JP4645334B2 - Fiber reinforced plastic parts - Google Patents

Description

The present invention relates to a fiber-reinforced plastic member that is lightweight, has excellent mechanical properties such as strength and elastic modulus, and has a smooth surface .

  Fiber reinforced plastic made of glass fiber, carbon fiber, aramid fiber, alumina fiber and boron fiber and matrix resin is lightweight and has excellent mechanical properties such as strength and elastic modulus. Widely used in sports equipment and automobile applications.

In particular, the use of a fiber reinforced plastic member can reduce the weight, and as a result, fuel consumption can be improved, and as a result, emission CO ₂ can be reduced. Therefore, there is an increasing trend to use the fiber reinforced plastic member for automobile applications.

  When using fiber reinforced plastic parts for automobiles, especially for outer panels such as hoods, roofs, trunk lids, doors, etc., not only in terms of functionality such as light weight, mechanical properties such as strength and elastic modulus, Also on the design surface, it is required to have a smooth surface such that the mapping is clearly projected.

  However, the conventional fiber reinforced plastic member has a problem that it is difficult to obtain a smooth surface. Specifically, this is a phenomenon in which irregularities reflecting the texture or stitches of woven fabric, knitted fabric, etc. are generated on the surface of the fiber reinforced plastic member, which is called “print through”. This is because, in a fiber reinforced plastic member, the matrix resin is cured and shrunk during molding, and heat shrinkage occurs when it is cooled from the molding temperature to room temperature. When the material is used, the surface thickness of the matrix resin in the recesses of the woven fabric, knitted fabric, etc. is larger than the surface layer thickness of the matrix resin in other portions. At this time, the shrinkage amount of the matrix resin in the thickness direction is the shrinkage rate in the thickness direction. Is proportional to the product of the surface layer thickness of the resin and the shrinkage amount in the thickness direction of the concave portion of the woven or knitted fabric having a large surface layer thickness of the matrix resin is larger than the shrinkage amount in the thickness direction in other portions. Unevenness occurs on the surface of the reinforced plastic member.

  Conventionally, a method of providing a surface layer made of a thermosetting resin as described below has been used for such a problem.

  First, it is a method using a liquid thermosetting resin composition called gel coat. In this method, a liquid thermosetting resin composition is sprayed onto a mold using a sprayer or the like and cured to form a surface layer in advance on the side to be a design surface, and then a fiber reinforced plastic member is molded (Patent Document 1). 2).

  Further, there is a method of using a film made of a thermosetting resin composition called a surface film or a surface material. In this method, a surface film or a surface material is disposed on the side to be a design surface and cured to form a surface layer. In this method, the surface layer may be formed prior to the molding of the fiber reinforced plastic member, or may be formed simultaneously with the molding (Patent Document 3).

  However, in these conventional methods, it cannot be said that the effect of reducing the unevenness of the surface is sufficient, and in order to eliminate “print-through”, it is necessary to take a sufficient thickness of the surface layer. However, taking a sufficient thickness of the surface layer means an increase in the weight of the surface layer, and hence an increase in the weight of the fiber reinforced plastic member, resulting in a loss of the feature of the fiber reinforced plastic member that is lightweight.

Thus, no technique has been found so far that can obtain a fiber-reinforced plastic member having a smooth surface without impairing the characteristics of the fiber-reinforced plastic member that is lightweight.
JP-A-8-207149 JP 2003-48263 A British Patent No. 2379633

  An object of the present invention is to provide a technique capable of obtaining a fiber-reinforced plastic member having a smooth surface without impairing the feature of the fiber-reinforced plastic that is lightweight in view of the background of the prior art. is there.

In order to solve the above problems, the present invention employs the following means. That is, the fiber-reinforced plastic member of the present invention is
(1) The following constituent elements [A], [B], and [C] are included, and the constituent element [C] is disposed on at least one side of the constituent element [A] via the constituent element [B]. A fiber-reinforced plastic member characterized by that.

[A] Fiber reinforced plastic including woven or knitted reinforced fiber and thermosetting resin [B] Low elastic modulus surface layer having a tensile modulus of 0.1 to 500 MPa [C] Tensile modulus of 1000 to 30000 MPa A high-modulus surface layer (2) The fiber-reinforced plastic according to (1) above, wherein the ratio of the tensile modulus of component [B] to the tensile modulus of component [C] is 0.0003 to 0.01 Element.

( 3 ) The fiber-reinforced plastic member according to (1) or (2) , wherein the constituent element [B] includes an elastomer.

( 4 ) The fiber-reinforced plastic member according to ( 3 ) above , wherein the elastomer contains at least one selected from silicone rubber, ethylene propylene rubber, acrylonitrile butadiene rubber, chloroprene rubber, and fluorine rubber.

( 5 ) The fiber-reinforced plastic member according to any one of (1) to ( 4 ) , wherein the constituent element [C] includes a reinforcing fiber.

( 6 ) The fiber-reinforced plastic member according to (5), wherein the reinforcing fibers contained in the component [C] are randomly oriented.

( 7 ) The fiber reinforced plastic member according to any one of (1) to ( 6 ) , wherein the surface roughness is 0.5 μm or less.

  The fiber-reinforced plastic member of the present invention is lightweight, has excellent mechanical properties such as strength and elastic modulus, has a smooth surface, and can be usefully used for an automobile outer plate and the like.

  The present invention includes the following components [A], [B], and [C] in order to obtain a fiber-reinforced plastic member having a smooth surface without impairing the characteristics of the fiber-reinforced plastic member that is lightweight. The constituent element [C] is laminated on at least one side of the constituent element [A] via the constituent element [B].

[A] Fiber reinforced plastic including woven or knitted reinforced fiber and thermosetting resin [B] Low elastic modulus surface layer having a tensile modulus of 0.1 to 500 MPa [C] Tensile modulus of 1000 to 30000 MPa In the fiber reinforced plastic member in which only the constituent element [C] is disposed on the surface of a certain high elastic modulus surface layer constituent element [A], surface irregularities are reduced by the high elastic modulus surface layer. However, the stress generated by the shrinkage of the matrix resin is large, and in order to prevent dents from being generated by this stress, it is necessary to make the component [C] considerably thick. However, increasing the thickness of the component [C] so that the dent is not conspicuous increases the weight of the surface layer, and consequently increases the weight of the fiber-reinforced plastic member. It is.

  The inventors have conceived of providing a layer that relieves stress caused by shrinkage between the constituent element [A] and the constituent element [C]. By using a low elastic modulus surface layer having specific properties as a layer to relieve stress, surface dents are dramatically reduced, and a smooth surface can be obtained even if the thickness of the component [C] is not so much. It was found that it can be obtained.

The component [A] of the present invention is a fiber-reinforced plastic containing a woven or knitted fabric of reinforcing fibers and a thermosetting resin .

  Specific examples of the reinforcing fiber of component [A] include glass fiber, carbon fiber, aramid fiber, alumina fiber, and boron fiber. Among these, carbon fibers are preferably used because they have excellent characteristics of high strength and high elastic modulus while being lightweight.

  As the reinforcing fiber of the component [A], both short fibers and long fibers can be used. When emphasizing mechanical properties, it is preferable to use reinforcing fibers having a length of 10 cm or more because fiber-reinforced plastics having excellent properties of high strength and high elastic modulus can be obtained while being lightweight. . When emphasizing moldability, it is preferable to use reinforcing fibers having a length of 10 cm or less.

