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WO2015098751A1 - 積層構造体およびその製造方法 - Google Patents

積層構造体およびその製造方法 Download PDF

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Publication number
WO2015098751A1
WO2015098751A1 PCT/JP2014/083711 JP2014083711W WO2015098751A1 WO 2015098751 A1 WO2015098751 A1 WO 2015098751A1 JP 2014083711 W JP2014083711 W JP 2014083711W WO 2015098751 A1 WO2015098751 A1 WO 2015098751A1
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WO
WIPO (PCT)
Prior art keywords
layer
laminated structure
core
resin foam
resin
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/JP2014/083711
Other languages
English (en)
French (fr)
Inventor
遼 森橋
猛 長谷川
洋祐 津村
健 ▲高▼木
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.)
Kawasaki Heavy Industries Ltd
Kawasaki Motors Ltd
Original Assignee
Kawasaki Heavy Industries Ltd
Kawasaki Jukogyo KK
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 Kawasaki Heavy Industries Ltd, Kawasaki Jukogyo KK filed Critical Kawasaki Heavy Industries Ltd
Priority to CN201480071251.7A priority Critical patent/CN106029362B/zh
Priority to US15/108,359 priority patent/US10603869B2/en
Publication of WO2015098751A1 publication Critical patent/WO2015098751A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Definitions

  • the present invention relates to a laminated structure configured by laminating a layer formed of a fiber reinforced resin and a layer formed of a resin foam, and a manufacturing method thereof.
  • FRP Fiber Reinforced Plastics
  • a thermosetting resin is typically used as a resin for producing a high-strength FRP.
  • CFRP Carbon Fiber Reinforced Plastics
  • RTM Resin Transfer Molding
  • VaRTM Vaum Assisted Transfer Resin Transfer Molding
  • SMC Sheet Molding Compound
  • FRP has not only high strength and light weight compared to metal, but also has the feature that it can realize complex shapes relatively easily. This is because a mold is used at the time of molding FRP, and for example, an aerodynamically excellent shape can be easily imparted to the molded product by the mold.
  • the core material 21 includes a honeycomb core and a resin foam. Since the head portion of the leading vehicle of the high-speed railway to which the FRP described above is applied is required to be lightweight and highly rigid, it has a sandwich structure. A bird or the like collides with the head portion of the head vehicle during traveling, and the honeycomb core is compressed (buckled) and destroyed, so a resin foam (foam core material) is used as the core material (Patent Document 1). reference). However, the foam core material is required not to be broken by an external force due to a load at the time of bird collision.
  • the top part of the leading vehicle of a high-speed railway is required to have strength to withstand the collision of birds and the like as described above, but in addition, even if it is exposed to flames and heat from the surroundings, Combustion resistance (flame resistance) is required so that flames, smoke, and poisonous gas are unlikely to occur.
  • Combustion resistance flame resistance
  • structural members that require flame resistance in addition to appropriate strength are not necessarily limited to the top of the leading vehicle of a high-speed railway, and also include structural members such as transportation means other than railways and building structures. Can be.
  • an object of the present invention is to make it possible to manufacture a laminated structure having both combustion resistance and sufficient strength to withstand collisions with birds and the like at a relatively low manufacturing cost.
  • a laminated structure includes a first layer formed of a fiber reinforced resin, a second layer formed of a fiber reinforced resin, and disposed opposite to the first layer.
  • a first core layer formed of a first resin foam and disposed between the first layer and the second layer; a second resin foam formed of the first core layer; and A second core layer disposed between the second resin layer and the first resin foam, the combustion resistance of the first resin foam being higher than that of the second resin foam.
  • the second resin foam has higher strength than the first resin foam.
  • the thickness of the second core layer is greater than the thickness of the first core layer.
  • first core layer and the second core layer are joined.
  • first core layer and the second core layer are joined by any one of adhesion, welding, fusion, or a combination thereof.
  • the first layer and the first core layer are joined by a part of the resin forming the first layer.
  • the second layer and the second core layer are joined by a part of the resin forming the second layer.
  • a third core layer formed of a resin foam having higher combustion resistance than the second resin foam is disposed between the second core layer and the second layer.
  • the second core layer and the third core layer are joined.
  • the second core layer and the third core layer are joined by any one of adhesion, welding, and fusion, or a combination thereof.
  • the second layer and the third core layer are joined by a part of the resin forming the second layer.
  • the first resin foam is formed of any of polyethylene terephthalate, phenol, and polyethersulfone.
  • the second resin foam is formed of any one of polyvinyl chloride, polymethacrylimide, polyimide, and polyetherimide.
  • the laminated structure is used as a structural member that forms at least a part of a leading portion of a leading vehicle of a railway vehicle.
  • the fiber reinforced resin is formed using a thermosetting resin.
  • the present invention provides a method for manufacturing a laminated structure, the step of forming a first core member with a first resin foam, and the formation of a second core member with a second resin foam.
  • a step of laminating the first core member and the second core member to form a core member assembly a step of laminating reinforcing fibers for forming a first FRP layer on a mold, Laminating the core member assembly with the first core member side facing the surface of the reinforcing fiber for forming the first FRP layer, and on the second core member side of the core member assembly, A step of laminating reinforcing fibers for forming two FRP layers, wherein the first resin foam has higher combustion resistance than the second resin foam.
  • the second resin foam has higher strength than the first resin foam.
  • the method further includes a step of forming a third core member between the second core member and the second layer.
