JP2001322179A - Sheet material made of frp - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a sheet material made of FRP which is suitable for transportation equipment and the like and light in weight, which has not only high rigidity and high strength, but also a surface quality sustaining the use for a long time and which is friendly to the environment and has the structure, material and surface properties of an outside sheet made of FRP. SOLUTION: This sheet material made of fiber reinforced plastic (hereinafter abbreviated as FRP) is prepared by coating a sheetlike matter made of the FRP using the textile constituted of carbon fibers as a reinforcing base, and the image sharpness of the surface thereof is 50% or above.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a plate made of FRP which is suitable as an outer plate of transportation equipment and industrial machines.

[0002]

2. Description of the Related Art Since FRP has excellent corrosion resistance, it has been attempted to use it as an outer plate of transportation equipment such as automobiles and various industrial machines. For example, an FRP called SMC (Sheet Molding Compound) is widely used for an outer plate such as a hood and a fender of an automobile.

[0003] SMC (see Japanese Patent Application Laid-Open No. 6-286008) is a slurry-like intermediate base material in which reinforcing fibers of glass short fibers (several cm in length) are mixed with polyester resin and the like. To form a base plate as an outer plate by shaping with a high pressure press (50 atm or more). Next, the surface of the base plate is scraped off with a sandpaper or a file to make it flat and smooth, and then colored to be painted.
It becomes an outer plate made of RP.

[0004] An outer plate made of SMC has a lower rigidity than a continuous fiber as a reinforcing fiber because the reinforcing fiber is a short fiber (non-continuous fiber). The elastic modulus is 70 GPa, which is 1/3 of the elastic modulus of steel 210 GPa), the thickness of the outer plate is larger than the metal outer plate, and it may not always be lighter than the metal outer plate. In many cases, even if it can be done, it will stay small. In addition, since the SMC skin is not continuous in fiber, the strength which is an important property as a skin other than the rigidity, particularly, the penetration is easily damaged by a local impact such that a flying object collides with the skin. Therefore, for skins used outdoors such as transportation equipment, it is necessary to take further protective measures for shock resistance such as increasing the thickness or sticking rubber, and a lightweight skin that can substitute a metal skin in terms of weight, that is, It is not an environmentally friendly skin for transport equipment.

[0005] However, the main reason why the outer plate made of SMC has been put to practical use is that the short fibers are randomly (almost uniformly) dispersed. This means that a uniform surface quality can be easily obtained. When continuous fibers are used, the unevenness of the surface of the base plate is larger than that of the short fibers due to uneven distribution of the fibers, unevenness due to meandering of the fibers, undulation, crossing of the fibers, and the like. This is because the labor of the shaving operation is large, and 2) the reinforcing fibers that are continuous during the shaving are also shaved, resulting in a problem that the mechanical and functional properties of the outer plate are further reduced.

[0006] Continuous fibers are preferred because a lighter outer panel having higher physical properties can be obtained in terms of rigidity and strength. However, the forms of continuous fibers are complex and diverse, such as unidirectional prepregs, woven fabrics, and three-dimensional woven fabrics, and none of them has been put to practical use.

On the other hand, members using continuous fibers as reinforcing fibers have been studied. RTM (resin transfer molding) where prepregs composed of continuous fibers and resin arranged in one direction are laminated on a mold and cured with an autoclave or the like, or a preform such as a woven fabric is set in the mold and resin is injected. ), Etc., but as described above,
The surface quality is low due to unevenness and uneven thickness due to fiber meandering, waviness, crossing of fibers, etc., which is unique to continuous fibers, and it has not been put to practical use as an outer plate of transportation equipment such as automobiles. Is the actual situation.

In order to improve the surface quality, a coating method called gel coating is employed. The gel coating method (see Japanese Patent Application Laid-Open No. H11-171942) is a method in which a resin material such as polyester which can be a surface of an outer plate is coated on an inner surface of a mold in advance, and a reinforcing fiber base is disposed on the main coating. Closing the mold, injecting the resin, curing, removing the mold, and transferring the coating to the surface of the FRP outer plate. This method is industrially effective because the shaving and painting of the surface can be omitted, but when it is cured by heating, the molded product as a whole is ineffective due to the difference in the linear expansion coefficient between the FRP and the gel coat layer. It is not suitable for an outer plate that requires precision because of deformation such as cracking, and the gel coat layer is not suitable for an outer plate due to cracking or wrinkling.
Further, as described above, FR using continuous fibers as reinforcing fibers
Since the surface of P is uneven, the thickness of the gel coat is 200
It is thicker than the coating film when coated with a micron or more, not only increases the weight, but also has the disadvantage that when the outer plate is deformed by the external force, the gel coat layer breaks or peels off and is not suitable for the outer plate .

