３での積層方向Ｘや、荷重方向糸１２の配列方向での荷重方向糸１２の偏りを抑制することができる。このため、製造されたエネルギー吸収部材１０においても、荷重方向糸１２の偏りや、荷重方向糸１２の偏りを原因とした樹脂密度のばらつきの発生を抑制することができる。
　（３）形状保持部２２は、第１端面１１ａから１層だけ設けられている。即ち、第１交絡糸１４ａ及び第２交絡糸１４ｂを用いて形成できる最小領域に設けられている。よって、形状保持部２２によって、繊維構造体１１の第１端面１１ａの層間結合力が過度に高まることを抑えつつ、形状を保持できる。
　（４）形状保持部２２及び本体部２４と、トリガ部２３とは、繊維構造体１１の織組織を異ならせて機能を異ならせている。このため、例えば、同じ織組織の繊維構造体を製造した後、その繊維構造体の荷重方向Ｚの先端に接着剤を塗布して形状保持部を形成したり、繊維構造体の厚みを薄くなるように加工してトリガ部や形状保持部を形成する場合と比べると、繊維構造体１１の製造が容易である。
　（５）形状保持部２２と本体部２４は、同じ織組織を有し、同じ層間結合力を有する。よって、形状保持部２２と、トリガ部２３と、本体部２４の全てを異なる織組織で形成する場合と比べて、繊維構造体１１の製造、ひいてはエネルギー吸収部材１０の製造を簡単にすることができる。
　（第２の実施形態）
　次に、エネルギー吸収部材を具体化した第２の実施形態を図２にしたがって説明する。第２の実施形態では、第１の実施形態と同様の部分についてはその詳細な説明を省略する。
　図２（ａ）に示すように、第２の実施形態のエネルギー吸収部材３０は、第１の実施形態のエネルギー吸収部材１０と同様に、筒状の繊維構造体３１を有し、その繊維構造体３１は、荷重方向Ｚに沿って並設された形状保持部３２と、トリガ部３３と、本体部３４とを有する。第２の実施形態の繊維構造体３１は、形状保持部３２及び本体部３４での層間結合力を高める方法が、第１の実施形態と異なる。繊維構造体３１は、３次元ブレイディング装置によって製造されている。また、繊維構造体３１は、荷重方向Ｚにおいて荷重が最初に加わるように構成された第１端面３１ａと、荷重方向Ｚにおいて該第１端面３１ａと反対側に位置する第２端面３１ｂとを有する。
　図２（ｂ）に示すように、繊維構造体３１は組紐組織である。形状保持部３２及び本体部３４の各々では、複数の繊維層３６と、繊維層３６を貫通するように組織された第１貫通糸３７ａ及び第２貫通糸３７ｂとを有する。各繊維層３６は、複数の荷重方向糸３５を配列して形成されている。荷重方向糸３５、第１貫通糸３７ａ、及び第２貫通糸３７ｂは、炭素繊維からなる無撚りの繊維束である。各繊維層３６において、積層方向Ｘに直交し、かつ荷重方向糸３５が配列された方向を配列方向Ｙとする。
　繊維構造体３１は、５つの繊維層３６を有している。５つの繊維層３６は、積層方向Ｘ、即ち径方向に配置された第１繊維層３６ａ、第２繊維層３６ｂ、第３繊維層３６ｃ、第４繊維層３６ｄ、及び第５繊維層３６ｅを含む。具体的には、積層方向Ｘの一端、即ち外端の繊維層３６が第１繊維層３６ａであり、以下、積層方向Ｘに沿って他端、即ち内端に向けて順に、第２繊維層３６ｂ、第３繊維層３６ｃ、第４繊維層３６ｄが並んでいる。繊維構造体３１において、形状保持部３２と本体部３４では、第１貫通糸３７ａは、積層方向Ｘに隣り合う２つの繊維層３６を貫通し、かつ貫通した各繊維層３６の荷重方向糸３５で折り返されている。即ち、第１貫通糸３７ａのうちの二本が、第１繊維層３６ａと第２繊維層３６ｂとを貫通し、かつ貫通した各繊維層３６ａ，３６ｂの荷重方向糸３５で折り返されている。第１貫通糸３７ａのうちの別の二本が、第２繊維層３６ｂと第３繊維層３６ｃとを貫通し、かつ貫通した各繊維層３６ｂ，３６ｃの荷重方向糸３５で折り返されている。第１貫通糸３７ａのうち更に別の二本が、第３繊維層３６ｃと第４繊維層３６ｄを貫通し、かつ貫通した各繊維層３６ｃ，３６ｄの荷重方向糸３５で折り返されている。