  • first layer and the second layer and the core member adjacent to these layers are joined by a part of the resin forming each of the first layer and the second layer.
  • the fiber reinforced resin is formed using a thermosetting resin.
  • the longitudinal cross-sectional view which showed the laminated structure by one Embodiment of this invention A simple support beam that receives an equally distributed load over its entire length, its cross-sectional view, and shear stress distribution diagram.
  • the longitudinal cross-sectional view which showed the laminated structure by other embodiment of this invention The longitudinal cross-sectional view which showed the laminated structure by the modification of embodiment shown in FIG.
  • the flowchart which showed the manufacturing method for manufacturing the laminated structure shown in FIG. The flowchart which showed the manufacturing method for manufacturing the laminated structure shown in FIG. 3 or FIG.
  • the laminated structure according to this embodiment is particularly suitable for the structural member at the top of the top vehicle of a high-speed railway.
  • the present invention is not limited to the application to the top part of the leading vehicle of a high-speed railway, and can be applied to structural members such as a side structure, a roof structure, and a wife structure of a high-speed railway. Structural members such as side structures, roof structures, and wife structures can also be targeted.
  • the laminated structure 1 is formed of a first FRP layer 10 formed of a fiber reinforced resin and a fiber reinforced resin, and is disposed to face the first FRP layer 10.
  • the second FRP layer 11 is provided.
  • the first FRP layer 10 is used as the leading part of the leading vehicle.
  • the second FRP layer 11 is positioned on the inner surface side of the leading portion of the leading vehicle.
  • the combustion-resistant core layer (1st core layer) 12 formed with the 1st resin foam is arrange
  • a high-strength core layer (second core layer) 13 made of the second resin foam is disposed between the combustion-resistant core layer 12 and the second FRP layer 11.
  • the first FRP layer 10 and the second FRP layer 11 may be formed using the same type of fiber reinforced resin, or may be formed using different types of fiber reinforced resin, preferably thermosetting. It is formed using a functional resin.
  • carbon fiber, glass fiber, aramid fiber or the like can be used regardless of the type of fiber. Regardless of the type of fiber weave, plain weave, twill weave, satin weave, unidirectional, non-woven fabric, etc. can be employed.
  • the type of fiber reinforced resin is not limited, but preferably a thermosetting resin having fluidity is used. Specifically, epoxy resin, unsaturated polyester resin, vinyl ester resin, phenol resin, Bismaleimide resin or the like is used.
  • a bag or pressurizing and heating method such as autoclave / prepreg molding, oven-cured prepreg molding, VaRTM molding, RTM molding, etc. can be adopted. .
  • the first FRP layer 10 and the combustion resistant core layer 12 are joined by a part of the resin forming the first FRP layer 10.
  • the second FRP layer 11 and the high-strength core layer 13 are joined by a part of the resin that forms the second FRP layer 11.
  • the combustion-resistant core layer 12 and the high-strength core layer 13 are joined by an adhesive, welding, fusion, or the like.
  • the adhesive for joining both the core layers 12 and 13 does not ask
  • welding a method of joining in a state where both core layers 12 and 13 are dissolved in a solvent (a state in which both core layers 12 and 13 are dissolved as a solute in the solvent), and an example of fusion are both cores.
  • both core layers 12 and 13 are locally melted and joined by frictional heat generated by vibrating layers 12 and 13, the welding method and the fusion method are not limited thereto.
  • the first resin foam for forming the combustion-resistant core layer 12 is more resistant to combustion than the second resin foam for forming the high-strength core layer 13.
  • High nature for example, polyethylene terephthalate (PET) can be used for the first resin foam, and polyvinyl chloride (PVC) can be used for the second resin foam.
  • PET polyethylene terephthalate
  • PVC polyvinyl chloride
  • PMI Polymethacrylimide
  • PET is more advantageous than PMI.
  • the second resin foam for forming the high-strength core layer 13 is higher in strength than the first resin foam for forming the combustion-resistant core layer 12.
  • PVC and PMI have higher strength than PET.
  • the thickness T2 of the high-strength core layer 13 is thicker than the thickness T1 of the combustion-resistant core layer 12.
  • the flame resistant core layer 12 and the high strength core layer 13 are disposed as described above. The shear stress required for the layer 12 can be reduced.
  • the core material constituting the laminated structure 1 has a two-layer structure including the combustion-resistant core layer 12 and the high-strength core layer 13.
  • the combustion-resistant core layer 12 can share the shear strength with the high-strength core layer 13.
  • the laminated structure 1 having both combustion resistance and high strength can be manufactured at a relatively low manufacturing cost.
  • the core material which is excellent in combustion resistance but inferior in strength, can be made thinner by increasing the thickness of the core material as compared with the case where the desired strength is ensured and used. . For this reason, manufacture becomes easy (it becomes easy to match
  • the neutral surface 14 of the shear stress is located in the impact-resistant core layer 13, an object (for example, a bird) collides with the laminated structure 1.
  • the maximum shear stress generated at this time can be handled by the high-strength core layer 13. Thereby, it can prevent reliably that damage, such as a crack, arises in the laminated structure 1 by an impact.
  • the first FRP layer 10 is used as the leading part of the leading vehicle.
  • the second FRP layer 11 is positioned on the inner surface side of the leading portion of the leading vehicle.
  • an additional combustion-resistant core layer (third core layer) 15 is disposed between the high-strength core layer 13 and the second FRP layer 11.