Since the form status of the strengthening fibers of component [A] is, is woven material or knitted, excellent handling properties. Especially, since the fiber reinforced plastic member which has the outstanding characteristic of being high intensity | strength and a high elasticity modulus while being lightweight can be obtained, it is preferable to use the thing of the arrangement structure of a single direction .

Thermosetting resin component [A] is used as a matrix resin, the heat resistance, Ru excellent balance of mechanical properties.

  Specific examples of the thermosetting resin of component [A] include unsaturated polyester resins, vinyl ester resins, epoxy resins, and phenol resins. Among them, it is preferable to use an epoxy resin because it has a particularly excellent balance between heat resistance and mechanical properties and small curing shrinkage.

  The fiber volume content of the component [A] is preferably 10 to 85% because a fiber-reinforced plastic having excellent properties of high strength and high elastic modulus can be obtained while being lightweight. 30 to 85% is more preferable, and 40 to 85% is more preferable. If it is less than 10%, the strength and elastic modulus of the fiber-reinforced plastic member obtained may be insufficient. If it is larger than 85%, the reinforcing fibers may come into contact with each other and rub against each other, resulting in a decrease in strength.

  Here, the fiber volume content is determined in accordance with ASTM D 3171.

  The constituent element [B] of the present invention is a low elastic modulus surface layer having a tensile elastic modulus of 0.1 to 500 MPa, more preferably a low elastic modulus surface layer of 0.1 to 100 MPa. 1 to 50 MPa is more preferable. When the pressure is less than 0.1 MPa, the [B] layer is easily deformed, so that the [C] layer is easily peeled off. If it is greater than 500 MPa, the effect of relaxing the stress is insufficient, and a smooth surface cannot be obtained.

  Here, the tensile elastic modulus is measured in accordance with ASTM D 638-02. However, the measurement temperature is 23 ° C. and the measurement speed is 10 mm / min. Further, the tensile elastic modulus is determined from the slope when the strain in the strain-stress curve is between 0.1% and 0.3%.

A sample for measuring the tensile modulus can be obtained as follows. When the material of the component [B] is known, the same material can be obtained and used as a sample. Moreover, each layer of the fiber reinforced plastic member can be peeled off, and the component [B] can be taken out to make a sample. In the case of a sample whose tensile modulus is difficult to measure, hardness can be substituted. In this case, the Shore A hardness measured in accordance with JIS K 6253 is preferably in the range of 1 to 100, more preferably in the range of 1 to 80, and in the range of 1 to 50. More preferred.

The linear expansion coefficient at 20 ° C. to 100 ° C. of the constituent element [B] is preferably 60 × 10 ⁻⁵ / ° C. or less, and more preferably 40 × 10 ⁻⁵ / ° C. or less. When it is higher than 60 × 10 ⁻⁵ / ° C., the shrinkage of the component [B] increases, and the surface may be dented.

  In addition, a linear expansion coefficient here is measured based on JISK7197.

  The thickness of the component [B] is preferably 10 to 500 μm, more preferably 10 to 400 μm, and even more preferably 10 to 300 μm. If it is smaller than 10 μm, the effect of relieving stress caused by shrinkage becomes insufficient, and a smooth surface may not be obtained. If it is larger than 500 μm, the weight of the surface layer increases, and consequently the weight of the fiber reinforced plastic member increases, and the characteristic of the fiber reinforced plastic member that it is lightweight may be impaired.

  The thickness of the component [B] is measured by the following method. First, a fiber reinforced plastic member is cut into a size of 5 cm in length and 2 cm in width using a diamond cutter, and the cut surface in the length direction is magnified 50 times with a microscope, and five different photographs are taken. As the microscope, an optical microscope or an apparatus having an equivalent function (for example, an electron microscope) is used. Next, for each of the five photographs taken, the thickness of the component [B] at the position where the thickness is minimum is measured, and the average value is calculated.

Basis weight of the component [B] is preferably from 10 to 500 g / ^{m 2,} more preferably if 10 to 400 g / ^{m 2,} more preferably if 10 to 300 g / ^{m 2.} If it is less than 10 g / m ² , the effect of relieving stress caused by shrinkage will be insufficient, and a smooth surface may not be obtained. If it is larger than 500 g / m ² , the weight of the surface layer increases, and consequently the weight of the fiber reinforced plastic member increases, and the feature of the fiber reinforced plastic member that is lightweight may be impaired.

  As the component [B], any of a cured product of a thermosetting resin, a thermoplastic resin, and an elastomer can be used.

  Among these, as the component [B], it is preferable to use an elastomer because it has a moderately low elastic modulus. In the present invention, the elastomer refers to a polymer exhibiting rubber elasticity at 25 ° C.

  Specific examples of elastomers include natural rubber, isoprene rubber, butadiene rubber, chloroprene rubber, acrylonitrile butadiene rubber, hydrogenated nitrile rubber, butyl rubber, ethylene propylene rubber, ethylene vinyl acetate rubber, acrylic rubber, polyether urethane rubber, polyester urethane rubber, Examples thereof include silicone rubber, fluororubber, polyolefin-based thermoplastic elastomer, polyurethane-based thermoplastic elastomer, polyester-based thermoplastic elastomer, and polyamide-based thermoplastic elastomer. Among these, as the elastomer, when at least one selected from silicone rubber, ethylene propylene rubber, acrylonitrile butadiene rubber, chloroprene rubber, and fluorine rubber is used, the elastomer is stable in a relatively wide temperature range from about 0 ° C. to about 100 ° C. Since it can be used, it is preferable.

  The elastomer preferably has a glass transition temperature of 0 ° C. or lower, more preferably −10 ° C. or lower, and further preferably −20 ° C. or lower. When the glass transition temperature is higher than 0 ° C., the elastomer may be in a glass state and become brittle when the ambient temperature becomes 0 ° C. or lower during use of the fiber reinforced plastic member.

  In addition, the glass transition temperature of an elastomer here is measured based on SACMA SRM 18R-94 using a viscoelasticity measuring apparatus. However, the measurement is performed in the Rectangular Torsion mode, the measurement frequency is 1 Hz, and the temperature increase rate is 5 ° C./min. In the obtained temperature-storage modulus curve, the intersection of the tangent in the glass region and the tangent in the transition region from the glass region to the rubber region is obtained, and the temperature of this intersection is defined as the glass transition temperature.

When an elastomer having a melting point is used as the component [B], the melting point of the elastomer is preferably 100 ° C. or higher, more preferably 120 ° C. or higher, and even more preferably 140 ° C. or higher. When the melting point is lower than 100 ° C., the elastomer may be melted when the ambient temperature becomes 100 ° C. or higher during use of the fiber-reinforced plastic member.
Here, the melting point of the elastomer is determined by DSC (Differential Scanning Calorimetry). The temperature is measured at a rate of temperature increase of 10 ° C./min, and the temperature at the peak of the melting peak in the obtained DSC curve is defined as the melting point.

  Specific examples of the form of the constituent element [B] include those in which particles of a low elastic modulus material such as an elastomer are arranged in a planar shape. In addition, fibers made of a material having a low elastic modulus such as an elastomer may be arranged in a single direction, two directions, random directions, or the like, or in the form of a mat, woven fabric, knitted fabric, or the like. Moreover, the sheet | seat of materials with low elasticity, such as an elastomer, is mentioned. When using a sheet, in order to improve the fluidity of the matrix resin at the time of molding, it can be used by making holes or making slits. Here, “particles of low elastic modulus material”, “fibers of low elastic modulus material”, “sheets of low elastic modulus material” are particles, fibers, Even if it is a sheet and contains a component having a high elastic modulus, the whole compound has a low elastic modulus. Moreover, in order to improve adhesiveness with a matrix resin, it can be used by providing fine irregularities on the surface.

