JP2002127944A - Frp made automobile panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an FRP made automobile panel having a reduced mass, good appearance, and high impact resistance. SOLUTION: This automobile panel is made of FRP using a cloth substrate made of continuous fiber as a reinforcing fiber. The cloth substrate has no seam on at least a surface of the panel.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an automobile panel made of FRP and relates to an FRP suitable for use in, for example, a roof or a hood.
Lightweight FR suitable for RP panel members, especially for detachable or openable roofs used in open cars
It relates to a P-made automobile roof.

[0002]

2. Description of the Related Art FRP is being used from the aircraft field to the automobile field due to its light weight and high durability. However, most of them are non-structural members such as spoilers and wings, There are few examples of application to structural members such as frames. In other words, the FRP used for the non-structural member is made of a homogeneous material (a material close to isotropic similar to a metal) in which short fibers of glass called SMC and unsaturated polyester resin are three-dimensionally mixed. Because it is a short fiber, its strength and rigidity are smaller than those of a continuous fiber, and the weight is heavier than a metal material when SMC is used as a structural material.

[0003] One of the effective means for weight reduction is SMC.
The use of continuous fibers similar to aircraft, instead of short fibers like FRP, requires that individual structures, designs (rigidity, etc.) be used for automobile parts in order to reduce the weight of FRP as compared to metal materials, as is called tailor-made material. , Strength, impact resistance, etc.). For this reason, for structural members such as roofs, hoods, and frames that have complicated required characteristics, a full-scale structural design using continuous fibers has not been made.

[0004] Further, another reason for avoiding the study of structural members using continuous fibers is also the appearance that affects the commerciality of automobiles. Compared to those using short fibers of several tens of mm in length as reinforcing fibers, FRP composed of continuous fibers is
In the case of a shaped member having irregularities unique to an automobile member, there is a further concern that the fiber arrangement becomes non-uniform, the appearance of the member is reduced, and the product is lost.

[0005]

However, the automotive industry seeks to reduce the weight of panel structural materials such as roofs in order to solve environmental problems and the like. There is a long-awaited need to provide FRP panel members.

An object of the present invention is to provide an FRP automobile panel excellent in appearance, impact resistance, etc. while achieving weight reduction, and to realize an automobile excellent in environmental compatibility, etc. .

[0007]

In order to achieve the above object, an FRP automobile panel according to the present invention is an automobile panel made of FRP using a woven base material made of continuous fibers as reinforcing fibers, At least one surface of the panel is characterized in that the textile substrate has no seams.

[0008] Specific examples of the FRP automobile panel according to the present invention include a roof panel and a hood panel, and can also be applied as a door panel. The continuous fibers are preferably carbon fibers.

In the above-mentioned FRP automobile panel, it is preferable that the layers forming both surfaces are, for example, formed integrally with the layer forming the upper surface and the layer forming the lower surface. Also, a core material may be interposed between the layer forming the upper surface and the layer forming the lower surface, and the panel may be configured in a sandwich structure.

It is preferable that a rib is formed on at least one surface of the panel, for example, on a layer forming the upper surface and / or a layer forming the lower surface. The ribs may be formed integrally with the layer forming the upper surface and / or the layer forming the lower surface. The heat transfer coefficient from one side of the panel to the other side is 0.04 to 0.1 W / m.
It can be set in the range of ° C.

When a roof is adopted as the FRP automobile panel according to the present invention, the roof can be configured as a detachable or openable roof, and the weight of the roof is 16 kg or less. Can be suppressed. Further, it is preferable that the layer forming the upper surface and the layer forming the lower surface be integrated at the opening of the end of the FRP automobile roof or the sunroof according to the present invention. Similarly, the hood can be kept below 10 kg. The thickness of the panel is preferably 0.2 to 3 in order to secure necessary rigidity and lightness.
It is preferable to set within the range of mm.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the FRP automobile roof and hood of the present invention will be described below with reference to the drawings. FIGS. 1 to 3 show an FRP automobile roof according to an embodiment of the present invention. An FRP automobile roof 1 includes a layer 5 forming an upper surface 2, a layer 6 forming a lower surface 3, and a core material 4. It is configured. The layer 5 that forms the upper surface and / or the layer 6 that forms the lower surface are made of FRP fibers having a woven base material made of continuous fibers as reinforcing fibers. FIG. 5 shows an FRP-made automobile hood 10 formed using a woven fabric base made of seamless continuous fibers.

