Cost Evaluation of Fiber Reinforced Thermoplastics for Mass Produced Cars

Cost Evaluation of Fiber Reinforced Thermoplastics for Mass Produced Cars

Kazuto TANAKA*, Toshiki UEMURA** and Tsutao KATAYAMA***

(Received October 19, 2009)

The utilization of plastic materials in automotive products is increasing because of environmental requirement on the automotive industry to produce light weight fuel efficient cars. Fiber Reinforced Plastics (FRP) have superior advantages of high-specific strength and high-specific modulus. For automotive products, however, FRP are not really used for mass-produced cars well due to its high cost. The utilization of FRP in automotive applications requires specific focus on manufacturing and cost constraints. High speed continuous Fiber Reinforced Thermoplastics (FRTP) process using electromagnetic induction heating system in combination with Non-woven Stitched Multi-axial Cloth (NSMC) was developed. This system can reduce production cycle times and the cost of manufacturing composite applications. This study presents the cost evaluation of FRTP manufactured by the high speed compression molding process. The evaluation takes into a count the material cost and the production cost. The cost of FRTP was compared with the costs of FRP made from prepreg and GMT.

-G[ YQTFU 㧦fiber reinforced plastics, cost evaluation, thermoplastic resin, non-woven stitched multi-axial cloth (NSMC), electromagnetic induction heating

ࠠ࡯ࡢ࡯࠼㧦❫⛽ᒝൻ᮸⢽ၮⶄว᧚ᢱ㧘ࠦࠬ࠻⹏ଔ㧘ᾲน႟ᕈ᮸⢽㧘ਇ❱Ꮣઃᄙጀᄙゲࠢࡠࠬ(NSMC)㧘㔚⏛⺃ዉടᾲ

㊂↥⥄േゞะߌ❫⛽ᒝൻᾲน႟ᕈ᮸⢽ၮⶄว᧚ᢱߩࠦࠬ࠻⹏ଔ

↰ਛ ๺ੱ㧘ᬀ᧛ ବၮ㧘 ጊ ொ↢

ߪߓ߼ߦ

⥄േゞ↥ᬺߦ߅޿ߡ㧘ൻ⍹Άᢱߩᨗᷢ໧㗴߿

CO

2

ߦࠃࠆ࿾⃿᷷ᥦൻ໧㗴╬ࠍ⸃᳿ߔࠆߚ߼ߦߪ㧘㊂↥

ゞਔߩゞ૕シ㊂ൻ߇ᔅⷐਇนᰳߣ⠨߃ࠄࠇߡ߅ࠅ㧘 ㇱຠߩ᮸⢽ൻ߇ᐢ߇ߞߡ޿ࠆ ^1㧕㧚․ߦ❫⛽ᒝൻ᮸⢽

ၮⶄว᧚ᢱ(Fiber Reinforced Plastics: FRP)ߪ㜞Ყᒝ ᐲ㧘㜞Ყ೰ᕈߣ޿߁ఝࠇߚᯏ᪾⊛․ᕈࠍᜬߜ㊄ዻ᧚

ᢱࠍ

FRPߦ⟎߈឵߃ࠆߎߣߦࠃࠆゞ૕ߩシ㊂ൻ߇ᦼ

ᓙߐࠇߡ޿ࠆ㧚

FRP

ߪ❫⛽ߣࡑ࠻࡝࠶ࠢࠬ᮸⢽ߢ᭴

ᚑߐࠇߡ߅ࠅ㧘❫⛽ߩ⒳㘃߿㊂㧘᮸⢽ߩ⒳㘃ߦࠃߞ ߡ᭽ޘߥᚑᒻᣇᴺ߇޽ࠅ㧘㕖Ᏹߦᐢ▸࿐ߥᯏ᪾⊛․

ᕈ㧘⵾ㅧ․ᕈࠍᜬߟ㧚߹ߚ㧘ᚑᒻᣇᴺߩ㆑޿ߦࠃࠅ ᯏ᪾⊛․ᕈߣࠦࠬ࠻߇ᄢ߈ߊ⇣ߥࠅ㧘❫⛽㧘᮸⢽㧘 ᚑᒻᣇᴺࠍㆡಾߦㆬቯߒലᨐ⊛ߦᵴ↪ߔࠆߎߣ߇᳞

߼ࠄࠇࠆ㧚

ߎࠇ߹ߢ⥄േゞߦ↪޿ࠄࠇߡ߈ߚ

FRP

᧚ᢱߣߒߡ ߪ ὇ ⚛ ❫ ⛽ ᒝ ൻ ᮸ ⢽ ၮ ⶄ ว ᧚ ᢱ

(Carbon Fiber Reinforced Plastics: CFRP)