  The constituent element [C] has a tensile modulus of 1000 to 30000 MPa, which is necessary for preventing surface dents, and more preferably 5000 to 30000 MPa. If the pressure is less than 1000 MPa, the rigidity of the component [C] is insufficient, and the component [C] is used in order to prevent the depression due to the stress caused by the shrinkage or the stress caused by the shrinkage. Must have a sufficient thickness. However, taking a sufficient thickness of the [C] layer means an increase in the weight of the surface layer, and hence an increase in the weight of the fiber-reinforced plastic member, and the feature of the fiber-reinforced plastic member that is lightweight is impaired. When it is larger than 30000 MPa, workability deteriorates when the component [C] is subjected to sanding or the like in the finishing step.

  Here, the tensile elastic modulus is measured in accordance with ASTM D 638-02. However, the measurement temperature is 23 ° C. and the measurement speed is 1 mm / min. Further, the tensile elastic modulus is determined from the slope when the strain in the strain-stress curve is between 0.1% and 0.3%. A sample for measuring the tensile modulus can be obtained as follows. If the material of the component [C] is known, the same material can be obtained and used as a sample. Further, each layer of the fiber reinforced plastic member is peeled off, and the component [C] can be taken out to make a sample.

In the present invention, it is preferable that the ratio of the tensile modulus of the component [B] for the tensile modulus of the component [C] is from 0.0003 to 0.01, more if 0.0003 to 0.001 preferable. If it is smaller than 0.0003 , the [B] layer is easily deformed, and the [C] layer is easily peeled off. On the other hand, if it is larger than 0.01, the rigidity of the constituent element [C] is insufficient for the effect of the constituent element [B] to relieve stress, and the surface may be dented.

  The thickness of the component [C] layer is preferably 50 to 500 μm, more preferably 100 to 400 μm, and even more preferably 200 to 400 μm. If it is smaller than 50 μm, the rigidity becomes insufficient, and a recess may be formed due to the stress caused by the shrinkage. If it is larger than 500 μm, the weight of the surface layer increases, and consequently the weight of the fiber reinforced plastic member increases, and the characteristic of the fiber reinforced plastic member that it is lightweight may be impaired.

  The thickness of component [C] is measured by the same method using the same test piece as that measured for the thickness of component [B].

Basis weight of the component [C] is preferably 60~600g / ^{m 2,} more preferably if 120~480g / ^{m 2,} more preferably if 240~480g / ^{m 2.} If it is less than 60 g / m ² , the rigidity of the constituent element [C] becomes insufficient, and a concave portion may be generated due to a stress caused by shrinkage. When it is larger than 600 g / m ² , the weight of the surface layer increases, and consequently the weight of the fiber reinforced plastic member increases, and the feature of the fiber reinforced plastic member that is lightweight may be impaired.

  As the component [C], either a cured product of a thermosetting resin or a thermoplastic resin can be used. Specific examples of thermosetting resins include unsaturated polyester resins, vinyl ester resins, epoxy resins, and phenol resins. Specific examples of thermoplastic resins include polyethylene, polypropylene, polyamide, polyamideimide, polycarbonate, and polysulfone. , Polyacetal, polyphenylene ether, polyphenylene sulfide, polyarylate, polyetherimide, polyethersulfone, polyetherketone, and the like, but are not limited thereto.

  Among these, since the balance between heat resistance and mechanical properties is excellent, it is preferable to use a cured product of a thermosetting resin. Especially, the balance between heat resistance and mechanical properties is particularly excellent, and the cure shrinkage is small. It is more preferable to use an epoxy resin because of its characteristics.

  Also, among these, it is preferable to use a thermoplastic resin because it does not require resin curing time and can easily be molded in a short time. Among them, polycarbonate is used because of its excellent impact resistance. Is more preferable.

  The thermosetting resin and / or thermoplastic resin used for the component [C] is preferably the same as the matrix resin of the component [A] because it can be easily molded.

  When a cured product of a thermosetting resin is used as the component [C], the glass transition temperature is preferably 80 ° C or higher, more preferably 90 ° C or higher, and further preferably 100 ° C or higher. When the glass transition temperature is lower than 80 ° C., when the ambient temperature becomes 80 ° C. or higher during use of the fiber reinforced plastic member, the cured product of the thermosetting resin may be in a rubber state, and the surface may be uneven.

  In addition, the glass transition temperature of the hardened | cured material of a thermosetting resin here is measured based on SACMA SRM 18R-94 using a viscoelasticity measuring apparatus. However, the measurement is performed in the Rectangular Torsion mode, the measurement frequency is 1 Hz, and the temperature increase rate is 5 ° C./min. In the obtained temperature-storage modulus curve, the intersection of the tangent in the glass region and the tangent in the transition region from the glass region to the rubber region is obtained, and the temperature of this intersection is defined as the glass transition temperature.

  Constituent element [C] preferably contains reinforcing fibers because the elastic modulus can be increased. As the reinforcing fiber, glass fiber, carbon fiber, aramid fiber, alumina fiber, boron fiber, and the like can be suitably used. Among them, carbon fiber is preferably used because it is lightweight and has a high elastic modulus. As the form of the reinforcing fiber, either a short fiber or a long fiber can be used. The array structure of reinforcing fibers includes a single direction, random orientation and the like because a smooth surface can be easily obtained. Further, as an aggregate form of the reinforcing fibers, a mat or the like can be given because a smooth surface can be easily obtained.

  When the constituent element [C] contains reinforcing fibers, the fiber volume content is preferably 1 to 50% and more preferably 1 to 30% because the constituent element [C] has an appropriate elastic modulus. preferable. If the reinforcing fiber content is less than 1%, the reinforcing fibers are unevenly distributed, resulting in unevenness of the effect. On the other hand, if it is larger than 50%, the weight of the component [C] becomes excessively large, the weight of the fiber reinforced plastic member increases, and the feature of the fiber reinforced plastic that is lightweight may be impaired.

  Here, the fiber volume content is determined in accordance with ASTM D 3171.

  The component [C] preferably includes an inorganic filler because the elastic modulus can be increased. As the inorganic filler, calcium carbonate, clay, talc, silica, wollastonite and the like can be suitably used. Among them, it is preferable to use an inorganic filler having a hollow structure because it is lightweight.

  When component [C] contains an inorganic filler, the filler content of component [C] is preferably 20 to 80% by weight, and more preferably 30 to 70% by weight. If it is less than 20% by weight, uneven distribution of the inorganic filler occurs and the effect becomes uneven. When the weight is larger than 80%, the weight of the component [C] becomes excessively large, the weight of the fiber reinforced plastic member increases, and the characteristic of the fiber reinforced plastic that it is lightweight may be impaired.

  In the fiber reinforced plastic member of the present invention, at least one surface has a surface roughness of preferably 0.5 μm or less, more preferably 0.3 μm or less, and further preferably 0.2 μm or less.

  The surface roughness is measured by the following method. As the sample, the same test piece as that measured for the thickness of the component [B] is used. First, the surface unevenness profile as shown in FIG. 1 is obtained by using a surf coder SE3400 manufactured by Kosaka Laboratory Co., Ltd. or a contact-type surface roughness meter having an equivalent function at any five locations of the sample. . At this time, the measurement distance is 10 mm, and the measurement speed is 2 mm / second. When the measurement result has anisotropy, the measurement is performed while changing the direction at each measurement point, and a surface unevenness profile in the direction in which the unevenness becomes the largest is obtained. The surface unevenness profile is enlarged and output so that the height of the unevenness can be recognized sufficiently. Next, as shown in FIG. 1, the intersection of the line connecting adjacent concave and convex portions and the line vertically lowered from the convex portion vertex, and the height R to the convex portion vertex, three places for each profile, a total of 15 Measure at various points, calculate the average value, and use it as the surface roughness. If you can measure fewer than 3 locations for each profile, increase the number of measurements so that you can measure a total of 15 locations.