In the above description, the continuous fiber refers to a state in which the fiber is not cut in the layer 5 and / or the layer 6 of the roof 1. That is, since the fibers are not cut, the rigidity of the fibers can be maximized, and the weight can be reduced most. Furthermore, since continuous fibers are in the form of a woven fabric in which fibers intersect with each other, the morphology is more stable than when a unidirectional prepreg is used, and the density of the fibers is reduced even when the fiber is formed into a shape with irregularities. A roof that is substantially uniform and has a good appearance can be formed.

Further, the roof 1 can be formed in a woven form.
For example, when a flying object collides with the roof 1,
It acts like a net that prevents it from penetrating. For this reason, it is not necessary to take any special measures against flying objects that cause the weight of the roof 1 to increase. Here, the woven structure refers to all woven structures in which fibers are interlaced, such as plain weave, satin weave, twill weave, and triaxial weave. Considering the size of the flying object assumed during traveling or the like, the most preferable is that the distance between the intersection points is in the range of 1 mm to 20 mm. In addition, 2
Stitched fabrics in which fibers are reinforced in the thickness direction of the fabric as well as dimensions, three-dimensional fabrics, and the like are also included in the fabric of the present invention.

The textile substrate arranged in the layer 5 forming the upper surface 2 and / or the layer forming the lower surface 3 of the roof 1 is made of a seamless material. The same applies to the hood 10 of FIG. By making the woven base material have no seams, the distribution of continuous fibers becomes uniform in the plane, the dispersion of mechanical properties is eliminated, and the reliability is improved.
Defects such as dents on the outer surface of the roof 1 due to uneven distribution of reinforcing fibers can be reduced. Further, the flying objects do not enter through the seams of the fabric. In addition, the unevenness of the surface becomes substantially uniform, and by coating, the appearance that can be sufficiently used as an automobile outer panel can be secured. Eliminating the joint is most effective on the outermost layer of the upper surface 2 where the mechanical properties and design are most required, but when the interior has design, the innermost layer may be made seamless. By eliminating the seam, the overlap required for the seam portion in the prepreg or the like becomes unnecessary, and the weight can be reduced. The direction of the fiber is preferably 0 ° / 90 °, where the straight traveling direction of the automobile is 0 °, because it has the effect of increasing the rigidity of the vehicle body. Also, 45
It is also preferable to improve the torsional rigidity by arranging in the direction of ° / −45 °.

The most preferable continuous fiber is a carbon fiber. By using at least high-strength, high-strength carbon fibers for the reinforcing fibers, the same weight as metal materials,
The roof 1 having safety can be obtained. Among carbon fibers, it is particularly preferable to use a high elongation carbon fiber having an elongation of 1.8% or more and 2.4% or less, because the impact resistance against flying objects is improved. Further, when the strength is 4500 MPa or more, elongation × strength, which is an energy absorption parameter, is remarkably improved, and the impact resistance of a seamless cloth laminate can be improved. Further, such high elongation carbon fiber has good deformation performance,
Even if the design is a complicated shape having irregularities, the predetermined shape of the roof 1 and the hood 10
The desired mechanical properties and surface properties can be obtained. Of course, other than carbon fiber, glass fiber or organic fiber may be used in combination. In particular, when a mat or a non-woven glass fiber is inserted into or on the surface of the woven fabric, the unevenness of the woven fabric can be reduced, which is preferable in appearance. In addition, FRP
Is a thermosetting resin such as epoxy resin, unsaturated polyester resin, phenol resin, vinyl ester resin, or acrylic resin, polycarbonate resin, polyethylene, polypropylene resin, polyamide resin, ABS resin, potybutylene terephthalate. Resins, thermoplastic resins such as polyacetal resins, and modified resins obtained by alloying these resins.