In the case of an outer panel used outdoors, moisture or rainwater or the like invades the inside of the FRP, and the crack and peeling of the gel coat layer may impair the lightweight and durability characteristics of the FRP. In addition, in the case of gel coat, compared to painting, there are extremely few color choices, it does not show an appearance rich in metallic feeling and fashionability, and it is necessary for color matching with other members, such as automobile skin, There is a problem that the value of the entire product is reduced and cannot be applied. There is also a concept of applying a coating on the gel coat layer, but in this case, a penalty of further weight increase and cost increase occurs.

As described above, FRP using continuous fiber
There are few practical examples of outer panels,
Actually, no quantitative index of the structure and surface quality of the RP skin has been established.

Regarding the criterion of the surface of the metal outer plate, it is apparent from many years' experience that gloss meters and tension meters are used confidentially by each company.
Since FRP has different mechanical properties, hardness, and coefficient of linear expansion from metals, practical surface criteria are different from those of metals. A low-dimensional technology that can simply apply that of metal does not result in a practically usable FRP skin.

For example, in the case of a metal outer plate, if a tool or the like falls during manufacturing, dents (permanent deformation) occur due to plastic deformation, and the quality of the surface can be easily determined by visual inspection. There is no dent that can be determined, and peeling occurs inside.

Therefore, if the dent of the surface is determined based on the same criteria as the metal, the peeling inside the FRP is overlooked, and the internal peeling proceeds during long-term use, and the performance as the outer plate cannot be maintained. Further, not only does the water accumulate in the peeling portion, which increases the weight, but also the water evaporates as the temperature rises and pushes up the coating film from the inside, causing the coating film to swell.

The linear expansion coefficient of the FRP in the thickness direction is larger than that of metal. If the surface has poor smoothness, rainwater and the like are stagnant due to deformation due to temperature change, and the lens effect due to light rays such as ultraviolet rays is caused. The unevenness of the coating deteriorates, resulting in a mottled outer plate.

Now, it has been found that the surface quality of the outer plate has a great effect on the fluid resistance to air and water in addition to the above-mentioned merchantability and long-term durability. In general, moving equipment such as boats, ships, and the like are required to have improved surface quality for energy saving. Normally, when the outer plate is made of FRP for the purpose of light weight, since the elastic modulus is lower than that of metal, the transport device is greatly deformed and the flow resistance changes more than the air resistance received while moving at high speed. From such a thing, F
For the RP surface, criteria different from the metal material should be set independently.

Again, F using continuous fibers
In order to put the RP skin into practical use, it is required to establish comprehensive technologies such as a structure, a material, and a quantitative index of surface quality suitable for the FRP skin.

[0017]

An object to be solved by the present invention is to solve the above-mentioned overall problem of the structure, material, and surface of an FRP outer plate using continuous fibers.

That is, an object of the present invention is to provide an environment-friendly FRP made of a light-weight, high-rigidity and high-strength material that is suitable for transportation equipment and has a surface quality that can withstand long-term use. FRP with plate structure, material and surface properties
It is to provide a board material.

[0019]

In order to achieve the above object, the present invention has the following arrangement. That is, (1) a plate material obtained by applying a coating to a plate made of a fiber-reinforced plastic using a woven fabric made of carbon fibers as a reinforcing base material,
An FRP plate material having a surface image clarity of 50% or more.

(2) The basis weight (Wg /
m ² ) to thickness (tmm) (W / t) is 700 to 1
700. The FRP plate material according to (1), wherein the FRP plate material is within a range of 700.

(3) The FRP plate material according to any one of (1) and (2), wherein the carbon fiber woven fabric has a cover factor in a range of 90 to 100%.

(4) The FRP plate according to any one of the above (1) to (3), wherein the FRP plate is an outer plate for transportation equipment.

(5) The F according to any one of (1) to (4), wherein the woven fabric is in the outermost surface layer of the plate.
RP plate material.