  The fiber reinforced plastic member of the present invention may include components other than the components [A], [B], and [C]. Further, the constituent elements other than the constituent elements [A], [B], and [C] are outside the constituent element [A], between the constituent elements [A] and [B], and the constituent elements [B]. It may be arranged between the component [C] and outside the component [C]. Further, there may be a plurality of constituent elements other than the constituent elements [A], [B], and [C]. As a constituent element other than the constituent elements [A], [B], and [C], a coating film may be present on the surface of the constituent element [C].

  For producing the fiber-reinforced plastic member of the present invention, any conventionally known method for producing a fiber-reinforced plastic member can be used.

Methods for producing fiber-reinforced plastic member of the present invention, how to use a prepreg, the reinforcing fiber substrate placed in a mold, after impregnating a thermosetting resin composition of the liquid, thereby heated and cured Resin transfer molding (RTM) method, pultrusion method and the like. Especially, since the fiber reinforced plastic member which has complicated shape can be manufactured easily, it is preferable to use the RTM method.

When using a prepreg, the following components [A2], [B2], provided the [C2] include, through the component [B2] at least one side of the component [A2], component [C2] The component [A2] is preferably heated and cured.

[A2] prepreg <br/> [B2] If the tensile modulus is used a low modulus sheet [C2] The thermosetting resin composition fill beam and / or a thermoplastic resin film prepreg is 0.1～500MPa, For example, it can be manufactured by the following procedure. First, the thermosetting resin composition film is arranged as the component [C2] on the design surface side, then the component [B2] is arranged, and then the component [A2] is laminated in the order of the prepreg. . After bagging with a bag film, it is cured while heating and pressing using an autoclave to produce a fiber reinforced plastic member. At this time, the thermosetting resin composition film is cured to be a component [C], and the prepreg is cured to be a component [A]. Further, as the component [C2], a thermoplastic resin film may be used. In this case, it is preferable to use a thermoplastic resin film shaped in advance into a desired shape. In the present invention, the thermosetting resin composition film is a film containing a thermosetting resin composition, may contain a thermoplastic resin, inorganic particles, reinforcing fibers, and the like, and heat the component [A2]. Any material may be used as long as it undergoes crosslinking during curing. In the present invention, the thermoplastic resin film is a film containing a thermoplastic resin as a main component (including 50% or more), and may contain a thermosetting resin, inorganic particles, reinforcing fibers, and the like.

  When the RTM method is used, the component [C1] includes the following components [A1], [B1], and [C1], and the component [C1] is disposed on at least one side of the component [A1] via the component [B1]. It is preferable to use a reinforcing fiber base characterized by being disposed because it can be easily molded.

[A1] Woven fabric and / or knitted fabric of reinforcing fiber [B1] Low elastic modulus sheet having a tensile elastic modulus of 0.1 to 500 MPa [C1] Mat of reinforcing fiber When the RTM method is used, for example, the following procedure is used. Can be manufactured. First, a mat of reinforcing fibers as [C1] is arranged on the design surface side in the mold, and then a woven fabric and / or knitted fabric of reinforcing fibers as components [B1] and [A1] is arranged. The mold is closed, [A1] and [C1] are impregnated with a liquid thermosetting resin composition, and then cured to produce a fiber-reinforced plastic member. At this time, the liquid thermosetting resin composition impregnated in [C1] is cured to be a constituent element [C], and the liquid thermosetting resin composition impregnated in [A1] is cured and configured. Become element [A].

  When the reinforcing fiber base is used, the constituent elements [A1], [B1], and [C1] may be independent, and a part of the constituent elements, that is, the constituent elements [A1], [B1], or The constituent elements [B1] and [C1] may be integrated in advance, or the constituent elements [A1], [B1] and [C1] may all be integrated. Among these, since the arrangement of the reinforcing fiber base in the mold is easy, at least a part of the constituent elements (constituent elements [A1] and [B1] or constituent elements [B1] and [C1]). Are preferably integrated in advance, and it is preferable that all components (components [A1], [B1], [C1]) are integrated.

  Moreover, when using RTM method, it can also manufacture in the following procedures, for example. First, a thermosetting resin film is disposed on the design surface side in the mold, and then a woven fabric and / or a knitted fabric of reinforcing fibers as the constituent elements “B1” and [A1] are disposed. The mold is closed, and after impregnating [A1] with a liquid thermosetting resin composition, it is cured to produce a fiber-reinforced plastic member. At this time, the thermosetting resin film is cured to become the constituent element [C], and the liquid thermosetting resin composition impregnated in [A1] is cured to become the constituent element [A]. The thermosetting resin film may be cured prior to the curing of the liquid thermosetting resin composition, or may be cured simultaneously with the curing of the liquid thermosetting resin composition. Moreover, you may use a thermoplastic resin film instead of a thermosetting resin film. In this case, it is preferable to use a thermoplastic resin film shaped in advance into a desired shape.

  The fiber-reinforced plastic member of the present invention is lightweight, has excellent mechanical properties such as strength and elastic modulus, and has a smooth surface, and is preferably used as an outer plate or aerodynamic member of a single vehicle or an automobile. Can do. Specific examples include front aprons, hoods, roofs, hardtops (removable roofs for open cars), pillars, trunk lids, doors, fenders, side mirror covers, and other automotive skins, front air dams, rear spoilers, side air dams, Examples include aerodynamic members such as engine undercovers.

  Moreover, the fiber-reinforced plastic member of the present invention can be preferably used for applications other than those described above. Specific examples include automobile interior materials such as instrument panels.

  Hereinafter, the present invention will be described specifically by way of examples.

  Main data of Examples and Comparative Examples are summarized in Tables 1 and 2.

  The materials used in Examples and Comparative Examples are as follows.

1. Carbon fiber fabric:
The woven fabric of the reinforcing fiber which is the constituent element [A1] of the present invention includes carbon fiber woven fabric CO6343B (product number, “Torayca (registered trademark)” T300-3K, carbon fiber basis weight: 198 g / m ² , Toray Industries, Inc. )).

2. RTM resin composition:
As the resin composition for RTM of the present invention, “Epicoat (registered trademark)” 828 (Japan Epoxy Resin, bisphenol A type epoxy resin) 100 wt%, “Cureazole (registered trademark)” 2E4MZ (product number, Shikoku Kasei Kogyo) A liquid epoxy resin composition containing 3 wt% of 2-ethyl-4-methylimidazole manufactured by Co., Ltd. was used.

3. Carbon fiber prepreg
The prepreg is a configuration element [A2], a carbon fiber prepreg P2053-12 (part number, "Torayca (registered trademark)" T800H used, carbon fiber weight per unit area: 125 g / ^{m 2,} the fiber content by weight: 70% Toray Industries, Inc.) was used.