The layer 5 forming the upper surface 2 and the layer 6 forming the lower surface 3 are not fitted at the end 7 of the roof 1 but are integrated. By unifying,
The upper surface 2 and the lower surface 3 are more firmly constrained and have high rigidity. In particular, integration is effective for torsional rigidity.
Although there is adhesive bonding as a method of integration, it is more preferable to form them at the same time in terms of economy and rigidity. Further, the upper surface and the lower surface are not merely in contact with each other on one side, and one surface of the upper surface 2 or the lower surface 3 may cover the other surface as shown in FIG. Of course, such a state in FIG. 4 does not need to cover the entire periphery of the roof 1, but in the case of a detachable type, it is preferable that the state shown in FIG. By wrapping or folding, the strength of the end portion 7 is improved, and moisture can be prevented from entering from the boundary between the upper surface 2 and the lower surface 3, so that the roof 1 has excellent durability. Further, by wrapping, the structure has a resistance to peeling caused by a difference in the Poisson's ratio between the upper surface 2 and the lower surface 3. Further, the end portion 7 is a portion where the stress is concentrated against the ground or the like during attachment / detachment, and the roof 1 is tough against the stress.

In this embodiment, the layer 5 forming the upper surface 2 of the FRP is used to greatly reduce the weight of the roof 1.
And a sandwich structure in which a core material 4 is interposed between a layer 6 and an inner surface 3. With the sandwich structure, the weight can be significantly reduced and high rigidity can be achieved. If the weight is greatly reduced to about 16 kg or less, a detachable roof can be easily attached and detached by one person, which is preferable in terms of work safety. Further, even in the case of an openable roof, the motor used can be reduced in size and space, contributing to light weight and energy saving. In particular, a sandwich structure in which the layer 5 and the layer 6 are integrated in the sandwich structure is preferable in terms of mechanical properties because deformation of the core member 4 can be prevented and breakage of the core member 4 can be suppressed.
Further, the layers 5 and 6 are provided so that the core material 4 is not exposed to the outside air.
Is integrated, the core material 4 can be prevented from being deteriorated by moisture absorption or ultraviolet rays, and a roof having a preferable durability can be obtained. FIG.
As described above, when the upper and lower surfaces are wrapped, the effect of preventing deterioration due to intrusion of moisture or the like is enhanced.

As the core material 4, a honeycomb material, a foam material, or the like can be used. Honeycomb materials are aluminum, paper,
It is a planar body having a polygonal cross section and a hollow cross section made of a polymer material or the like. The foam material is a lightweight foam mainly composed of a polymer material represented by urethane foam or acrylic foam, and has a specific gravity of about 0.01 to 0.8. For the purpose of improving heat resistance and rigidity, a modified foam material to which ceramic particles are added is also included. Among these core materials 4, the most preferable one has a specific gravity of 0.01 to
Lightweight foam up to 0.2. The use of lightweight foam allows one side to the other side, that is, from the upper surface 2 to the lower surface 3
The heat transfer coefficient to the metal can be lower. Specifically, when the heat transfer coefficient is set to 0.04 to 0.1 W / m ° C., the cooling efficiency of the cooler becomes 100 times or more as compared with the case of metal, so that the fuel efficiency is greatly improved, energy consumption is reduced,
It is also useful for environmental protection.

Layer 5 forming upper surface 2 and / or lower surface 3
The protrusions 9 made of resin or metal can be formed on the layer 6 for forming. In the present embodiment, the projections 9 are provided on the layer 5. The projections 9 can be formed integrally or separately from the layers 5, 6. Since such projections 9 contribute to improvement in rigidity, the roof 1 and the hood 10 can be made lighter. The cross section of the protrusion 9 can be formed in an I, L, T, H shape or the like, or a half moon, a crescent moon, a hemisphere, or the like.
It is efficient to provide such a protrusion 9 in a direction in which rigidity is desired.

The projection 9 can be made of resin, metal, or the like. When the projections 9 are made of resin, weight reduction can be promoted,
Durability can be improved. When the projection 9 is made of metal,
Metal processing can be performed, and joining and connection with other parts can be performed by metal joining. Above all, the projections 9 made of a magnetic metal are preferable because, in addition to the effect of improving the rigidity, the processing of the roof 1 and the hood 10 allows the use of a magnetic tape and the temporary fixing of metal fittings. When the projections 9 are formed on the layer 5, the projections 9 are preferably provided in the direction of the layer 6 in terms of aerodynamic resistance and design. On the other hand, when it is formed on the layer 6, it is preferable to provide it in the direction of the layer 5 in order to protect the occupant's head. It can also be used as a hook attachment part for lowering.

