Composite structure formed of fiber reinforced plastic sheet and metallic sheet, and manufacturing method thereof

Patent metadata

Field	Value
Publication number	US-2016016359-A1
Application number	US-201414776005-A
Country	US
Kind code	A1
Filing date	Mar 12, 2014
Priority date	Mar 13, 2013
Publication date	Jan 21, 2016
Grant date	—

Abstract

A manufacturing method of a composite structure includes: (a) preparing: a metallic sheet(s) having a through-hole(s) penetrating throughout the metallic sheet(s) in its thickness direction; (b) setting a prepreg(s), constituting a fiber reinforced plastic sheet(s), and the metallic sheet in a pair of dies, which have a recess(es) arranged at a position(s) opposed to one side opening(s) of the through-hole(s), the recess(es) having a larger diameter than the one side opening; (c) closing the dies, wherein, upon closing, (ca) the prepreg(s) and the metallic sheet are molded to the predetermined shape, while surface-contacting therebetween, (cb) at least one of the prepreg(s) and a patch member(s) is extruded into the through-hole(s), so that the shaft part is molded, and (cc) the patch member(s) forms at least part of a head part(s) in the recess(es), the head part(s) integrated with the shaft part(s) and engaging on the metallic sheet(s).

First claim

1 . A method of manufacturing a composite structure formed a fiber reinforced plastic sheet and a metallic sheet, comprising:
preparing a pair of dies for molding a composite structure of a predetermined shape; preparing a metallic sheet(s) having at least one opening defined by a through-hole(s) penetrating the metallic sheet(s) in a thickness direction of the metallic sheet(s); setting a patch member(s) on one of the pair of dies, the patch member(s) made of plastic and having a larger size than the opening(s); setting a prepreg(s) to constitute a fiber reinforced plastic sheet(s) and the metallic sheet(s) in the pair of dies in a manner that the metallic sheet(s) is interposed between the prepreg(s) and the patch member(s); and closing the pair of dies, and simultaneously, selectively applying pressure on a corresponding portion(s) located inwardly of the at least one opening so as to joint-bond the prepreg(s), the metallic sheet and the patch member(s) each other by bonding the prepreg(s) to the patch member(s) through the at least one opening, thereby producing the composite structure molded in the predetermined shape.

2 . The manufacturing method of the composite structure according to claim 1 , wherein
the one die of the pair of dies has a recess(es) receiving the patch member(s), the recess(es) open toward a removal direction of the composite structure after molded.

3 . The manufacturing method of the composite structure according to claim 1 , wherein
the pair of dies have a step difference profile(s) arranged on the inner surface extending in a relative movement direction of the pair of dies, and wherein the recess(es) is defined by the step difference profile(s).

4 . The manufacturing method of the composite structure according to claim 1 , wherein
the fiber reinforced plastic sheet(s) is bonded to one side surface(s) of the metallic sheet(s).

5 . The manufacturing method of the composite structure according to claim 1 , wherein
the fiber reinforced plastic sheet(s) contains continuous reinforce fiber.

6 . The method of manufacturing a composite structure according to claim 1 , further comprising:
as the prepreg(s), preparing a prepreg(s) having a thickening part(s) arranged at a position(s) opposed to the through-hole(s); and extruding the thickening part(s) into the through-hole(s) so as to bond to the patch member(s) set in the pair of dies.

7 . The manufacturing method of the composite structure according to claim 1 , wherein
the patch member(s) is set on the prepreg, instead of being set on the pair of dies.

8 . The manufacturing method of the composite structure according to claim 2 , wherein
a shaft part(s) is molded in the through-hole(s) so that the shaft part(s) is integrated with the prepreg, and wherein a head or engaging part(s) is molded in the recess(es) so that the head or engaging part(s) is integrated with the shaft part(s) and has a larger diameter(s) than the opening(s).

9 . A method of manufacturing a composite structure formed of a fiber reinforced plastic sheet and a metallic sheet, comprising:
preparing:
a metallic sheet(s) having a through-hole(s) penetrating the metallic sheet(s) in a thickness direction of the metallic sheet(s);
a prepreg(s) in order to constitute a fiber reinforced plastic sheet(s);
a pair of dies for molding a composite structure into a predetermined shape, wherein the pair of dies can have a recess(es) arranged at a position(s) opposed to one side opening(s) of the through-hole(s), the recess(es) having a larger diameter than the one side opening, and
a patch member(s) to be set at a position(s) opposed to the through-hole(s);
setting the prepreg(s) and the metallic sheet in the pair of dies; and closing the pair of dies, wherein, upon closing,
the prepreg(s) and the metallic sheet are molded into the predetermined shape, while surface-contacting therebetween,
at least one of the prepreg(s) and the patch member(s) is extruded into the through-hole(s), so that the shaft part is molded, and
the patch member(s) forms at least part of a head part(s) in the recess(es), the head part(s) being integrated with the shaft part(s) and engaging on the metallic sheet(s).

10 . The method of manufacturing a composite structure according to claim 9 , wherein
the patch member(s) is set in the recess(es), and thereafter, upon closing the pair of dies, the prepreg(s) is extruded into the through-hole(s) to bond to the patch member(s), thereby molding the shaft part(s) and the head part(s).

11 . The method of manufacturing a composite structure according to claim 9 , wherein
the patch member(s) is set on the prepreg(s), and thereafter, upon closing the pair of dies, the patch member(s) is extruded into the through-hole(s), and further into the recess(es), thereby molding the shaft part(s) and the head part(s).

12 . The method of manufacturing a composite structure according to claim 9 , wherein
a first patch member(s) as the patch member(s) is set on the prepreg(s), and a second prepreg(s) as the patch member(s) is set in the recess(es), and thereafter, upon closing the pair of dies, the first patch member(s) is extruded into the through-hole(s) to be bonded to the second patch member(s), thereby molding the shaft part(s) and the head part(s).

13 . (canceled)

14 . A composite structure having a fiber reinforced plastic sheet and a metallic sheet, comprising:
a metallic sheet(s) having a plurality of through-holes which are configurated to penetrate throughout in a thickness direction of the metallic sheet and to open on one side surface and the other side surface of the metallic sheet(s); a fiber reinforced plastic sheet(s) bonded on the one side surface of the metallic sheet(s); a plurality of plastic shaft parts disposed in the through-hole(s) and integrated with the fiber reinforced plastic sheet(s); and a plurality of plastic head parts distributedly arranged on the other side surface and integrated with the plastic shaft parts, each of the plastic head parts having a lager diameter on the other side of the metallic sheet(s) than the opening of the through-hole to be engaged with the metallic sheet(s).

15 . The composite structure according to claim 14 , wherein the head parts are arrayed on different surfaces of the composite structure.

16 . The composite structure according to claim 14 , wherein the head parts are arranged so as to represent a staggered arrangement on at least one surface of the metallic sheet.

Assignees

• Aisin Takaoka Ltd

Inventors

• Kondo Kiyohito
• Yamashita Yuji

Classifications

• B29C70/68

  by incorporating or moulding on preformed parts, e.g. inserts or layers {, e.g. foam blocks (mould constructions therefor B29C33/12; joining preformed parts by moulding B29C65/70)} · CPC title

• B29C70/682

  Preformed parts characterised by their structure, e.g. form · CPC title

• B29C70/86

  Incorporated in coherent impregnated reinforcing layers, {e.g. by winding} · CPC title

• B29C66/721

  Fibre-reinforced materials (B29C66/729 takes precedence) · CPC title

• B29C70/465

  and impregnating by melting a solid material, e.g. sheets, powders of fibres · CPC title