(6) The thickness of the coating is 20 to 200 μm
The FRP plate material according to any one of the above (1) to (5), which is:

(7) The F according to any one of (1) to (6), wherein the coating is a clear coating.
RP plate material.

[0026]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described in detail based on an embodiment shown in FIG. First, the FRP board 1 of the present invention uses a woven fabric 3 made of continuous carbon fibers as a reinforcing base material.

The plate material here is not limited to a flat plate,
Of course, a plate having a curvature is also included.

By using continuous carbon fibers as reinforcing fibers,
High elastic modulus and strength, which are one of the characteristics of carbon fiber, can be exhibited, and resistance to dents required for an outer plate, rigidity, and strength can be achieved with light weight. And since it is a continuous fiber, the penetration impact resistance which is a very important property for the outer panel can be obtained. That is, rigidity and impact characteristics can be obtained with a light weight that cannot be achieved with short single fibers. Of course, deformation resistance, maximum load, displacement, and energy absorption are also large.

Further, since the continuous fibers are in the form of a woven fabric, the penetration resistance is higher than that obtained by laminating prepregs arranged in one direction, even though the reinforcing fibers have the same amount. This is because, in principle, the woven fabric has a net-like structure in which fibers intersect, and can catch flying objects.

The woven fabric has two layers (single layer) orthogonal to each other.
The physical properties in the directions are equal, and the outer plates can be configured with a smaller number of sheets, and the weight can be reduced, as compared with the case where prepregs arranged in one direction are stacked. For example, if an outer plate is formed by laminating two prepregs orthogonally, an out-of-plane torsional deformation called a saddle shape occurs due to heat shrinkage during curing. The out-of-plane deformation is caused not only by external force but also by a temperature change. It also occurs when an in-plane stress acts on the outer plate, which deforms the outer plate into an irregular shape, which is not preferable in terms of appearance and aerodynamics.

In order to realize a structure corresponding to a woven fabric with a prepreg, at least three sheets (4 in the case of the same prepreg) are used.
Sheets) are required. That is, a woven fabric is more suitable for reducing the weight of a thin outer panel having a thickness of only a few mm than a prepreg laminate.

Further, the reinforcing fibers are made lightweight and have a high elastic modulus,
By using high-strength carbon fibers, the outer plate is lightweight and has high mechanical properties, and is also excellent in environmental resistance.

Further, a coating 2 is applied to the outer panel. The coating is not only thinner (typically 150 microns or less) and lighter than the gelcoat, but also has many options in properties as well as color. By selecting an appropriate paint, the gloss and unevenness of the surface, low and high temperature environments, water resistance, UV resistance environment, etc.
This is because properties and functions that cannot be completely covered can be imparted to the RP portion, and practicality as an outer plate is generated for the first time. For example, in the case where the resin portion of the FRP is a resin that is weak against ultraviolet rays, by applying a coating excellent in ultraviolet rays,
It can impart ultraviolet light resistance as an outer plate. Of course, various appearances (make-up) are possible, and painting is preferable in terms of design. In the outer panel, it is necessary to perform color matching with other members in consideration of safety and the like, and delicate color matching becomes possible by painting. In addition, by coating, moisture and light rays do not directly enter the FRP, so that a highly durable outer panel having excellent environmental resistance can be obtained. The coating also affects the image clarity described below, and is preferable in terms of fluid resistance.

Preferably, the thickness of the coating is from 20 microns (μm) to 200 microns (μm) or less. If it exceeds 200 microns, the coating film tends to peel off, which is not preferable in terms of mechanical properties and appearance. On the other hand, when the thickness is less than 20 microns, light rays such as sunlight are directly incident, which may cause deterioration or uneven coating, which is not preferable in terms of design. By being within this range, the weight of the FRP outer plate is not increased and the FRP outer plate is preferable in terms of durability. More preferably, it is 40 to 100 microns.

Next, the outer plate surface 4 of the present invention has an image sharpness of 50% or more. Image sharpness (S) means ASTM
The two numerical values NSIC * (A) and NSIC (B) are described in ASTM D5767 using a commercially available tester (for example, S89-A manufactured by Suga Test Instruments Co., Ltd.).
Measure according to D5767. A is called “clouds and rainbows”, and B corresponds to “snow and avatars”.