　具体的には、隣り合う２つの繊維層３６において、第１貫通糸３７ａは一方の繊維層３６の荷重方向糸３５で折り返された後、他方の繊維層３６において配列方向Ｙに沿って１本の荷重方向糸３５を飛ばした次の荷重方向糸３５に向かうように延びている。そして、第１貫通糸３７ａは、２つの繊維層３６を貫通し、後者の繊維層３６の荷重方向糸３５で折り返されている。よって、第１貫通糸３７ａは、積層方向Ｘに隣り合う２つの繊維層３６を、配列方向Ｙに異なる荷重方向糸３５を介して相反する方向から挟むように各荷重方向糸３５で折り返されている。そして、第１貫通糸３７ａは、隣り合う２つの繊維層３６を結合している。
　第２貫通糸３７ｂは、積層方向一端の第１繊維層３６ａと、積層方向他端の第４繊維層３６ｄのみを貫通して折り返すように組織されている。そして、各繊維層３６の各荷重方向糸３５を第１貫通糸３７ａと第２貫通糸３７ｂで挟み込み、積層方向Ｘに隣り合う繊維層３６同士の層間結合力を高めている。形状保持部３２と、本体部３４は同じ構造であり、層間結合力も同じである。なお、形状保持部３２は、荷重方向Ｚの第１端面３１ａから１層だけ設けられている。
　図２（ｃ）に示すように、トリガ部３３では、４つの繊維層３６それぞれを第２貫通糸３７ｂが貫通して折り返すように組織されている。そして、第１貫通糸３７ａは、第１繊維層３６ａと第２繊維層３６ｂを貫通し、各繊維層３６の荷重方向糸３５に沿って折り返すように組織されるとともに、第３繊維層３６ｃと第４繊維層３６ｄを貫通し、各繊維層３６の荷重方向糸３５に沿って折り返すように組織されている。
　よって、トリガ部３３では、第１貫通糸３７ａは、第２繊維層３６ｂと第３繊維層３６ｃを跨るように貫通しておらず、第２繊維層３６ｂと第３繊維層３６ｃは、第１貫通糸３７ａによって結合されていない。すなわち、トリガ部３３では、第１貫通糸３７ａによる積層方向への結合がされず、繊維層３６同士を積層方向に結合していない部位が存在する。したがって、トリガ部３３では、４つの繊維層３６のうち、積層方向Ｘの両側の２層だけで層間結合力が高められており、４つの繊維層３６の全てが、隣り合う繊維層３６同士で結合された形状保持部３２及び本体部３４に比べて、トリガ部３３の層間結合力が低くなっている。よって、繊維構造体３１において、形状保持部３２及び本体部３４の各々は、第１貫通糸３７ａ及び第２貫通糸３７ｂを用いて複数の繊維層３６を結合することで、織組織によってトリガ部３３よりも高い層間結合力を有する。
　そして、本実施形態のエネルギー吸収部材３０は、三次元ブレイディング装置によって製造された繊維構造体３１に、熱硬化性樹脂１５を含浸硬化させて製造され、樹脂の含浸硬化はＲＴＭ（レジン・トランスファー・モールディング）法で行われる。
　従って、第２の実施形態によれば、第１の実施形態に記載の効果に加えて以下の効果を得ることができる。
　（６）第２の実施形態のエネルギー吸収部材３０は、繊維構造体３１を三次元ブレイディング装置により製造でき、筒状のエネルギー吸収部材３０を容易に製造することができる。
　（第３の実施形態）
　次に、エネルギー吸収部材を具体化した第３の実施形態を図３にしたがって説明する。なお、第３の実施形態では、第１の実施形態と同様の部分についてはその詳細な説明を省略する。
　図３（ａ）に示すように、第３の実施形態のエネルギー吸収部材４０は、第１の実施形態のエネルギー吸収部材１０と同様に、筒状の繊維構造体４１を有し、その繊維構造体４１は、荷重方向Ｚに沿って並設された形状保持部４２と、トリガ部４３と、本体部４４とを有する。また、繊維構造体４１は、荷重が最初に加わるように構成された第１端面４１ａを有し、荷重方向Ｚにおいて第１端面４１ａと反対側に位置する第２端面４１ｂを有する。
　図３（ｂ）に示すように、第３の実施形態の繊維構造体４１は、積層された複数の繊維層４６を有する。繊維層４６は、複数の荷重方向糸としての経糸４５ａと、複数の緯糸４５ｂとを一本ずつ交互に組み合わせた平織り（織物）によって形成されている。本実施形態では、繊維層４６を平織りとしたが、平織り以外にも、朱子織りや綾織りで形成されていてもよい。
　各繊維層４６において、積層方向Ｘに直交し、かつ経糸４５ａが配列された方向を配列方向Ｙと定義する。繊維構造体１１は、５つの繊維層４６を有している。５つの繊維層４６は、積層方向Ｘ、即ち径方向に配置された第１繊維層４６ａ、第２繊維層４６ｂ、第３繊維層４６ｃ、第４繊維層４６ｄ、及び第５繊維層４６ｅを含む。具体的には、積層方向Ｘの一端、即ち外端に位置する繊維層４６が第１繊維層４６ａであり、以下、積層方向Ｘに沿って他端、即ち内端に向けて順に、第２繊維層４６ｂ、第３繊維層４６ｃ、第４繊維層４６ｄが並んでいる。