4). Elastomer:
The following three components were used as the component [B1] of the present invention.
(1) Acrylonitrile butadiene rubber (NBR) sheet A
Acrylonitrile butadiene rubber, IN-120-6 (product number, manufactured by Irumagawa Rubber Co., Ltd., tensile elastic modulus: 4 MPa, Shore A hardness: 60, glass transition temperature: -30 ° C, melting point: none) Three types having a thickness of 300 μm, 500 μm, and 600 μm were used.
(2) Acrylonitrile butadiene rubber (NBR) sheet B
Two types of medium and high nitrile grade acrylonitrile butadiene rubber (manufactured by Kureha Elastomer Co., Ltd., tensile elastic modulus: 3 MPa, Shore A hardness: 40, glass transition temperature: −40 ° C., melting point: none) with thicknesses of 150 μm and 300 μm Was used.
(3) Polyurethane elastomer (PUE) sheet Polyurethane elastomer, DUS605-CER (product number, manufactured by Seadam Co., Ltd., tensile elastic modulus: 95 MPa, Shore A hardness: 96, glass transition temperature: −9 ° C., melting point: 164 ° C.) The one having a thickness of 300 μm was used.

5. Carbon fiber mat As the component [C1] of the present invention, a carbon fiber mat, BO030 (product number, 30 g / m ² , manufactured by Toray Industries, Inc.) was used.

6). Glass fiber mat As a constituent element [C1] of the present invention, glass fiber mat, EPM-4025 (product number, 25 g / m ² , manufactured by Japan Vilene Co., Ltd.)
7). Thermosetting resin composition film As component [C2] of the present invention, AF126-2 (product number, epoxy resin film adhesive, basis weight: 149 g / m ² , thickness: 130 μm, manufactured by Sumitomo 3M Limited) was used.

  Next, measurement methods in Examples and Comparative Examples are shown below.

1. Fiber volume content of component [A] The fiber volume content was determined according to ASTM D 3171.

2. Thickness of component [B] A fiber reinforced plastic member is cut to a size of 5 cm in length and 2 cm in width using a diamond cutter, and the cut surface in the length direction is magnified 50 times with a microscope, and five different photographs are taken. I took a picture. An optical microscope was used as the microscope. Next, for each of the five photographs taken, the thickness of the component [B] at the position where the thickness was the minimum was measured, and the average value was calculated.

3. Weight of component [B] The component [B] was cut into a size of 5 cm in length and 2 cm in width using a cutter, and the length and width were accurately measured using a caliper to determine the area. Next, the weight of the sample was measured using a balance. The basis weight of the [B] layer was calculated from the obtained area and the weight of the test piece.

4). Elastic modulus of component [B] The tensile elastic modulus was measured according to ASTM D 638-02 using “Instron (registered trademark)” 5565 (manufactured by Instron). However, the measurement temperature was 23 ° C., and the measurement speed was 10 mm / min. Moreover, the tensile elastic modulus was calculated | required from the inclination in the strain in a strain-stress curve between 0.1% and 0.3%.

5. Glass transition temperature of component [B] The glass transition temperature was measured according to SACMA SRM 18R-94 using a viscoelasticity measuring apparatus ARES (manufactured by Rheometric Scientific). However, the measurement was performed in the Rectangular Torsion mode, the measurement frequency was 1 Hz, and the temperature elevation rate was 5 ° C./min. In the obtained temperature-storage modulus curve, the intersection of the tangent in the glass region and the tangent in the transition region from the glass region to the rubber region was determined, and the temperature at this intersection was taken as the glass transition temperature.

6). Melting | fusing point of component [B] Melting | fusing point was calculated | required by DSC (Differential Scanning Calorimetry). As a measuring device, Pyris1 DSC (manufactured by PerkinElmer) was used. The temperature was measured at a heating rate of 10 ° C./min, and the temperature at the peak of the melting peak in the obtained DSC curve was taken as the melting point.

7). Thickness of component [C] Thickness is measured by the same method using the same test piece as the thickness of component [B].

8). The basis weight of the component [C] The component [C] was cut to a size of 5 cm in length and 2 cm in width using a diamond cutter, and the length and width were accurately measured using a caliper to determine the area. Next, the weight of the sample was measured using a balance. The basis weight of the [B] layer was calculated from the obtained area and the weight of the test piece.

9. Elastic modulus of component [C] The tensile elastic modulus was measured according to ASTM D 638-02 using “Instron 5565 (registered trademark)” (manufactured by Instron). However, the measurement temperature was 23 ° C., and the measurement speed was 10 mm / min. Moreover, the tensile elastic modulus was calculated | required from the inclination in the strain in a strain-stress curve between 0.1% and 0.3%.

10. Glass transition temperature of component [C] The glass transition temperature was measured according to SACMA SRM 18R-94 using a viscoelasticity measuring device ARES (manufactured by Rheometric Scientific). However, the measurement was performed in the Rectangular Torsion mode, the measurement frequency was 1 Hz, and the temperature elevation rate was 5 ° C./min. In the obtained temperature-storage modulus curve, the intersection of the tangent in the glass region and the tangent in the transition region from the glass region to the rubber region was determined, and the temperature at this intersection was taken as the glass transition temperature.

11. Fiber volume content of component [C] The fiber volume content was determined according to ASTM D 3171.

12 Fabrication of Fiber Reinforced Plastic Member Fiber reinforced plastic was cut into a size of 5 cm in length and 2 cm in width using a diamond cutter, and the length and width were measured using a caliper to determine the area. Next, the weight of the test piece was measured using a balance. The basis weight of the fiber reinforced plastic was calculated from the obtained area and the weight of the test piece.

13. Surface Roughness of Fiber Reinforced Plastic Member For the sample, the same test piece as that used for measuring the thickness of the component [B] was used. First, surface unevenness profiles were obtained at any five locations of the sample using a contact-type surface roughness meter, Surfcoder SE3400 manufactured by Kosaka Laboratory. At this time, measurement was performed while changing the direction of measurement. At this time, the measurement distance was 10 mm, and the measurement speed was 2 mm / second. Further, the surface unevenness profile was output after being magnified 5000 to 20000 times so that the height of the unevenness could be recognized sufficiently. Next, as shown in FIG. 1, the intersection of the line connecting adjacent concave and convex portions and the line vertically lowered from the convex portion vertex, and the height R to the convex portion vertex, three places for each profile, a total of 15 The surface roughness was measured and the average value was calculated as the surface roughness.

(Comparative Example 1)
A fiber reinforced plastic member consisting only of the constituent element [A] was produced and subjected to various measurements.

  In this comparative example, a carbon fiber fabric was used as the component [A1], and a fiber reinforced plastic member was manufactured by the RTM method.

  A carbon fiber woven fabric 4ply cut so that each side is a square with a side of 300 mm parallel to either warp or weft was laminated in a mold, and a peel ply and a resin distribution medium were laminated thereon. Next, bagging was performed using a nylon film, and the pressure was reduced to [atmospheric pressure-0.1] (MPa) using a vacuum pump. Then, the mold was held at 90 ° C., and an RTM resin composition was injected. Injection was terminated 5 minutes after the RTM resin composition flowed into the mold, and demolding started 40 minutes after the RTM resin composition flowed into the mold to obtain a fiber-reinforced plastic member. .

  The Vf of the component [A] was 51% and was sufficiently high.

When the basis weight of the fiber reinforced plastic member was measured, it was 1270 g / m ² , and it was found to be very lightweight.

  However, when the surface roughness of the fiber reinforced plastic member was measured, it was 1.60 μm, and it was found that the surface smoothness was insufficient.

(Comparative Example 2)
A fiber reinforced plastic member composed only of the constituent element [A] and the constituent element [C] was manufactured, and various measurements were performed.

  In this comparative example, a fiber reinforced plastic member was manufactured by the RTM method using a carbon fiber fabric as the component [A1] and a carbon fiber mat as the component [C1].