  • the combustion-resistant core layer 12 on the first FRP layer 10 side is referred to as the first combustion-resistant core layer 12
  • the combustion-resistant core layer 15 on the second FRP layer 11 side is referred to as the second combustion-resistant core layer 15. Call it.
  • the second combustion-resistant core layer 15 is formed of a resin foam having higher combustion resistance than the second resin foam that forms the high-strength core layer 13.
  • the second flame resistant core layer 15 may be formed of the same type of resin foam as the first flame resistant core layer 12, or may be formed of a different type of resin foam.
  • the thickness T1 of the first flame resistant core layer 12 and the thickness T3 of the second flame resistant core layer 15 are the same.
  • the thickness T1 of the first combustion-resistant core layer 12 and the thickness T3 of the second combustion-resistant core layer 15 can be made different.
  • the thicknesses T1, T2, and T3 of each layer may be set so that the neutral surface 14 of the shear stress is located in the high-strength core layer 13. preferable.
  • the second FRP layer 11 and the second combustion resistant core layer 15 are joined by a part of the resin forming the second FRP layer 11.
  • the combustion-resistant core layer 13 and the second high-strength core layer 15 are joined by an adhesive, welding, fusion, or the like.
  • the types of materials that can be used as the first resin foam and the second resin foam are the same as those described for the laminated structure 1 shown in FIG.
  • the same actions and effects as the laminated structure 1 shown in FIG. 1 can be obtained. Furthermore, since the laminated structure 1A according to the present embodiment includes the combustion-resistant core layer 15 on the second FRP layer 11 side, it is possible to ensure the combustion resistance on both surfaces of the laminated structure 1A.
  • the thickness T1 of the first flame resistant core layer 12 and the thickness T3 of the second flame resistant core layer 15 are the same, if both the core layers 12 and 15 are formed of the same material, a laminated structure 1A can be used without distinguishing the front and back.
  • the thickness T1 of the first flame resistant core layer 12, the thickness T2 of the high strength core layer 13, and the thickness T3 of the second flame resistant core layer 15 are the same.
  • the thickness is set.
  • the types of materials that can be used as the first resin foam and the second resin foam are the same as those described for the laminated structure 1 shown in FIG.
  • the neutral surface 14 of the shear stress is located in the high-strength core layer 13, so that the strength of the laminated structure 1B can be ensured.
  • the thickness T1 of the first flame resistant core layer 12 and the thickness T3 of the second flame resistant core layer 15 are the same, if both the core layers 12 and 15 are formed of the same material, a laminated structure 1B can be used without distinguishing the front and back.
  • the manufacturing method according to the present embodiment is a method for manufacturing the laminated structure 1 shown in FIG.
  • the first resin foam forms a flame resistant core member (corresponding to the flame resistant core layer 12). Then, a high-strength core member (corresponding to the high-strength core layer 13) is formed by the second resin foam (step S1). As the first resin foam, one having higher combustion resistance than the second resin foam is used.
  • step S2 the flame-resistant core member and the high-strength core member are laminated and joined together to form a core member assembly.
  • An adhesive, welding, fusion, or the like is used for joining both core members.
  • reinforcing fibers for forming the first FRP layer are laminated on the mold (step S3). Further, the combustion-resistant core member of the core member assembly is laminated on the surface of the reinforcing fiber for forming the first FRP layer (step S4). Further, reinforcing fibers for forming the second FRP layer are laminated on the surface of the high-strength core member of the core member assembly. (Step S5). Finally, the FRP laminated structure 1 is formed using various FRP manufacturing methods such as autoclave, RTM, and VaRTM molding (step S6).
  • the types of materials that can be used as the first resin foam and the second resin foam are as already described for the laminated structure 1 shown in FIG.
  • the manufacturing method according to the present embodiment is a method for manufacturing the laminated structures 1A and 1B shown in FIG. 3 or FIG.
  • a pair of flame resistant core members (the first flame resistant core layer 12 and the second flame resistant core layer 12 and the second flame resistant core layer 12) are formed by the first resin foam.
  • a high-strength core member (corresponding to the high-strength core layer 13) is formed by the second resin foam (step S1A).
  • the first resin foam one having higher strength than the second resin foam is used.
  • step S2A a pair of combustion-resistant core members are laminated on both surfaces of the high-strength core member and joined together to form a core member assembly.
  • An adhesive, welding, fusion or the like is used for joining the core members.
  • reinforcing fibers for forming the first FRP layer are laminated on the mold (step S3A).
  • one combustion-resistant core member of the core member assembly is opposed to the surface of the reinforcing fiber for forming the first FRP layer (step S4A).
  • reinforcing fibers for forming the second FRP layer are laminated on the surface of the other combustion-resistant core member of the core member assembly (step S5A).
  • FRP laminated structures 1A and 1B are formed using various FRP manufacturing methods such as autoclave, RTM, and VaRTM molding (step S6A).