　繊維構造体４１において、形状保持部４２及び本体部４４の各々では、複数の繊維層４６が、複数の面内糸４７及び抜け止め糸４８で結合されている。面内糸４７及び抜け止め糸４８に加え、上述の経糸４５ａ、緯糸４５ｂは炭素繊維からなる無撚りの繊維束である。
　積層方向一端の第１繊維層４６ａの表面には、複数の抜け止め糸４８が、経糸４５ａの配列方向Ｙに間隔を空けて設けられている。複数の面内糸４７のそれぞれは、積層方向他端の第４繊維層４６ｄの表面から、４つの繊維層４６の積層体内に挿入され、４つの繊維層４６を積層方向Ｘに貫通した後、第１繊維層４６ａの表面で抜け止め糸４８の外側を通って折り返されている。さらに、面内糸４７は、第１繊維層４６ａの表面から、４つの繊維層４６の積層体内に挿入され、４つの繊維層４６を積層方向Ｘに貫通した後、第４繊維層４６ｄの表面に引き出されている。そして、面内糸４７は、第１繊維層４６ａ及び第４繊維層４６ｄの表面で繰り返し折り返され、面内糸４７により、４つの繊維層４６が複数箇所で結合されている。
　図３（ｃ）に示すように、繊維構造体４１において、トリガ部４３は、繊維層４６を積層しただけの構成であり、繊維層４６同士が面内糸４７及び抜け止め糸４８によって結合されていない。したがって、トリガ部４３では、形状保持部４２及び本体部４４に比べて層間結合力が低くなっている。すなわち、形状保持部４２及び本体部４４の各々は、織組織によってトリガ部４３よりも高い層間結合力を有する。
　従って、第３の実施形態によれば、第１の実施形態に記載の効果に加えて以下の効果を得ることができる。
　（７）第３の実施形態のエネルギー吸収部材４０において、形状保持部４２及び本体部４４では、繊維層４６同士が面内糸４７及び抜け止め糸４８によって結合されているのに対し、トリガ部４３では、繊維層４６同士が面内糸４７及び抜け止め糸４８によって結合されていない。このため、繊維構造体４１の製造の際、４つの繊維層４６を、形状保持部４２及び本体部４４でのみ、面内糸４７及び抜け止め糸４８によって結合すればよい。したがって、形状保持部４２、トリガ部４３、及び本体部４４を有する繊維構造体４１を簡単に製造することができる。
　上記各実施形態は以下のように変更されてもよい。
　○　第１の実施形態及び第２の実施形態の各々において、トリガ部２３，３３においても、全ての繊維層で、第１交絡糸１４ａ及び第２交絡糸１４ｂや、第１貫通糸３７ａ及び第２貫通糸３７ｂにより積層方向Ｘの結合を行ってもよい。この場合、トリガ部２３，３３での第１交絡糸１４ａ及び第２交絡糸１４ｂによる交絡回数や、第１貫通糸３７ａ及び第２貫通糸３７ｂによる貫通回数を、形状保持部や本体部での交絡回数や貫通回数よりも少なくしてトリガ部での層間結合力を形状保持部及び本体部より低くしてもよい。
　又は、トリガ部２３，３３での第１交絡糸１４ａ及び第２交絡糸１４ｂの太さや、第１貫通糸３７ａ及び第２貫通糸３７ｂの太さを、形状保持部及び本体部での太さより細くしてトリガ部での層間結合力を形状保持部及び本体部より低くする。
　○　第３の実施形態において、トリガ部４３にも、面内糸４７及び抜け止め糸４８を用いてもよい。この場合、図４に示すように、トリガ部４３での面内糸４７及び抜け止め糸４８の使用本数を、形状保持部４２及び本体部４４での使用本数より少なくし、トリガ部４３での層間結合力を、形状保持部４２及び本体部４４の層間結合力より低くしてもよい。
　又は、図示しないが、トリガ部４３でも面内糸４７及び抜け止め糸４８を使用する場合、トリガ部４３で使用する面内糸４７の太さを、形状保持部４２及び本体部４４より細くしてもよい。そして、使用する面内糸４７及び抜け止め糸４８の本数がトリガ部４３と、形状保持部４２及び本体部４４とで同じであっても、太さの差によって、トリガ部４３での層間結合力を、形状保持部４２及び本体部４４の層間結合力より低くしてもよい。
　○　第２の実施形態の形状保持部３２において、第１貫通糸３７ａ及び第２貫通糸３７ｂによる繊維層３６の結合の仕方は適宜変更してもよい。また、第１貫通糸３７ａと第２貫通糸３７ｂの２種類の貫通糸を使わず、１種類の貫通糸だけで繊維層３６同士を結合してもよい。