The roof 1 of the present invention includes not only a portion covering the upper portion of the occupant but also front and rear window portions (a front window portion,
Openings such as a rear window portion) and a sunroof can be integrally formed. By integrating the window with the roof 1, the upper part of the vehicle including the window becomes highly rigid, the torsion resistance, which is a weak point of the open car, is improved, and the driving performance and comfort of the vehicle are improved. Because you do. Preferably, if the window frame portion is also integrally formed with the roof 1, further weight reduction can be achieved. Also, by using a transparent plastic such as a polycarbonate resin in addition to glass as the material of the window portion, the roof 1 with reduced attachment and detachment labor can be obtained. Note that the roof 1 can be fixed to the vehicle body with a bracket (not shown) or the like. The fitting may be joined to the roof 1 later. Further, it may be embedded in the core material 4 having a sandwich structure and integrated with the roof 1. Further, the hood 10 according to the present invention
Can also be joined to the vehicle body with metal fittings or the like. Also,
It is also possible to provide an inner for reducing head impact, a sound absorbing material or a sound insulating material for reducing engine noise on the inner surface side of the roof or hood.

The technical idea of the present invention is not limited to a roof and a hood, but also to a trunk lid, a platform,
It is also applicable to panels such as doors.

[0024]

Next, the features of the panel member of the present invention will be described based on embodiments. Example 1 Carbon fiber (carbon fiber: strength 4.9 GPa, elastic modulus 235)
GPa, elongation 2.1%) 3 plain weave cloths (cloth basis weight 200 g / m ² ) (fiber direction is 0 ° / 90)
° and 45 ° / -45 ° and 0 ° / 90 ° in order and 0.6 mm thick FRP (fiber content 40
%) As layer 5 and carbon fiber (carbon fiber: strength 5.6 GP)
a, ^two plain weave cloths (cloth weight: 198 g / m ² ) (elastic modulus: 300 GPa, elongation: 1.9%) (fiber direction: 0 ° / 90 ° direction) and 0.4 mm thick made of epoxy resin FRP (fiber content 40%) as layer 6,
An 8 mm high-density urethane foam (specific gravity 0.
06), a detachable automobile roof was integrally formed by an RTM (resin transfer molding) method with a core material 4 made of the same. The roof 1 weighs 7 kg and weighs 3 kg even when a polycarbonate window is attached.
At 0 kg, it was easy to carry alone. Also,
Table 1 shows the torsional rigidity of the roof 1 and the impact test results when aluminum balls weighing 1 kg from a height of 3 m were dropped and dropped freely at the center of the roof 1.

Example 2 An automobile roof was prepared in exactly the same manner as in Example 1 except that the end of the layer 5 was folded back to the layer 6 side.
An impact test was performed. The results were as shown in Table 1. Further, the end (turned portion) of the roof was subjected to a bending fatigue test, and no peeling was observed.

Comparative Examples 1 and 2 The same test as in Examples 1 and 2 was performed on a commercially available roof made of SMC (short glass fiber / polyester resin) and aluminum. The results were as shown in Table 1.

[0027]

[Table 1]

Example 3 Carbon fiber (carbon fiber: strength 4.9 GPa, elastic modulus 235)
GPa, elongation: 2.1%), three seamless satin weave cloths (cloth basis weight: 200 g / m ² ) (the traveling direction of the vehicle is 0 °, and the fiber arrangement direction is 0 ° / surface). 90 °, 45 ° / −45 °, 0 ° / 90 °) and 0.6 mm thick FRP (fiber content 45%) made of epoxy resin are used as the lower surface, and carbon fiber (carbon fiber: strength 3.5 GPa, Seamless plain weave cloth (having a cloth weight of 198) having an elastic modulus of 235 GPa and an elongation of 1.5%.
g / m ² ) 3 sheets (fiber arrangement direction is 0 ° / 9 from the surface side)
0 °, 45 ° / −45 °, 0 ° / 90 °) and 0.6 mm thick FRP (fiber content 40
%) As an upper surface, and a symmetrically configured automobile hood (1.5 mx 1.5 m) composed of 6 mm acrylic foam (specific gravity 0.05) between the upper surface and the lower surface was integrally formed by RTM (resin transfer molding) method. . The joint between the upper and lower crosses was treated as shown in FIG. 3, and a urethane resin coating was applied to suppress peeling. The weight of the hood is 8 kg, and the bending rigidity in the front-back direction of the panel and
Table 2 shows the results of an impact test in which an aluminum ball having a height of 5 m and a weight of 1 kg was freely dropped on the center of the panel.