ߣࠟ࡜ࠬ❫⛽ᒝൻ᮸⢽ၮ ⶄว᧚ᢱ(Glass Fiber Reinforced Plastics: GFRP)߇޽

ࠆ㧚

CFRP

ߪ὇⚛❫⛽ߩ㜞Ყᒝᐲ㧘㜞Ყ೰ᕈߣ޿߁

․ᕈߦ⿠࿃ߒߡ㧘FRPߩਛߢ߽㧘ᦨ߽Ყᒝᐲ㧘Ყ೰

ᕈ߇㜞ߊ㧘⥶ⓨᯏߥߤߩャㅍᯏེߦᄙߊ↪޿ࠄࠇࠆ㧚

* Department of Biomedical Engineering, Doshisha University, Kyoto TEL&FAX: +81-774-65-6408, E-mail: ktanaka@mail.doshisha.ac.jp

** E-mail: dmi0124@mail4.doshisha.ac.jp

*** E-mail: tkatayam@mail.doshisha.ac.jp

Table 1. Properties of reinforcement fibers

³⁾

.

Tensile strength

(GPa)

Tensile modulus (GPa)

Specific gravity Material cost (yen/kg) Carbon fiber (CF) (3K35t)

(12K24t) 6.2 4.2

310 240

1.8 1.8

9000 3500

Glass fiber (GF) 3.4 75.5 2.5 200

Table 2. Properties of matrix resins

⁴⁾

.

Bending strength

(MPa)

Bending modulus (MPa)

Specific gravity Material cost (yen/kg)

Epoxy (EP) 125 2840 1.15 1000

Polyamide 6 (PA6) 123 2500 1.14 500

Polypropylene (PP) 36 1300 0.9 100

ߒ߆ߒ㧘⥄േゞಽ㊁ߢߪࠦࠬ࠻߇㜞޿ߣ޿߁໧㗴߆ ࠄ৻ㇱߩ㜞⚖ゞߩᄖ᧼᧚߿࠼࡜ࠗࡉࠪࡖࡈ࠻߳ߩ૶

↪ߦߣߤ߹ߞߡ޿ࠆ㧚

CFRP

ߩᚑᒻᣇᴺߣߒߡߪࡊ

࡝ࡊ࡟ࠣࠍ↪޿ߡࠝ࡯࠻ࠢ࡟࡯ࡉߦࠃࠅᚑᒻߔࠆᚻ ᴺ߇ਥᵹߢ޽ࠅ㧘ࡑ࠻࡝࠶ࠢࠬ᮸⢽ߦߪࡊ࡝ࡊ࡟ࠣ

⵾ㅧᕈ㧘ᚑᒻᕈߥߤߩℂ↱߆ࠄਥߦࠛࡐࠠࠪ᮸⢽ߥ ߤߩᾲ⎬ൻᕈ᮸⢽߇૶↪ߐࠇߡ޿ࠆ㧚ߒ߆ߒ㊂↥ゞ ߦߪ㧘㜞ߓࠎᕈ㧘࡝ࠨࠗࠢ࡞ᕈ㧘㊂↥ᕈߥߤߦఝࠇ ߚᾲน႟ᕈ᮸⢽ࠍ↪޿ࠆߎߣ߇ㆡߒߡ޿ࠆߣ⠨߃ࠄ ࠇࠆ㧚