　○　第１の実施形態の形状保持部２２において、第１交絡糸１４ａ及び第２交絡糸１４ｂが交絡する繊維層１３は３層以上であってもよく、この場合、挟み込む荷重方向糸１２は、積層方向Ｘに隣り合う３本以上となる。
　○　各実施形態において、形状保持部２２，３２，４２の層間結合力は、トリガ部２３，３３，４３の層間結合力より高ければ、本体部２４，３４，４４の層間結合力より低くてもよいし、高くてもよい。
　○　各実施形態において、形状保持部２２，３２，４２の層間結合力がトリガ部２３，３３，４３の層間結合力より高ければ、形状保持部２２，３２，４２と本体部２４，３４，４４とで織組織が異なっていてもよい。
　○　各実施形態では、マトリックス樹脂として熱硬化性樹脂１５を用いたが、その他の種類の樹脂を用いてもよい。
　○　各実施形態において、積層する繊維層１３，３６，４６の数は任意に変更してもよい。
　○　荷重方向糸１２，３５、第１交絡糸１４ａ、第２交絡糸１４ｂ、第１貫通糸３７ａ、第２貫通糸３７ｂ、経糸４５ａ、緯糸４５ｂ、面内糸４７、及び抜け止め糸４８は、炭素繊維に限らない。例えば、各糸は、エネルギー吸収部材１０，３０，４０に要求される物性に対応して適宜変更してもよい。使用できる糸としては、アラミド繊維、ポリ－ｐ－フェニレンベンゾビスオキサゾール繊維、超高分子量ポリエチレン繊維、ガラス繊維やセラミック繊維等の任意の繊維が挙げられる。
　○　繊維構造体１１，３１，４１の形状は筒状でなくてもよく、荷重方向Ｚに荷重方向糸が延びる柱状や板状であってもよい。

Claims (5)

  1. 　衝撃荷重を受けた際の衝撃エネルギーを吸収するように構成されたエネルギー吸収部材であって、
    　含浸された樹脂を有する繊維構造体を備え、
    　前記繊維構造体は、荷重が加わる方向と直交する方向に積層された複数の繊維層を有し、各繊維層は、荷重が加わる方向に延びる複数の荷重方向糸を配列してなり、前記繊維構造体は、前記複数の繊維層の結合により層間結合力を有し、
    　前記繊維構造体は、荷重が最初に加わるように構成された第１端面と、荷重が加わる方向において該第１端面と反対側に位置する第２端面とを有し、
    　前記繊維構造体は、
    　前記第１端面を含む形状保持部と、
    　前記第２端面を含み、前記繊維構造体の破壊の進行を抑制する本体部と、
    　前記形状保持部と前記本体部との間に配置され、衝撃荷重を受けた際に破壊の起点となるトリガ部とを備え、
    　前記形状保持部及び前記本体部の各々は、織組織によって前記トリガ部よりも高い層間結合力を有するエネルギー吸収部材。
  2. 　前記形状保持部では、積層方向に隣り合う前記繊維層同士が前記荷重方向糸を交絡糸で挟み込むことで結合され、前記トリガ部では、前記交絡糸により前記繊維層同士を積層方向に結合していない部位が存在する請求項１に記載のエネルギー吸収部材。
  3. 　前記形状保持部は組紐組織で形成され、前記形状保持部は、前記荷重方向糸と交差する方向に配列され、かつ前記繊維層を貫通する貫通糸を含み、積層方向に隣り合う前記繊維層同士が前記貫通糸によって結合され、前記トリガ部では、前記貫通糸により前記繊維層同士を積層方向に結合していない部位が存在する請求項１に記載のエネルギー吸収部材。
  4. 　前記繊維層は織物で構成され、前記形状保持部では、積層方向一端の前記繊維層の表面に沿って配設された抜け止め糸と、積層された前記繊維層を積層方向に貫通し、かつ前記抜け止め糸の外を通って折り返された面内糸とで前記繊維層同士が結合され、前記トリガ部では、前記面内糸及び抜け止め糸による前記繊維層同士の結合がなされていない請求項１に記載のエネルギー吸収部材。
  5. 　前記樹脂は熱硬化性樹脂である請求項１に記載のエネルギー吸収部材。
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EP3190307A4 (en) 2017-08-30
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