In the present invention, S = ｛0.75 × A + 0.2
The value calculated by the formula of 5 × B｝ × 100/100 is defined as image sharpness (S). In this range, the FRP skin becomes an extremely practical skin and is a preferred member for transportation equipment.

The fact that A is high does not mean that there is no blur and there is no merchantability, but that it reflects more light and can suppress deterioration and temperature rise due to light. further,
It is easy for a third party to easily recognize the image by visual inspection or the like, which is preferable in terms of safety.

Another B corresponds to unevenness (scratch) on the order of microns. Stress concentration at the tip of the flaw increases according to the size of the flaw, and destruction from the tip of the flaw proceeds. Therefore, the smaller the flaw, the higher the durability of the outer plate. The larger the value of B obtained by the image rendition measuring device is, the smaller the size of the flaw is, which is preferable as the outer plate. Further, the outer plate having a large roughness tends to adhere dirt, and the dirt accumulates to lower the smoothness of the surface and increase the fluid resistance. Furthermore, it corresponds to the size limit of a flaw that can be detected by a human.

When the value of the image clarity is 70% or more, the appearance becomes high and the outer plate is further provided, which is preferable. For reference, the present image clarity can be applied to a metal outer plate, but the level of the metal outer plate performed by the inventors was varied, with 40 to 60% being the most.

Hereinafter, the present invention will be described in more detail.

First, the carbon fiber in the present invention is PAN
Either (polyacrylonitrile) type or pitch type can be used. PAN-based carbon fiber has strength,
It is more preferable from the viewpoint of the balance between elastic modulus and elongation in fabricating the fabric. For outer panels, the higher the strength and the elastic modulus, the better. However, in order to impart impact resistance, the elongation is 1.4.
% Or more of carbon fibers is preferred. FRP elongation is JIS
It is determined according to K-7054, and strictly means tensile fracture strain.

The carbon fiber is formed into a woven form such as plain weave, twill weave, or satin weave in a continuous fiber state. In particular, in the woven fabric in the present invention, the ratio (W / t) of the basis weight (Wg / m ² ) and the thickness (tmm) of the carbon fiber woven fabric is preferably in the range of 700 to 1700. The woven fabric within this range is called a thin material, which is thin for the basis weight, has a structure in which the fibers are spread, and has small undulation in the thickness direction of the fibers.
High strength and rigidity are realized, and the outer panel can be made lighter. In addition, since the irregularities on the surface of the woven fabric are small, the surface quality of the outer plate is also improved, and high image clarity can be secured with a thinner coating film. The basis weight and thickness of the fabric are JIS R7
Measure according to 602.

Further, when the cover factor of the carbon fiber woven fabric is in the range of 90 to 100%, the portion composed of only the resin is extremely small, the out-of-plane impact characteristics are increased, and the resin is shrunk in the thickness direction. Surface unevenness and unevenness are eliminated, and high image clarity is obtained, which is preferable. Assuming that the flying object is a small piece in the penetrating impact, a more preferable cover factor is in the range of 95 to 100%.

The cover factor Cf of the carbon fiber fabric is
As described and defined in Japanese Patent Application Laid-Open No. Hei 7-118988, when an area having an area S1 is set on a woven fabric by an element related to the size of a void formed between yarns, the area S1 In S2, the area of the void formed between the yarns is
Means the value defined by the following equation.

Cover factor Cf = ｛(S1-S2)
/ S1｝ × 100 In addition, since the woven fabric contributes to particularly important surface rigidity and surface quality among the physical properties of the outer plate, the position of the woven fabric is preferably near the surface layer of the plate. . The presence of the high-rigidity carbon fibers on the surface layer of the outer panel increases the surface rigidity of the outer panel, and enables weight reduction. The most preferred location is the outermost layer. In addition, when a multiaxial fabric such as a biaxial or triaxial fabric is present in the outermost layer, a unique fabric design can be imparted to the outer plate. Further, by arranging the woven fabric having the relationship between the basis weight and the thickness in the above range as the outermost layer, the surface of the outer plate becomes extremely smooth, and high image clarity can be obtained with a thin coating film.

That is, the basis weight (Wg /
m ² ) to thickness (tmm) (W / t) is 700 to 1
The thin woven fabric in the range of 700 has a small unevenness and meandering in the thickness direction of the fiber, so when it is used as an outer plate, the thickness change of the resin layer on the surface is small, and it is smoother before and after coating. This is because a good surface can be obtained.