  A carbon fiber mat 2ply cut so as to be a square with a side of 300 mm is laminated on a mold, and then a carbon fiber fabric 4ply cut so that each side is a square with a side of 300 mm parallel to either warp or weft The peel ply and the resin distribution medium were laminated thereon. After lamination, molding was performed in the same manner as in Comparative Example 1 to obtain a fiber reinforced plastic member.

  The Vf of the component [A] was 51% and was sufficiently high.

  Moreover, the thickness, basis weight, elastic modulus, and fiber volume content of the component [C] showed good values. The glass transition temperature was sufficiently high.

When the basis weight of the fiber reinforced plastic member was measured, it was found to be 1600 g / m ² and very light.

  However, when the surface roughness of the fiber reinforced plastic member was measured, it was 0.69 μm, and it was found that the surface smoothness was improved, but it was still insufficient.

(Comparative Example 3)
A fiber reinforced plastic member composed only of the constituent element [A] and the constituent element [C] was manufactured, and various measurements were performed.

  In this comparative example, a fiber reinforced plastic member was manufactured by the RTM method using a carbon fiber fabric as the component [A1] and a carbon fiber mat as the component [C1].

  A carbon fiber mat 4ply cut so as to be a square with a side of 300 mm is laminated on a mold, and then a carbon fiber fabric 4ply cut so that each side is a square with a side of 300 mm parallel to either warp or weft The peel ply and the resin distribution medium were laminated thereon. After lamination, molding was performed in the same manner as in Comparative Example 1 to obtain a fiber reinforced plastic member.

  The Vf of the component [A] was 51% and was sufficiently high.

  Moreover, the elastic modulus, fiber volume content, etc. of the constituent element [C] showed good values. The glass transition temperature was sufficiently high.

When the basis weight of the fiber reinforced plastic member was measured, it was found to be 1900 g / m ² and very light.

However, when the surface roughness of the fiber reinforced plastic member was measured, it was 0.58 μm, and the surface smoothness was improved, but it was found that it was still insufficient.
Example 1
A fiber reinforced plastic member is manufactured which is composed of the constituent elements [A], [B], and [C], and the constituent element [C] is disposed on one side of the constituent element [A] via the constituent element [B]. Various measurements were performed.

  In this example, a carbon fiber woven fabric is used as the component [A1], a NBR sheet A having a thickness of 300 μm is used as the component [B1], a carbon fiber mat is used as the component [C1], and fiber reinforcement is performed by the RTM method. A plastic part was produced.

  The carbon fiber mat 2ply cut so as to be a square with a side of 300 mm is laminated on the mold, the NBR sheet A cut so as to be a square with a side of 300 mm is laminated, and then each side is either warp or weft A carbon fiber woven fabric 4ply cut so as to form a parallel square of 300 mm on one side was laminated on a mold, and a peel ply and a resin distribution medium were laminated thereon. After lamination, molding was performed in the same manner as in Comparative Example 1 to obtain a fiber reinforced plastic member.

  The Vf of the component [A] was 51% and was sufficiently high.

  Moreover, the thickness and basis weight of the component [B] showed good values. The elastic modulus was 4 MPa, which was found to be sufficiently low. It was also found that the glass transition temperature was sufficiently low and there was no melting point.

  Moreover, the thickness, basis weight, elastic modulus, and fiber volume content of the component [C] showed good values. The glass transition temperature was sufficiently high.

When the basis weight of the fiber reinforced plastic member was measured, it was found to be 1900 g / m ² and very light.

Moreover, when the surface roughness of the fiber reinforced plastic member was measured, it was found that the surface roughness was 0.17 μm and the surface smoothness was very excellent.
(Example 2)
A fiber reinforced plastic member is manufactured which is composed of the constituent elements [A], [B], and [C], and the constituent element [C] is disposed on one side of the constituent element [A] via the constituent element [B]. Various measurements were performed.

  In this example, a carbon fiber fabric is used as the constituent element [A1], a NBR sheet A having a thickness of 500 μm is used as the constituent element [B1], a carbon fiber mat is used as the constituent element [C1], and fiber reinforcement is performed by the RTM method. A plastic part was produced.

  The carbon fiber mat 2ply cut so as to be a square with a side of 300 mm is laminated on the mold, the NBR sheet A cut so as to be a square with a side of 300 mm is laminated, and then each side is either warp or weft A carbon fiber woven fabric 4ply cut so as to form a parallel square of 300 mm on one side was laminated on a mold, and a peel ply and a resin distribution medium were laminated thereon. After lamination, molding was performed in the same manner as in Comparative Example 1 to obtain a fiber reinforced plastic.

  The Vf of the component [A] was 51% and was sufficiently high.

  Moreover, the thickness and basis weight of the component [B] showed good values. The elastic modulus was 4 MPa, which was found to be sufficiently low. It was also found that the glass transition temperature was sufficiently low and there was no melting point.

  Moreover, the thickness, basis weight, elastic modulus, and fiber volume content of the component [C] showed good values. The glass transition temperature was sufficiently high.

When the basis weight of the fiber reinforced plastic member was measured, it was 2090 g / m ² , which was found to be relatively light.

Moreover, when the surface roughness of the fiber reinforced plastic member was measured, it was found that the surface roughness was 0.14 μm and the surface smoothness was very excellent.
(Example 3)
A fiber reinforced plastic member is manufactured which is composed of the constituent elements [A], [B], and [C], and the constituent element [C] is disposed on one side of the constituent element [A] via the constituent element [B]. Various measurements were performed.

  In this example, a carbon fiber fabric is used as the constituent element [A1], a NBR sheet A having a thickness of 600 μm is used as the constituent element [B1], a carbon fiber mat is used as the constituent element [C1], and fiber reinforcement is performed by the RTM method. A plastic part was produced.

  The carbon fiber mat 2ply cut so as to be a square with a side of 300 mm is laminated on the mold, the NBR sheet A cut so as to be a square with a side of 300 mm is laminated, and then each side is either warp or weft A carbon fiber woven fabric 4ply cut so as to form a parallel square of 300 mm on one side was laminated on a mold, and a peel ply and a resin distribution medium were laminated thereon. After lamination, molding was performed in the same manner as in Comparative Example 1 to obtain a fiber reinforced plastic.

  The Vf of the component [A] was 51% and was sufficiently high.

  Moreover, the thickness and basis weight of the component [B] showed good values. The elastic modulus was 4 MPa, which was found to be sufficiently low. It was also found that the glass transition temperature was sufficiently low and there was no melting point.

  Moreover, the thickness, basis weight, elastic modulus, and fiber volume content of the component [C] showed good values. The glass transition temperature was sufficiently high.

When the basis weight of the fiber reinforced plastic member was measured, it was found to be 2240 g / m ² and relatively light.

Further, when the surface roughness of the fiber reinforced plastic member was measured, it was found that the surface roughness was 0.12 μm and the surface smoothness was very excellent.
Example 4
A fiber reinforced plastic member is manufactured which is composed of the constituent elements [A], [B], and [C], and the constituent element [C] is disposed on one side of the constituent element [A] via the constituent element [B]. Various measurements were performed.

  In this example, a carbon fiber woven fabric is used as the component [A1], a NBR sheet A having a thickness of 300 μm is used as the component [B1], a carbon fiber mat is used as the component [C1], and fiber reinforcement is performed by the RTM method. A plastic part was produced.