COMPARATIVE EXAMPLE 3 In Example 3, the fabric on the lower surface was connected substantially linearly in the front-rear direction of the vehicle body at the center of the hood (the overlap was 5 m).
m) Other than that, the same test as in Example 3 was performed in the same manner as in Example 3. The results were as shown in Table 2.

[0030]

[Table 2]

[0031]

As described above, when using the FRP automobile panel of the present invention, the panel can be significantly reduced in weight and the appearance, impact resistance, etc. can be improved, so that it is safe and environmentally compatible. It is possible to realize an energy-saving vehicle with excellent performance. In the case of a removable panel,
There is also an effect that the burden on the worker is reduced.

[Brief description of the drawings]

FIG. 1 is a perspective view of an automobile using an FRP automobile roof according to an embodiment of the present invention.

FIG. 2 is a perspective view of the FRP automobile roof shown in FIG. 1;

FIG. 3 is a III-III of the FRP automobile roof shown in FIG. 2;
It is an expanded sectional view which follows a line.

FIG. 4 is an enlarged cross-sectional view of an end of an FRP automobile roof in another embodiment different from FIG. 2;

FIG. 5 is a perspective view of an automobile using an FRP automobile hood according to another embodiment of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 FRP automobile roof 2 Upper surface 3 Lower surface 4 Core material 5 Layer forming upper surface 6 Layer forming lower surface 7 End 8 Window part of automobile 9 Projection 10 FRP automobile hood

Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat II (Reference) B60J 7/10 B60J 7/10 A B62D 25/06 B62D 25/06 C 25/10 25/10 A (72) Inventor Nishiyama, etc.1515 Tsutsui, Matsumaemachi, Matsumae-cho, Iyo-gun, Ehime F-term in the Ehime Plant of Toray Industries Co., Ltd. JL03 YY00A YY00C

Claims (16)

[Claims] 1. An automotive panel made of FRP using a woven base made of continuous fibers as a reinforcing fiber, wherein the woven base has no seams on at least one surface of the panel. . 2. The FRP automobile panel according to claim 1, wherein the continuous fibers are carbon fibers. 3. The F according to claim 1, wherein the textile substrate has no seams on both sides of the panel.
RP automobile panel. 4. The FRP automobile panel according to claim 1, wherein a thickness of the panel is in a range of 0.2 to 3 mm. 5. The carbon fiber has an elongation of 1.8% to 2.4.
%. The FRP-made automobile panel according to claim 2, wherein the value is in the range of%. 6. The carbon fiber has a strength of 4500 to 800.
It is within the range of 0 MPa, characterized by the above-mentioned.
5. The FRP automobile panel according to any one of 5. 7. The FR according to claim 1, wherein both surfaces of the panel are formed integrally.
P-made automotive panel. 8. The panel has a sandwich structure in which a foam material is inserted between both surfaces thereof.
The FRP automobile panel according to claim 1. 9. The FRP automobile panel according to claim 1, wherein a rib is formed on at least one surface of the panel. 10. The panel according to claim 1, wherein the panel is detachable or openable and weighs 16 kg or less.
The FRP automobile panel according to any one of the above. 11. The FRP according to claim 1, wherein a heat transfer coefficient from one surface of the panel to another surface is in a range of 0.04 to 0.1 W / m ° C. Car panels. 12. The FRP automobile panel according to claim 1, wherein the panel has an opening, and the opening is integrated with both surfaces of the panel. 13. The FRP automobile panel according to claim 1, which is a roof panel. 14. The FRP automobile panel according to claim 1, wherein the panel is a hood panel. 15. The FRP according to claim 14, wherein an acrylic resin window is mounted on the hood.
Car panels. 16. The FRP automobile panel according to claim 1, which is a door panel.