Further, when the cover factor is 90 to 10
When it is within the range of 0%, since there is no portion made of only resin in the thickness direction of the outer plate, extremely important characteristics in terms of durability, such as image clarity, are improved and practicality is enhanced, which is preferable.

Next, other than carbon fibers, inorganic fibers such as glass fibers, alumina fibers and silicon nitride fibers, and organic fibers such as aramid fibers and nylon may be used in combination.
These long fibers, short fibers, woven or matted materials, or a mixture of these forms are regularly or irregularly arranged in carbon fiber or resin to provide impact resistance, vibration damping properties, etc. Can be improved.

Among them, glass fiber is inexpensive,
Good tensile strength balance. The glass fiber refers to a fibrous glass such as so-called E glass, C glass, or S glass containing silicon dioxide (SiO ₂ ) as a main component, and preferably has a fiber diameter of about 5 to 20 μm. The glass cloth improves the rigidity and, at the same time, retains the resin, so that the moldability is improved. Suitable is a basis weight of 20 g /
m ^{2 to} 400 g / m ² . When it is used for the surface layer, it is preferred that it is 20 to 50 g / m ² , because it does not impair the design of the woven fabric and can maintain the transparency.

The amount of glass fiber used is preferably 50% by weight or less of carbon fiber when rigidity is required, and is preferably 80% by weight or less when impact resistance is required.

Organic fibers are not brittle like carbon fibers and glass fibers, but are ductile, flexible, and do not easily break when bent. In addition, synthetic fibers have the advantage of not having the possibility of electric corrosion as compared with carbon fibers, and thus have the advantage of not requiring any measures against electric corrosion.

Further, when compared with glass fiber, it is easy to dispose because it can be burned. Further, since the specific gravity is about half that of glass fiber, the member can be made extremely lightweight. There are also features.

Next, the resin constituting the FRP of the present invention is:
Thermosetting resin such as epoxy resin, vinyl ester resin, unsaturated polyester resin, phenol resin, benzoxazine resin, or acrylic resin, polyethylene, polypropylene resin, polyamide resin, ABS resin, pottybutylene terephthalate resin, polyacetal resin, polycarbonate Thermoplastic resin such as resin, etc.
And modified resins obtained by alloying these resins.

Of these, epoxy resins, polyester resins, vinyl ester resins, and modified resins of these resins, which are excellent in chemical resistance, weather resistance, etc., are preferred. In addition, phenolic resins and benzoxazine resins are also excellent in flame retardancy and are preferred for outer panels requiring heat resistance.

Further, a transparent resin such as an acrylic resin or a polycarbonate resin is preferable in terms of design. Among them, acrylic resins are preferable because of their excellent weather resistance. Furthermore, the weather resistance can be further improved by adding 3 to 20% of an ultraviolet absorber, a solar absorber, and an antioxidant to these transparent resins.

Next, the ratio of the reinforcing fibers in the FRP is
It is preferable that the weight ratio is in the range of 30% to 75% with respect to the resin. If it is less than 30%, it may be necessary to sacrifice weight reduction in order to make the rigidity and impact resistance of the outer plate equal to those of the metal outer plate.

The reason why the content is 75% or less is that if the content is more than 75%, it becomes difficult to impregnate the resin, voids may be generated, and the physical properties may be unfavorable.

Although the thickness of the FRP outer plate varies depending on the application, it is preferably in the range of 0.5 to 8 mm in the case of the outer plate of transportation equipment running on the ground such as an automobile. Below this range, a problem may occur in the penetration resistance, and above this, the lightness is not sufficient.

In the case of transportation equipment moving in the sky, the speed is even faster, so that the range is preferably 1 to 10 mm.

It is also preferable to adopt a sandwich structure or a structure in which a frame is provided on a part of the outer plate.

Next, paints include, for example, silicone / epoxy resin paint, acrylic resin paint, urethane resin paint,
Polyester resin paint, epoxy resin paint, fluorine resin paint, cashew resin paint, alkyd resin paint, amino alkyd resin paint, phenol resin paint, oil paint,
It can be selected from synthetic resin paints such as oil varnish, nitric cellulose and lacquer, water-soluble resin paints, paints including primer surfacer, primer surfacer putty and the like.