  • the types of materials that can be used as the first resin foam and the second resin foam are as already described for the laminated structures 1A and 1B shown in FIGS.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)
  • Moulding By Coating Moulds (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

　積層構造体(1)は、繊維強化樹脂で形成された第一層(10)と、繊維強化樹脂で形成され、第一層(10)に対向して配置された第二層(11)と、第一の樹脂発泡体で形成され、第一層(10)と第二層(11)との間に配置された第一コア層(12)と、第二の樹脂発泡体で形成され、第一コア層(12)と第二層(11)との間に配置された第二コア層(13)と、を備える。第一の樹脂発泡体は、第二の樹脂発泡体よりも耐燃焼性が高い。耐燃焼性と鳥などの衝突に耐えうる高強度性を兼備した積層構造体を、比較的小さな製造コストで製造できる。

Description

積層構造体およびその製造方法
　本発明は、繊維強化樹脂で形成された層と、樹脂発泡体で形成された層とを積層して構成された積層構造体およびその製造方法に関する。
　従来、炭素繊維やガラス繊維などの繊維で樹脂を強化した材料である繊維強化プラスチック（Fiber Reinforced Plastics: FRP）が、金属に比べて高強度で且つ軽量であることから、航空機、鉄道、自動車などに幅広く適用されている。高強度なＦＲＰを製造するための樹脂としては、典型的には熱硬化性樹脂が使用される。
　ＦＲＰの製造方法は各種あるが、例えば航空機に使用される高品質の炭素繊維強化プラスチック（Carbon Fiber Reinforced Plastics: CFRP）部品は、プリプレグを用いるオートクレーブ成形により製造される。
　また、金型キャビティ内に繊維を配置し、樹脂を圧入するＲＴＭ（Resin Transfer Molding）、注入圧力を真空圧のみで行うＶａＲＴＭ（Vacuum Assisted Resin Transfer Molding）がある。その他として、多品種少量生産向けの製造方法として、ハンドレイアップ法、スプレーアップ法、大量生産向けの製造方法として、ＳＭＣ（Sheet Molding Compound）がある。
　ＦＲＰは、金属に比べて高強度、軽量というだけではなく、複雑な形状を比較的容易に実現できるという特長を持っている。これは、ＦＲＰの成形時に型を用いるためであり、例えば空力的に優れた形状を型によって成形品に容易に付与することができる。
　ＦＲＰを適用した典型例としては、高速鉄道の先頭車両の先頭部をＦＲＰによって製造する場合があげられる。先頭車両の先頭部を、ＦＲＰではなく金属部材で製造する場合、格子状に溶接で組み立てられたフレーム上に、曲げ加工を施したアルミ板などの外板を溶接する。この際、溶接時の熱変形により、所定の形状を得ることは困難である。また、先頭形状を機械加工でアルミなどのブロック材から削り出す方法もあるが、材料のロスが大きくなる。これに対して、ＦＲＰを使用する場合には、上記の通り型を利用して複雑な形状を容易に成形することができるので、製造コストを抑えることができる。
　また、ＦＲＰ単体では所望の剛性が得られない場合には、図７に示したように、ＦＲＰ２０をコア材２１に積層したサンドイッチ構造とする。コア材２１としては、典型的にはハニカムコアや樹脂発泡体があげられる。上記で述べたＦＲＰを適用した高速鉄道の先頭車両の先頭部には、軽量、高剛性が求められるため、サンドイッチ構造体となっている。この先頭車両の先頭部には走行中、鳥などが衝突し、ハニカムコアでは圧縮（座屈）破壊してしまうことから、樹脂発泡体（発泡コア材）がコア材として用いられる（特許文献１参照）。ただし、この発泡コア材には鳥衝突時の荷重で外力で破壊しないものであることが求められる。
特開平１０－２７３０４２号公報
　ところで、高速鉄道の先頭車両の先頭部は、上記の通り鳥などの衝突に耐えるための強度が要求されるが、それに加えて、周囲からの炎や熱に曝されていても、着火、着炎、発煙、毒ガスの発生などが起こり難いように、耐燃焼性（耐燃性）が要求される。
　しかしながら、ＦＲＰと樹脂発泡体とを積層して形成した積層構造体を先頭車両の先頭部に適用するに際して、鳥などの衝突に耐えうる強度に加えて耐燃焼性を積層構造体それ自身に持たせる試みが、これまでに十分にはなされていなかった。
　ここで、鳥などの衝突に耐えうる十分な強度と耐燃焼性および軽量性とを兼備した樹脂発泡体はこれまでのところ存在しない。
　強度にはやや劣るが耐燃焼性に優れた、比較的安価な樹脂発泡体も存在するが、積層構造体の発泡コア材の全体をこの樹脂発泡体で形成しようとすると、所望の強度を確保するために発泡コア材の厚さを厚くする必要がある。そのため、積層構造体全体の厚さが増してしまい、型の曲面に沿わせにくい、重量、コストが増加するという問題がある。