  A carbon fiber mat 1ply cut so as to be a square with a side of 300 mm is laminated on the mold, and an NBR sheet A cut so as to be a square with a side of 300 mm is laminated, and then each side is either warp or weft. A carbon fiber woven fabric 4ply cut so as to form a parallel square of 300 mm on one side was laminated on a mold, and a peel ply and a resin distribution medium were laminated thereon. After lamination, molding was performed in the same manner as in Comparative Example 1 to obtain a fiber reinforced plastic.

  The Vf of the component [A] was 51% and was sufficiently high.

  Moreover, the thickness and basis weight of the component [B] showed good values. The elastic modulus was 4 MPa, which was found to be sufficiently low. It was also found that the glass transition temperature was sufficiently low and there was no melting point.

  Moreover, the thickness, basis weight, elastic modulus, and fiber volume content of the component [C] showed good values. The glass transition temperature was sufficiently high.

When the basis weight of the fiber reinforced plastic member was measured, it was found to be 1740 g / m ² and very light.

Moreover, when the surface roughness of the fiber reinforced plastic member was measured, it was found that the surface roughness was 0.43 μm and the surface smoothness was relatively excellent.
(Example 5)
A fiber reinforced plastic member is manufactured which is composed of the constituent elements [A], [B], and [C], and the constituent element [C] is disposed on one side of the constituent element [A] via the constituent element [B]. Various measurements were performed.

  In this example, a carbon fiber woven fabric is used as the component [A1], a NBR sheet A having a thickness of 300 μm is used as the component [B1], a carbon fiber mat is used as the component [C1], and fiber reinforcement is performed by the RTM method. A plastic part was produced.

  The carbon fiber mat 3ply cut so as to be a square with a side of 300 mm is laminated on the mold, the NBR sheet A cut so as to be a square with a side of 300 mm is laminated, and then each side is either warp or weft. A carbon fiber woven fabric 4ply cut so as to form a parallel square of 300 mm on one side was laminated on a mold, and a peel ply and a resin distribution medium were laminated thereon. After lamination, molding was performed in the same manner as in Comparative Example 1 to obtain a fiber reinforced plastic.

  The Vf of the component [A] was 51% and was sufficiently high.

  Moreover, the thickness and basis weight of the component [B] showed good values. The elastic modulus was 4 MPa, which was found to be sufficiently low. It was also found that the glass transition temperature was sufficiently low and there was no melting point.

  Moreover, the thickness, basis weight, elastic modulus, and fiber volume content of the component [C] showed good values. The glass transition temperature was sufficiently high.

When the basis weight of the fiber reinforced plastic member was measured, it was 2140 g / m ² , and it was found to be relatively light.

Moreover, when the surface roughness of the fiber reinforced plastic member was measured, it was found that the surface roughness was 0.13 μm and the surface smoothness was very excellent.
(Example 6)
A fiber reinforced plastic member is manufactured which is composed of the constituent elements [A], [B], and [C], and the constituent element [C] is disposed on one side of the constituent element [A] via the constituent element [B]. Various measurements were performed.

  In this example, a carbon fiber woven fabric is used as the component [A1], a NBR sheet A having a thickness of 300 μm is used as the component [B1], a carbon fiber mat is used as the component [C1], and fiber reinforcement is performed by the RTM method. A plastic part was produced.

  The carbon fiber mat 4ply cut so as to be a square with a side of 300 mm is laminated on the mold, the NBR sheet A cut so as to be a square with a side of 300 mm is laminated, and then each side is either warp or weft. A carbon fiber woven fabric 4ply cut so as to form a parallel square of 300 mm on one side was laminated on a mold, and a peel ply and a resin distribution medium were laminated thereon. After lamination, molding was performed in the same manner as in Comparative Example 1 to obtain a fiber reinforced plastic.

  The Vf of the component [A] was 51% and was sufficiently high.

  Moreover, the thickness and basis weight of the component [B] showed good values. The elastic modulus was 4 MPa, which was found to be sufficiently low. It was also found that the glass transition temperature was sufficiently low and there was no melting point.

  Moreover, the thickness, basis weight, elastic modulus, and fiber volume content of the component [C] showed good values. The glass transition temperature was sufficiently high.

When the basis weight of the fiber reinforced plastic member was measured, it was 2280 g / m ² , which was found to be relatively light.

Moreover, when the surface roughness of the fiber reinforced plastic member was measured, it was found that the surface roughness was 0.11 μm and the surface smoothness was very excellent.
(Example 7)
A fiber reinforced plastic member is manufactured which is composed of the constituent elements [A], [B], and [C], and the constituent element [C] is disposed on one side of the constituent element [A] via the constituent element [B]. Various measurements were performed.

  In this example, a carbon fiber woven fabric is used as the component [A1], a NBR sheet B having a thickness of 150 μm is used as the component [B1], a carbon fiber mat is used as the component [C1], and fiber reinforcement is performed by the RTM method. A plastic part was produced.

  A carbon fiber mat 2ply cut so as to be a square with a side of 300 mm is laminated on the mold, an NBR sheet B cut so as to be a square with a side of 300 mm is laminated, and then each side is either warp or weft A carbon fiber woven fabric 4ply cut so as to form a parallel square of 300 mm on one side was laminated on a mold, and a peel ply and a resin distribution medium were laminated thereon. After lamination, molding was performed in the same manner as in Comparative Example 1 to obtain a fiber reinforced plastic.

  The Vf of the component [A] was 51% and was sufficiently high.

  Moreover, the thickness and basis weight of the component [B] showed good values. The elastic modulus was 3 MPa, which was found to be sufficiently low. It was also found that the glass transition temperature was sufficiently low and there was no melting point.

  Moreover, the thickness, basis weight, elastic modulus, and fiber volume content of the component [C] showed good values. The glass transition temperature was sufficiently high.

When the basis weight of the fiber reinforced plastic member was measured, it was found to be 1790 g / m ² and very light.

Moreover, when the surface roughness of the fiber reinforced plastic member was measured, it was found that the surface roughness was 0.18 μm and the surface smoothness was very excellent.
(Example 8)
A fiber reinforced plastic member is manufactured which is composed of the constituent elements [A], [B], and [C], and the constituent element [C] is disposed on one side of the constituent element [A] via the constituent element [B]. Various measurements were performed.

  In this example, a carbon fiber fabric is used as the constituent element [A1], a NBR sheet B having a thickness of 300 μm is used as the constituent element [B1], a carbon fiber mat is used as the constituent element [C1], and fiber reinforcement is performed by the RTM method. A plastic part was produced.

  A carbon fiber mat 2ply cut so as to be a square with a side of 300 mm is laminated on the mold, an NBR sheet B cut so as to be a square with a side of 300 mm is laminated, and then each side is either warp or weft A carbon fiber woven fabric 4ply cut so as to form a parallel square of 300 mm on one side was laminated on a mold, and a peel ply and a resin distribution medium were laminated thereon. After lamination, molding was performed in the same manner as in Comparative Example 1 to obtain a fiber reinforced plastic.

  The Vf of the component [A] was 51% and was sufficiently high.

  Moreover, the thickness and basis weight of the component [B] showed good values. The elastic modulus was 3 MPa, which was found to be sufficiently low. It was also found that the glass transition temperature was sufficiently low and there was no melting point.

  Moreover, the thickness, basis weight, elastic modulus, and fiber volume content of the component [C] showed good values. The glass transition temperature was sufficiently high.

When the basis weight of the fiber reinforced plastic member was measured, it was found to be 1900 g / m ² and very light.