The above coating materials are roughly classified into one-pack type, two-pack type,
Multi-component air drying or room temperature drying paint, baking paint,
It is broadly classified into UV curable paints, electron beam curable paints, etc. Further, they are called spray paint, roll paint, flow coater paint, brush paint, etc., depending on the coating method.

In selecting a coating material, it is preferable to select a coating composition having good adhesion to the FRP resin. Also, FR
Since P is inferior in UV resistance to metal, it is preferable to select a paint having excellent weather resistance. Specifically, they are called sun-blocking paints or ultraviolet-blocking paints.
Acrylic / urethane / epoxy / silcon paint with black pigments such as cobalt oxide, copper oxide, iron black, etc. And fluorine-based paints. In the case of clear coating, the above additives are particularly indispensable.

In addition, carbon black, graphite,
A conductive paint in which a conductive filler such as a metal powder is dispersed is preferable. Paints added with tin oxide or antimony oxide based conductors provide a transparent conductive coating, so use the design of carbon fiber fabrics and prevent dust and dirt from adhering to the outer panels of automobiles and the like due to static electricity. It is a preferred conductive paint for the purpose of imparting the effect of suppressing antistatic.

It is also effective to apply a luminescent paint (luminous paint) described in JIS K5671 to the whole or a part of the outer panel of the transport equipment which needs to call attention at night or the like. is there.

The coating method is spray (spray) coating (air gun or airless method, etc.), electrostatic coating (electrostatic spraying method, gun method, etc.), electrodeposition coating (cation type, anion type, etc.), powder coating In addition to (a thermal spraying method, a fluid immersion method, an electrostatic powder coating method, etc.), a known special coating method can be applied.

Among them, the FRP outer plate of the present invention is preferable because the heat resistance is lower than that of a metal,
C. or lower, electrostatic coating using FRP as an anode is preferable because of its excellent coatability. Further, since carbon fibers are conductive, electrostatic coating is also a preferable coating method because of high use efficiency of the coating.

The thickness of the coating is preferably in the range of 20 to 200 microns. As described above, if it is smaller than the above range, light rays such as ultraviolet rays may enter the FRP and reduce durability. Also,
If it is larger than this range, the coating film may peel off from the FRP when subjected to an impact or during long-term use. A more preferred coating thickness is between 40 and 100 microns. In addition, when applying this thickness coating, FRP
The surface of the molded plate is preferably subjected to degreasing or sanding for removing the release agent. By using a non-silicone-based release agent, degreasing and sanding operations can be eliminated or reduced. The coating temperature is closely related to the heat-resistant temperature of the outer plate, and it is preferable that the coating be dried near the heat-resistant temperature. In the case of a car outer panel, the heat-resistant temperature is about 100 ° C., and the drying temperature of the paint is 60 to 11
The temperature is preferably in the range of 0 ° C. The drying time is 3
Minutes to about 60 minutes.

The color of the coating is determined by the color arrangement with other members.
It is preferable that the P outer plate has a clear coating in which the state of deterioration of the FRP portion and the state of internal damage can be visually observed. By being clear, the state of the FRP can be grasped precisely, and there is also an effect that a third person who has only experience with a metal outer plate has a chance to use the FRP outer plate. Of course, the clear coating also has the effect of increasing the commercial value by utilizing the design of the woven structure. The clear coating may be on the whole or part of the outer panel.

The typical clear paints are silicone / epoxy paints and acrylic paints. However, urethane paints, mixtures of these paints, and alloy paints are colored clear. No problem.

The image sharpness of 50% or more can be achieved, for example, by arranging a woven substrate made of continuous carbon fiber in a metal mold having a surface accuracy of # 800 or more, evacuating the inside of the mold, and removing air bubbles. It can be obtained by injecting and curing a resin that has been performed for a long time at a mold temperature or higher, and then applying a uniform coating method such as a spray gun. Since the molding shrinkage and thermal shrinkage of the resin at the time of molding also affect the surface quality, an epoxy resin having a small molding shrinkage and a low shrinkage resin mixed with a filler such as talc or glass fine particles are preferable. The molding temperature is preferably at least 10 ° C. higher than the temperature at which the outer panel is used. The temperature is 90 ° C. or higher, more preferably 110 ° C. or higher, for an automobile outer panel.
As the carbon fiber woven fabric, a woven fabric having a structure in which the ratio between the basis weight and the thickness is large is appropriate. The coating is performed by a coating method such as a spray gun capable of forming a thin film uniformly. If the coating film is too thin or too thick, the clarity of the image tends to decrease.