　なお、適切な強度に加えて耐燃焼性を要求される構造部材は、必ずしも高速鉄道の先頭車両の先頭部に限られるものではなく、鉄道以外の輸送手段や建築構造物などの構造部材も対象となり得る。
　そこで、本発明の目的は、耐燃焼性と鳥などの衝突に耐えうる十分な強度を兼備した積層構造体を、比較的小さな製造コストで製造できるようにすることにある。
　上記課題を解決するために、本発明による積層構造体は、繊維強化樹脂で形成された第一層と、繊維強化樹脂で形成され、前記第一層に対向して配置された第二層と、第一の樹脂発泡体で形成され、前記第一層と前記第二層との間に配置された第一コア層と、第二の樹脂発泡体で形成され、前記第一コア層と前記第二層との間に配置された第二コア層と、を備え、前記第一の樹脂発泡体は、前記第二の樹脂発泡体よりも耐燃焼性が高い、ことを特徴とする。
　また、好ましくは、前記第二の樹脂発泡体は、前記第一の樹脂発泡体よりも強度が高い。
　また、好ましくは、前記第二コア層の厚さは、前記第一コア層の厚さよりも厚い。
　また、好ましくは、前記第一コア層と前記第二コア層とが接合されている。
　また、好ましくは、前記第一コア層と前記第二コア層との接合が、接着、溶着、融着のいずれか、またはそれらの組合せで行なわれる。
　また、好ましくは、前記第一層と前記第一コア層とが、前記第一層を形成する樹脂の一部によって接合されている。
　また、好ましくは、前記第二層と前記第二コア層とが、前記第二層を形成する樹脂の一部によって接合されている。
　また、好ましくは、前記第二コア層と前記第二層との間に、前記第二の樹脂発泡体よりも耐燃焼性が高い樹脂発泡体で形成された第三コア層が配置されている。
　また、好ましくは、前記第二コア層と前記第三コア層とが接合されている。
　また、好ましくは、前記第二コア層と前記第三コア層との接合が、接着、溶着、融着のいずれか、またはそれらの組合せで行なわれる。
　また、好ましくは、前記第二層と前記第三コア層とが、前記第二層を形成する樹脂の一部によって接合されている。
　また、好ましくは、前記第一の樹脂発泡体は、ポリエチレンテレフタレート、フェノール、ポリエーテルスルホンのいずれかで形成されている。
　また、好ましくは、前記第二の樹脂発泡体は、ポリ塩化ビニル、ポリメタクリルイミド、ポリイミド、ポリエーテルイミドのいずれかで形成されている。
　また、好ましくは、前記積層構造体は、鉄道車両の先頭車両の先頭部の少なくとも一部を形成する構造部材として使用される。
　また、好ましくは、前記繊維強化樹脂は、熱硬化性樹脂を用いて形成されている。
　上記課題を解決するために、本発明は、積層構造体の製造方法において、第一の樹脂発泡体によって第一コア部材を形成する工程と、第二の樹脂発泡体によって第二コア部材を形成する工程と、前記第一コア部材と前記第二コア部材とを積層してコア部材組立体を形成する工程と、成形型に第一ＦＲＰ層を形成するための強化繊維を積層する工程と、前記第一ＦＲＰ層形成のための強化繊維の表面に前記コア部材組立体の前記第一コア部材側を対向させて積層する工程と、前記コア部材組立体の前記第二コア部材側に、第二ＦＲＰ層を形成するための強化繊維を積層する工程と、を備え、前記第一の樹脂発泡体は、前記第二の樹脂発泡体よりも耐燃焼性が高い、ことを特徴とする。
　また、好ましくは、前記第二の樹脂発泡体は、前記第一の樹脂発泡体よりも強度が高い。
　また、好ましくは、前記第二コア部材と前記第二層との間に、第三コア部材を形成する工程をさらに備える。
　また、好ましくは、前記第一層および前記第二層と、これらの層に隣接するコア部材とを、前記第一層および前記第二層のそれぞれを形成する樹脂の一部によって接合する。
　また、好ましくは、前記繊維強化樹脂は、熱硬化性樹脂を用いて形成される。
　本発明によれば、耐燃焼性と鳥などの衝突に耐えうる高強度性を兼備した積層構造体を、比較的低い製造コストで製造することができる。
本発明の一実施形態による積層構造体を示した縦断面図。 全長に等分布荷重を受ける単純支持はりとその断面図、およびせん断応力分布図。 本発明の他の実施形態による積層構造体を示した縦断面図。 図３に示した実施形態の一変形例による積層構造体を示した縦断面図。 図１に示した積層構造体を製造するための製造方法を示したフローチャート。 図３または図４に示した積層構造体を製造するための製造方法を示したフローチャート。 従来の積層構造体を説明するための分解斜視図。
　以下、本発明の一実施形態による積層構造体について、図面を参照して説明する。
　本実施形態による積層構造体は、特に高速鉄道の先頭車両の先頭部の構造部材に適したものである。但し、本発明は、高速鉄道の先頭車両の先頭部への適用に限られるものではなく、高速鉄道の側構体や屋根構体、妻構体などの構造部材も対象となり得るし、一般的な鉄道車両の側構体や屋根構体、妻構体などの構造部材も対象となり得る。
　図１に示したように、本実施形態による積層構造体１は、繊維強化樹脂で形成された第一ＦＲＰ層１０と、繊維強化樹脂で形成され、第一ＦＲＰ層１０に対向して配置された第二ＦＲＰ層１１とを備える。