Further, when the surface roughness of the fiber reinforced plastic member was measured, it was found that the surface roughness was 0.12 μm and the surface smoothness was very excellent.
Example 9
A fiber reinforced plastic member is manufactured which is composed of the constituent elements [A], [B], and [C], and the constituent element [C] is disposed on one side of the constituent element [A] via the constituent element [B]. Various measurements were performed.

  In this embodiment, a carbon fiber fabric is used as the component [A1], a PUE sheet having a thickness of 300 μm is used as the component [B1], a carbon fiber mat is used as the component [C1], and fiber reinforced plastic is obtained by the RTM method. A member was manufactured.

  A carbon fiber mat 2ply cut so as to be a square with a side of 300 mm is laminated on the mold, a PUE sheet cut so as to be a square with a side of 300 mm is laminated, and then each side is parallel to either warp or weft A carbon fiber woven fabric 4ply cut so as to be a square with a side of 300 mm was laminated on a mold, and a peel ply and a resin distribution medium were laminated thereon. After lamination, molding was performed in the same manner as in Comparative Example 1 to obtain a fiber reinforced plastic.

  The Vf of the component [A] was 51% and was sufficiently high.

  Moreover, the thickness and basis weight of the component [B] showed good values. The elastic modulus was 95 MPa, which was found to be relatively low. It was also found that the glass transition temperature was relatively low and the melting point was sufficiently high.

  Moreover, the thickness, basis weight, elastic modulus, and fiber volume content of the component [C] showed good values. The glass transition temperature was sufficiently high.

When the basis weight of the fiber reinforced plastic member was measured, it was found to be 1950 g / m ² and very light.

Moreover, when the surface roughness of the fiber reinforced plastic member was measured, it was found that the surface roughness was 0.43 μm and the surface smoothness was relatively excellent.
(Example 10)
A fiber reinforced plastic member is manufactured which is composed of the constituent elements [A], [B], and [C], and the constituent element [C] is disposed on one side of the constituent element [A] via the constituent element [B]. Various measurements were performed.

  In this example, a carbon fiber fabric is used as the constituent element [A1], a NBR sheet A having a thickness of 300 μm is used as the constituent element [B1], a glass fiber mat is used as the constituent element [C1], and fiber reinforcement is performed by the RTM method. A plastic part was produced.

  A glass fiber mat 2ply cut so as to be a square with a side of 300 mm is laminated on the mold, and an NBR sheet B cut so as to be a square with a side of 300 mm is laminated, and then each side is either warp or weft A carbon fiber woven fabric 4ply cut so as to form a parallel square of 300 mm on one side was laminated on a mold, and a peel ply and a resin distribution medium were laminated thereon. After lamination, molding was performed in the same manner as in Comparative Example 1 to obtain a fiber reinforced plastic.

  The Vf of the component [A] was 51% and was sufficiently high.

  Moreover, the thickness and basis weight of the component [B] showed good values. The elastic modulus was 4 MPa, which was found to be sufficiently low. It was also found that the glass transition temperature was sufficiently low and there was no melting point.

  Moreover, the thickness, basis weight, elastic modulus, and fiber volume content of the component [C] showed good values. The glass transition temperature was sufficiently high.

When the basis weight of the fiber-reinforced plastic member was measured, it was found to be 1890 g / m ² and very light.

Moreover, when the surface roughness of the fiber reinforced plastic member was measured, it was found that the surface roughness was 0.40 μm and the surface smoothness was relatively excellent.
( Comparative Example 4 )
A fiber reinforced plastic member made of fiber reinforced plastic and constituent elements [B] and [C] and having a constituent element [C] disposed on one side of the fiber reinforced plastic through the constituent element [B] is manufactured. Measurements were made.

In this comparative example , a carbon fiber prepreg is used as the component [A2], a NBR sheet B having a thickness of 150 μm is used as the component [B2], and a thermosetting resin composition film is used as the component [C2]. A fiber-reinforced plastic member was produced by a method using

The thermosetting resin composition film 2ply cut so as to be a square with a side of 300 mm is laminated on the mold, the NBR sheet B cut so as to be a square with a side of 300 mm is laminated, and then a square with a side of 300 mm The carbon fiber prepreg 8ply cut so as to become was laminated in the order of (0 ° / 90 °) _2S . Next, after bagging with a bag film, using an autoclave, it was cured for 2 hours while being heated to 130 ° C. and pressurized to 0.3 MPa to obtain a fiber-reinforced plastic.

The Vf of the fiber reinforced plastic was 58%, which was sufficiently high.

  Moreover, the thickness and basis weight of the component [B] showed good values. The elastic modulus was 4 MPa, which was found to be sufficiently low. It was also found that the glass transition temperature was sufficiently low and there was no melting point.

  Moreover, the thickness, basis weight, elastic modulus, and fiber volume content of the component [C] showed good values. The glass transition temperature was sufficiently high.

When the basis weight of the fiber reinforced plastic member was measured, it was 1870 g / m ² , and it was found to be very lightweight.

Moreover, when the surface roughness of the fiber reinforced plastic member was measured, it was found that the surface roughness was 0.10 μm and the surface smoothness was excellent.
(Comparative Example 5 )
A fiber reinforced plastic member made only of fiber reinforced plastic was manufactured and subjected to various measurements.

In this comparative example , a carbon fiber prepreg was used as the component [A2] to produce a fiber reinforced plastic member.

A carbon fiber prepreg 8ply cut so as to be a square with a side of 300 mm was laminated on the mold in the order of (0 ° / 90 °) _2S . Next, after bagging with a bag film, using an autoclave, it was cured for 2 hours while being heated to 130 ° C. and pressurized to 0.3 MPa to obtain a fiber-reinforced plastic.

The Vf of the fiber reinforced plastic was 58%, which was sufficiently high.

When the basis weight of the fiber reinforced plastic member was measured, it was found to be 1430 g / m ² and very light.

  Moreover, when the surface roughness of the fiber reinforced plastic member was measured, it was found that the surface roughness was 0.60 μm and the surface smoothness was insufficient.

  The present invention can be applied not only to the use of the outer plate of a single vehicle or an automobile, but also to the use of aerodynamic members such as a rear spoiler and an engine undercover, but the application range is not limited thereto.

FIG. 1 is a surface unevenness profile obtained by a contact-type surface roughness meter used for calculating the surface roughness.

Claims (7)

It includes the following components [A], [B], and [C], and the component [C] is disposed on at least one side of the component [A] via the component [B]. Fiber reinforced plastic member.
[A] Fiber reinforced plastic including woven or knitted reinforced fiber and thermosetting resin [B] Low elastic modulus surface layer having a tensile modulus of 0.1 to 500 MPa [C] Tensile modulus of 1000 to 30000 MPa A high modulus surface layer The fiber-reinforced plastic member according to claim 1, wherein the ratio of the tensile elastic modulus of the constituent element [B] to the tensile elastic modulus of the constituent element [C] is 0.0003 to 0.01. The fiber-reinforced plastic member according to claim 1 or 2, wherein the component [B] includes an elastomer. The fiber-reinforced plastic member according to claim 3, wherein the elastomer comprises at least one selected from silicone rubber, ethylene propylene rubber, acrylonitrile butadiene rubber, chloroprene rubber, and fluoro rubber. The fiber-reinforced plastic member according to any one of claims 1 to 4, wherein the constituent element [C] includes a reinforcing fiber. The fiber-reinforced plastic member according to claim 5, wherein the reinforcing fibers contained in the constituent element [C] are randomly oriented. The fiber-reinforced plastic member according to any one of claims 1 to 6, wherein the surface roughness is 0.5 µm or less .

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