In addition to the RTM molding method, any known molding techniques such as a hand lay-up method, a prepreg gray-up method, a pultrusion method (pull-out molding method), a pull wind method, a filament wind method, and a SCRIMP method may be used. .

The plate material of the present invention can be used as an inner / outer plate of transportation equipment such as automobiles, high-speed vehicles, high-speed boats, motorcycles, bicycles, and the like. Specifically, car panels such as doors, bonnets, fenders, trunk lids, hard disks, side mirror covers, etc., leading vehicle nose, roof,
Vehicle outer panels such as side panels and doors, wing inner panels and outer panels for wing trucks,
Aero parts such as air spoilers and side skirts to be mounted on cars and motorcycles, such as roofs and floors.

[0074]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The features of the FRP outer plate of the present invention will be described by way of examples. (Example 1) Plain weave structure made of carbon fiber (elastic modulus: 235 GPa, strength: 5 GPa, elongation: 2.1%) in a convex (male) mold having an ultra-mirror finish with # 1200 having the shape of an automobile door 5 cloths (basis weight 200g / m ² , thickness 0.2mm, cover factor 97%)
Close the female mold, inject epoxy resin at 80 ° C., and further heat (step cure) to 120 ° C. to obtain a thickness of 1.
A 0 mm outer plate was made. When the cross section was observed, the void was 1% or less, and the volume content (Vf) of the fiber was 55%.
%Met.

The base plate was degreased with acetone, sprayed with a urethane paint at room temperature to form a 50-micron coating film, and dried at 80 ° C. for 30 minutes.
% CFRP skin was obtained.

The outer panel was treated with a metal weather treatment apparatus for 48 hours, and subjected to a weather resistance test in which a color difference was measured by a color difference meter. When the change is large (Delta E is 5 or more), x; when the change is slight (Delta E is 3 or more and less than 5), Δ; when there is almost no change (Delta E is less than 3), o; (Delta E is 1 or less), the result of evaluation in four steps of ◎ was ◎.

Further, when the rigidity of this outer plate was measured by a bending test, the outer plate had a specific rigidity (elastic modulus / specific gravity) 1.5 times that of Al. "Dent resistance" was confirmed.

Further, the outer panel was arranged side by side with a commercially-available metal automobile outer panel, and a visual recognition test was conducted (a plurality of panels were arranged, and a sensory test was conducted to determine which draws attention or which stands out. Was evaluated in three steps of ×, outstanding ○, and extremely outstanding ◎).
Met. (Comparative Example 1) In Example 1, a cloth of a plain weave structure (basis weight 300 g / m) made of glass fiber (elastic modulus 70 GPa, strength 2.8 GPa, elongation 4%) was used as the carbon fiber fabric base material.
² , thickness 0.45mm, cover factor 85%)
An outer plate having a thickness of 1.2 mm was formed by RTM molding in the same manner as in Example 1 except that the sheets were stacked. No void was observed in the cross-section observation, and the volume content (Vf) of the fiber was 50%.

The base plate was degreased and coated in the same manner as in Example 1 to form a 70-micron coating film. The image clarity was 45%.

When the outer panel was subjected to the same weather resistance test, bending test, and recognizability test as in Example 1, the specific rigidity was found to be AL of 0.6.
×, the weather resistance was 、, and the recognition test was ×. (Comparative Example 2) The image clarity of the CFRP skin obtained in the same manner as in Example 1 except that the coating treatment was omitted was 58%.

The outer panel was subjected to the same weather resistance test, bending test, and recognizability test as in Example 1, and it was found that the specific rigidity was AL of 1.5.
×, the weather resistance was ×, and the recognition test was ◎. (Comparative Example 3) In Example 1, except that the surface after coating was polished with a file, the image clarity of the CFRP outer plate obtained in the same manner as in Example 1 was 35%.