　なお、積層構造体１を高速鉄道の先頭車両の先頭部に使用する際には、例えば先頭部の外面側に耐燃焼性を付与したい場合には、第一ＦＲＰ層１０を先頭車両の先頭部の外面側に位置させ、第二ＦＲＰ層１１を先頭車両の先頭部の内面側に位置させる。
　第一ＦＲＰ層１０と第二ＦＲＰ層１１との間には、第一の樹脂発泡体で形成された耐燃焼性コア層（第一コア層）１２が配置されている。耐燃焼性コア層１２と第二ＦＲＰ層１１との間には、第二の樹脂発泡体で形成された高強度コア層（第二コア層）１３が配置されている。
　第一ＦＲＰ層１０と第二ＦＲＰ層１１とは、同じ種類の繊維強化樹脂を用いて形成しても良いし、異なる種類の繊維強化樹脂を用いて形成しても良く、好ましくは、熱硬化性樹脂を用いて形成される。
　繊維強化樹脂の材料としては、繊維についてはその種類を問わず、炭素繊維、ガラス繊維、アラミド繊維などを使用することができる。繊維の織形態についてもその種類を問わず、平織、綾織、朱子織、一方向、不織布などを採用することができる。
　繊維強化樹脂の樹脂についても、その種類を問わないが、好ましくは、流動性のある熱硬化性樹脂が用いられ、具体的には、エポキシ樹脂、不飽和ポリエステル樹脂、ビニルエステル樹脂、フェノール樹脂、ビスマレイミド樹脂などが使用される。
　繊維強化樹脂を成形するための手法についても、その種類を問わず、バッグもしくは加圧し、加熱する手法であるオートクレーブ／プリプレグ成形、オーブン硬化プリプレグ成形、ＶａＲＴＭ成形、ＲＴＭ成形などを採用することができる。
　第一ＦＲＰ層１０と耐燃焼性コア層１２とは、第一ＦＲＰ層１０を形成する樹脂の一部によって接合されている。第二ＦＲＰ層１１と高強度コア層１３とは、第二ＦＲＰ層１１を形成する樹脂の一部によって接合されている。
　耐燃焼性コア層１２と高強度コア層１３とは、接着剤、溶着、融着などによって接合されている。両コア層１２、１３を接合するための接着剤は、その種類を問わない。また、溶着の一例として、溶剤で両コア層１２、１３を溶かした状態（溶剤中に両コア層１２、１３が溶質として溶け込んだ状態）にして接合する方法、融着の一例として、両コア層１２、１３を振動させて発生させた摩擦熱で両コア層１２、１３を局所的に融解状態にして接合する方法が挙げられるが、溶着方法および融着方法はこれらに限られない。
　本実施形態による積層構造体１においては、耐燃焼性コア層１２を形成するための第一の樹脂発泡体は、高強度コア層１３を形成するための第二の樹脂発泡体よりも耐燃焼性が高い。例えば、第一の樹脂発泡体にはポリエチレンテレフタレート（ＰＥＴ）を使用し、第二の樹脂発泡体にはポリ塩化ビニル（ＰＶＣ）を使用することができる。第一の樹脂発泡体としては、ポリメタクリルイミド（ＰＭＩ）を使用することもできる。但し、コスト面から見ると、ＰＭＩよりもＰＥＴの方が有利である。
　好ましくは、高強度コア層１３を形成するための第二の樹脂発泡体は、耐燃焼性コア層１２を形成するための第一の樹脂発泡体よりも強度が高いものとされる。上述した材料で言えば、ＰＶＣやＰＭＩは、ＰＥＴよりも強度が高い。
　図１に示したように、耐燃焼性コア層１２の厚さＴ１よりも、高強度コア層１３の厚さＴ２の方が厚くなっている。図２より、矩形断面の構造体に発生するせん断応力は中立面で最大となるため、上記のように耐燃焼性コア層１２と高強度コア層１３を配置させることによって、耐燃焼性コア層１２に必要なせん断応力を低くすることができる。
　つまり、本実施形態による積層構造体１によれば、積層構造体１を構成するコア材を、耐燃焼性コア層１２と高強度コア層１３から成る二層構造としたので、耐燃焼能力を耐燃焼性コア層１２に、耐せん断強度を高強度コア層１３に、それぞれ分担させることができる。
　このため、耐燃焼性と高強度とを兼備した積層構造体１を、比較的小さな製造コストで製造することができる。
　また、耐燃焼性には優れるが強度に劣るコア材を、その厚さを増大させることで所望の強度を確保して使用する場合に比べて、コア層全体の厚さを薄くすることができる。このため、製造がしやすくなり（型の形状に合わせやすくなり）、重量、コストも低減することができる。
　また、本実施形態による積層構造体１によれば、せん断応力の中立面１４が耐衝撃性コア層１３の中に位置しているので、積層構造体１に物体（例えば鳥）が衝突した際に生じる最大せん断応力を、高強度コア層１３で受け持つことできる。これにより、衝撃によって積層構造体１に亀裂などの損傷が生じることを確実に防止できる。
　なお、積層構造体１を高速鉄道の先頭車両の先頭部に使用する際には、例えば先頭部の外面側に耐燃焼性を付与したい場合には、第一ＦＲＰ層１０を先頭車両の先頭部の外面側に位置させ、第二ＦＲＰ層１１を先頭車両の先頭部の内面側に位置させる。
　一方、先頭車両の先頭部の内面側に耐燃焼性を付与したい場合には、第一ＦＲＰ層１０と第二ＦＲＰ層１１の配置を逆転させる。
　また、先頭車両の先頭部の外面側と内面側の両方に耐燃焼性を付与したい場合には、次に述べる本発明の他の実施形態による積層構造体を使用することができる。
　以下、本発明の他の実施形態による積層構造体について、図３を参照して説明する。