When the outer panel was subjected to the same weather resistance test, bending test and recognition test as in Example 1, the specific stiffness was found to be AL of 1.5.
×, the weather resistance was ×, and the recognition test was ×. (Example 2) A carbon fiber (elastic modulus 240 GPa, strength 4.8) was placed on a flat plate type
GPa, elongation 2.0%), 12 sheets of satin-woven cloth (basis weight 200g / m ² , thickness 0.18mm, cover factor 99%) are stacked on top of each other. Injection and hardening were performed at a temperature of ° C. to prepare a 2.4 mm-thick outer plate. Observing the cross section,
The void was 1% or less, and the fiber volume content (Vf) was 56%.

A clear coating of 70 microns was formed directly on the flat plate with a silicone / epoxy paint to which an ultraviolet absorber was added. The image clarity of the outer panel was 90%.

When the outer panel was subjected to the same weather resistance test, bending test, and recognizability test as in Example 1, the specific rigidity was 1.6 at AL.
×, the weather resistance was ◎, and the recognition test was ◎. (Example 3) In Example 1, a cloth having a plain weave structure (basis weight 300 g / m ² , thickness 0.4 mm, made of carbon fiber (elastic modulus 240 GPa, strength 4.8 GPa, elongation 2.0%)) and a cover was used. An outer plate having a thickness of 1.4 mm was prepared in the same manner as in Example 1 except that four sheets of (factor 95%) were stacked. When the cross section was observed, the void was 1% or less, and the volume content (Vf) of the fiber was 48%.

The base plate was degreased and coated with urethane in the same manner as in Example 1 to form a coating film of 150 μm. The image sharpness was 51%. In addition, pits were found at various places on the surface.

The outer panel was subjected to the same weather resistance test, bending test, and recognizability test as in Example 1.
×, the weather resistance was Δ, and the recognition test was ○. (Comparative Example 4) An outer plate having a thickness of 1.4 mm (Vf = V) was obtained in the same manner as in Example 3 except that the carbon fiber fabric was misaligned and the cover factor was changed to 88%.
48%).

The underplate was degreased and coated with urethane in the same manner as in Example 1 to form a coating film of 150 μm. As a result, undulation was observed on the surface, and the image sharpness was 2%.

The outer panel was subjected to the same weather resistance test, bending test, and recognizability test as in Example 1.
×, the weather resistance was Δ, and the recognition test was ×.

The above results are summarized in Table 1.

[0090]

[Table 1]

[0091]

The FRP sheet material according to the present invention can exhibit the following remarkable functions and effects comprehensively, and becomes a sheet material that can be practically used for transportation equipment and the like. 1) Light weight by using continuous carbon fiber,
High strength and high rigidity can improve fuel efficiency of transportation equipment and reduce carbon dioxide emissions. 2) Since it is in the form of a woven fabric, it is possible to produce a lightweight thin plate material without warping, and at the same time, it has excellent impact damage resistance and is safe in the event of a collision in transportation equipment. 3) Since it has a coating, it can be an outer plate having environmental resistance and design properties. 4) Since the image clarity is 50% or more, it is safe to catch the eyes of a third party, and at the same time, the durability and the aerodynamic resistance characteristics can be expected to be improved.

[Brief description of the drawings]

FIG. 1 is a view showing a cross section of an FRP plate material of the present invention.

[Explanation of symbols]

 1: FRP plate 2: coating 3: continuous carbon fiber fabric 4: outer plate surface

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) C08L 101: 00 B29C 67/14 P

Claims (7)

[Claims] 1. A plate material obtained by coating a plate made of a fiber-reinforced plastic (hereinafter abbreviated as FRP) using a woven fabric made of carbon fibers as a reinforcing base material, and having a surface with a sharp image clarity of 50.
% Of FRP plate material. 2. The basis weight (Wg / m ² ) of the carbon fiber fabric.
And the ratio (W / t) of the thickness (tmm) to 700 to 1700
The FR according to claim 1, wherein
P plate material. 3. The cover factor of the carbon fiber fabric is 9
2. The method according to claim 1, wherein the value is in the range of 0 to 100%.
3. The FRP plate material according to any one of items 1 to 2. 4. The F-plate according to claim 1, wherein the FRP plate material is an outer plate for a transportation device.
RP plate material. 5. The FRP plate material according to claim 1, wherein the woven fabric is in the outermost surface layer of the plate. 6. The FRP plate material according to claim 1, wherein said coating has a thickness of 20 to 200 μm or less. 7. The FRP plate material according to claim 1, wherein said coating is a clear coating.