　本実施形態による積層構造体１Ａは、高強度コア層１３と第二ＦＲＰ層１１との間に、追加の耐燃焼性コア層（第三コア層）１５が配置されている。以下では、第一ＦＲＰ層１０側の耐燃焼性コア層１２を第一耐燃焼性コア層１２と呼び、第二ＦＲＰ層１１側の耐燃焼性コア層１５を第二耐燃焼性コア層１５と呼ぶ。
　第二耐燃焼性コア層１５は、高強度コア層１３を形成する第二の樹脂発泡体よりも耐燃焼性が高い樹脂発泡体で形成されている。第二耐燃焼性コア層１５は、第一耐燃焼性コア層１２と同じ種類の樹脂発泡体で形成しても良いし、異なる種類の樹脂発泡体で形成しても良い。
　本実施形態による積層構造体１Ａにおいては、第一耐燃焼性コア層１２の厚さＴ１と、第二耐燃焼性コア層１５の厚さＴ３とが同一である。第一耐燃焼性コア層１２と第二耐燃焼性コア層１５とを同じ材料で形成することにより、部品の共通化を図ることができる。
　また、第一耐燃焼性コア層１２の厚さＴ１と、第二耐燃焼性コア層１５の厚さＴ３とを異ならせることもできる。但し、積層構造体１Ａの強度を十分に確保するために、せん断応力の中立面１４が高強度コア層１３の中に位置するように各層の厚さＴ１、Ｔ２、Ｔ３を設定することが好ましい。
　第二ＦＲＰ層１１と第二耐燃焼性コア層１５とが、第二ＦＲＰ層１１を形成する樹脂の一部によって接合されている。耐燃焼性コア層１３と第二高強度コア層１５とが接着剤、溶着、融着などによって接合されている。
　第一の樹脂発泡体および第二の樹脂発泡体として使用できる材料の種類は、図１に示した積層構造体１について説明したものと同様である。
　本実施形態による積層構造体１Ａにおいても、図１に示した積層構造体１と同じ作用・効果が得られる。さらに、本実施形態による積層構造体１Ａは、第二ＦＲＰ層１１側にも耐燃焼性コア層１５を備えているので、積層構造体１Ａの両面において耐燃焼性を確保することができる。
　また、第一耐燃焼性コア層１２の厚さＴ１と、第二耐燃焼性コア層１５の厚さＴ３とが同一なので、両コア層１２、１５を同じ材料で形成すれば、積層構造体１Ａを表裏の区別無く使用することができる。
　次に、図３に示した実施形態の一変形例による積層構造体について、図４を参照して説明する。
　この積層構造体１Ｂにおいては、第一耐燃焼性コア層１２の厚さＴ１と、高強度コア層１３の厚さＴ２と、第二耐燃焼性コア層１５の厚さＴ３とが、同一の厚さに設定されている。
　第一の樹脂発泡体および第二の樹脂発泡体として使用できる材料の種類は、図１に示した積層構造体１について説明したものと同様である。
　本変形例による積層構造体１Ｂにおいても、せん断応力の中立面１４が高強度コア層１３の中に位置しているので、積層構造体１Ｂの強度を確保することができる。
　また、第一耐燃焼性コア層１２の厚さＴ１と、第二耐燃焼性コア層１５の厚さＴ３とが同一なので、両コア層１２、１５を同じ材料で形成すれば、積層構造体１Ｂを表裏の区別無く使用することができる。
　次に、本発明の一実施形態による積層構造体の製造方法について、図５を参照して説明する。本実施形態による製造方法は、図１に示した積層構造体１を製造するための方法である。
　図５に示したように、本実施形態による積層構造体１の製造方法においては、第一の樹脂発泡体によって耐燃焼性コア部材（耐燃焼性コア層１２に対応する。）を形成すると共に、第二の樹脂発泡体によって高強度コア部材（高強度コア層１３に対応する。）を形成する（工程Ｓ１）。第一の樹脂発泡体には、第二の樹脂発泡体よりも耐燃焼性が高いものを使用する。
　次に、耐燃焼性コア部材と高強度コア部材を積層し、互いに接合してコア部材組立体を形成する（工程Ｓ２）。両コア部材の接合には接着剤、溶着、融着などを用いる。
　次に、成形型に第一ＦＲＰ層を形成するための強化繊維を積層する（工程Ｓ３）。また、第一ＦＲＰ層形成のための強化繊維の表面にコア部材組立体の耐燃焼性コア部材を対向させて積層する（工程Ｓ４）。さらに、コア部材組立体の高強度コア部材の表面に、第二ＦＲＰ層を形成するための強化繊維を積層する。（工程Ｓ５）。最後にオートクレーブ、ＲＴＭ、ＶａＲＴＭ成形など各種ＦＲＰ製造方法を用いて、ＦＲＰの積層構造体１を形成する（工程Ｓ６）。
　第一の樹脂発泡体および第二の樹脂発泡体として使用できる材料の種類は、図１に示した積層構造体１について既に説明した通りである。
　次に、本発明の他の実施形態による積層構造体の製造方法について、図６を参照して説明する。本実施形態による製造方法は、図３または図４に示した積層構造体１Ａ、１Ｂを製造するための方法である。
　図６に示したように、本実施形態による積層構造体１Ａ、１Ｂの製造方法においては、第一の樹脂発泡体によって一対の耐燃焼性コア部材（第一耐燃焼性コア層１２および第二耐燃焼性コア層１５に対応する。）を形成すると共に、第二の樹脂発泡体によって高強度コア部材（高強度コア層１３に対応する。）を形成する（工程Ｓ１Ａ）。第一の樹脂発泡体には、第二の樹脂発泡体よりも強度が高いものを使用する。
　次に、一対の耐燃焼性コア部材を高強度コア部材の両面に積層し、互いに接合してコア部材組立体を形成する（工程Ｓ２Ａ）。コア部材同士の接合には接着剤、溶着、融着などを用いる。
　次に、成形型に第一ＦＲＰ層を形成するための強化繊維を積層する（工程Ｓ３Ａ）。また、第一ＦＲＰ層形成のための強化繊維の表面にコア部材組立体の一方の耐燃焼性コア部材を対向させて積層する（工程Ｓ４Ａ）。また、コア部材組立体の他方の耐燃焼性コア部材の表面に、第二ＦＲＰ層を形成するための強化繊維を積層する（工程Ｓ５Ａ）。最後にオートクレーブ、ＲＴＭ、ＶａＲＴＭ成形など各種ＦＲＰ製造方法を用いて、ＦＲＰの積層構造体１Ａ、１Ｂを形成する（工程Ｓ６Ａ）。
　第一の樹脂発泡体および第二の樹脂発泡体として使用できる材料の種類は、図３および図４に示した積層構造体１Ａ、１Ｂについて既に説明した通りである。
　１、１Ａ、１Ｂ　積層構造体
　１０　第一ＦＲＰ層
　１１　第二ＦＲＰ層
　１２　耐燃焼性コア層（第一耐燃焼性コア層）
　１３　高強度コア層
　１４　せん断応力の中立面
　１５　耐燃焼性コア層（第二耐燃焼性コア層）
 

Claims (20)

  1. 　繊維強化樹脂で形成された第一層と、
    　繊維強化樹脂で形成され、前記第一層に対向して配置された第二層と、
    　第一の樹脂発泡体で形成され、前記第一層と前記第二層との間に配置された第一コア層と、
    　第二の樹脂発泡体で形成され、前記第一コア層と前記第二層との間に配置された第二コア層と、を備え、
    　前記第一の樹脂発泡体は、前記第二の樹脂発泡体よりも耐燃焼性が高い、積層構造体。
  2. 　前記第二の樹脂発泡体は、前記第一の樹脂発泡体よりも強度が高い、請求項１記載の積層構造体。
  3. 　前記第二コア層の厚さは、前記第一コア層の厚さよりも厚い、請求項１または２に記載の積層構造体。
  4. 　前記第一コア層と前記第二コア層とが接合されている、請求項１乃至３のいずれか一項に記載の積層構造体。
  5. 　前記第一コア層と前記第二コア層との接合が、接着、溶着、融着のいずれか、またはそれらの組合せで行なわれる、請求項４記載の積層構造体。
  6. 　前記第一層と前記第一コア層とが、前記第一層を形成する樹脂の一部によって接合されている、請求項１乃至５のいずれか一項に記載の積層構造体。
  7. 　前記第二層と前記第二コア層とが、前記第二層を形成する樹脂の一部によって接合されている、請求項１乃至６のいずれか一項に記載の積層構造体。
  8. 　前記第二コア層と前記第二層との間に、前記第二の樹脂発泡体よりも耐燃焼性が高い樹脂発泡体で形成された第三コア層が配置されている、請求項１乃至６のいずれか一項に記載の積層構造体。
  9. 　前記第二コア層と前記第三コア層とが接合されている、請求項８記載の積層構造体。
  10. 　前記第二コア層と前記第三コア層との接合が、接着、溶着、融着のいずれか、またはそれらの組合せで行なわれる、請求項９記載の積層構造体。
  11. 　前記第二層と前記第三コア層とが、前記第二層を形成する樹脂の一部によって接合されている、請求項８乃至１０のいずれか一項に記載の積層構造体。
  12. 　前記第一の樹脂発泡体は、ポリエチレンテレフタレート、フェノール、ポリエーテルスルホンのいずれかで形成されている、請求項１乃至１１のいずれか一項に記載の積層構造体。
  13. 　前記第二の樹脂発泡体は、ポリ塩化ビニル、ポリメタクリルイミド、ポリイミド、ポリエーテルイミドのいずれかで形成されている、請求項１乃至１２のいずれか一項に記載の積層構造体。
  14. 　前記積層構造体は、鉄道車両の先頭車両の先頭部の少なくとも一部を形成する構造部材として使用される、請求項１乃至１３のいずれか一項に記載の積層構造体。
  15. 　前記繊維強化樹脂は、熱硬化性樹脂を用いて形成されている、請求項１乃至１４のいずれか一項に記載の積層構造体。
  16. 　積層構造体の製造方法において、
    　第一の樹脂発泡体によって第一コア部材を形成する工程と、
    　第二の樹脂発泡体によって第二コア部材を形成する工程と、
    　前記第一コア部材と前記第二コア部材とを積層してコア部材組立体を形成する工程と、
    　成形型に第一ＦＲＰ層を形成するための強化繊維を積層する工程と、
    　前記第一ＦＲＰ層形成のための強化繊維の表面に前記コア部材組立体の前記第一コア部材側を対向させて積層する工程と、
    　前記コア部材組立体の前記第二コア部材側に、第二ＦＲＰ層を形成するための強化繊維を積層する工程と、を備え、
    　前記第一の樹脂発泡体は、前記第二の樹脂発泡体よりも耐燃焼性が高い、積層構造体の製造方法。
  17. 　前記第二の樹脂発泡体は、前記第一の樹脂発泡体よりも強度が高い、請求項１６記載の積層構造体の製造方法。
  18. 　前記第二コア部材と前記第二層との間に、第三コア部材を形成する工程をさらに備えた、請求項１６または１７に記載の積層構造体の製造方法。
  19. 　前記第一層および前記第二層と、これらの層に隣接するコア部材とを、前記第一層および前記第二層のそれぞれを形成する樹脂の一部によって接合する、請求項１６乃至１８のいずれか一項に記載の積層構造体の製造方法。
  20. 　前記繊維強化樹脂は、熱硬化性樹脂を用いて形成される、請求項１６乃至１９のいずれか一項に記載の積層構造体の製造方法。
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