GFRP

ߪ㧘

CFRP

ߦᲧߴߡࠦࠬ࠻߇ૐߊ㊂↥⥄േゞ ߢᄙߊ↪޿ࠄࠇߡ޿ࠆ㧚ߘߩਛ㑆ၮ᧚ߣߒߡߪఝࠇ ߚ ↢ ↥ ᕈ ࠍ ᜬ ߟ

GMT(Glass Mat reinforced Thermoplastics)߇ᄙߊ↪޿ࠄࠇߡ޿ࠆ㧚ߒ߆ߒ㧘 GMT

ࠃࠅᚑᒻߒߚࠟ࡜ࠬ❫⛽ᒝൻᾲน႟ᕈ᮸⢽ၮⶄว᧚ ᢱ(Glass Fiber Reinforced Thermoplastics: GFRTP)ߪࠟ

࡜ࠬ❫⛽߇ਇㅪ⛯❫⛽ߣߥߞߡ޿ࠆߚ߼ߦ㧘Ყᒝᐲ㧘 Ყ೰ᕈ߇Ყセ⊛ૐߊ㧘ࠃࠅఝࠇߚᯏ᪾⊛․ᕈࠍᜬߟ

GFRTP

ࠍ⵾ㅧߔࠆߦߪ㧘ࠟ࡜ࠬㅪ⛯❫⛽ࠍ↪޿ࠆߎ

ߣ߇ᦸ߹ߒ޿ߣ⠨߃ࠄࠇࠆ㧚

ㅪ⛯❫⛽ࠍ↪޿ߚᾲน႟ᕈ᮸⢽ၮⶄว᧚ᢱߪ㜞೰

ᕈ㧘㜞ߓࠎᕈ㧘࡝ࠨࠗࠢ࡞ᕈߩὐߢ⥄േゞ↪᧚ᢱߣ ߒߡఝࠇࠆߣ⠨߃ࠄࠇࠆ㧚ߒ߆ߒ㧘ᾲน႟ᕈ᮸⢽ߪ ᾲ⎬ൻᕈ᮸⢽ߣᲧߴߡṁⲢ☼ᐲ߇㜞ߊ᮸⢽ߩ❫⛽߳

ߩ฽ᶐ߇࿎㔍ߢ޽ߞߚߎߣ߆ࠄ㊂↥ᕈߦ໧㗴߇޽ߞ ߚ㧚ㄭᐕ㧘ᚒޘߪ

FRTP

⵾ㅧᛛⴚߣߒߡਛ㑆ၮ᧚ߩ

NSMC(Non-woven Stitched Multi-axial Cloth)

ߣ㜞ㅦട ᾲ಄ළࠪࠬ࠹ࡓࠍ⚵ߺวࠊߖߚ

FRTP

㜞ㅦࡊ࡟ࠬᚑ ᒻᴺࠍ㐿⊒ߒߡ߈ߚ ²⁾㧚ߎߩᣂᚑᒻᣇᴺߢߪㅪ⛯❫

⛽ᒝൻ᮸⢽ၮⶄว᧚ᢱߩ㜞ㅦᚑᒻ߇น⢻ߢ޽ࠅ㧘ᚑ ᒻࠨࠗࠢ࡞ᤨ㑆ࠍ⍴❗ൻߔࠆߎߣ߇น⢻ߢ޽ࠆ㧚ᧄ ႎߢߪߎߩᣂᚑᒻᴺߦࠃࠅ⵾ㅧߒߚ

FRTP

ߩࠦࠬ࠻

⹏ଔࠍⴕ޿㧘ࡊ࡝ࡊ࡟ࠣ㧘

GMT

ߣᲧセ㧘ᬌ⸛ߔࠆߎ ߣ߆ࠄᣂᚑᒻᣇᴺߦࠃࠆ㊂↥⥄േゞ↪

FRP

ᚑᒻߩ᦭

↪ᕈࠍᬌ⸽ߔࠆ㧚

↢↥Ꮏ⒟߅ࠃ߮᧚ᢱ

↢↥Ꮏ⒟

੹࿁ߩࠦࠬ࠻⹏ଔߢߪ㧘ᒝൻ❫⛽ߣࡑ࠻࡝࠶ࠢࠬ᮸

⢽ࠍਛ㑆ၮ᧚ߦടᎿࠍߔࠆᎿ⒟㧔ਛ㑆ၮ᧚ടᎿᎿ⒟㧕 ߣ㧘ߘߩਛ㑆ၮ᧚ࠍടᾲ࿶❗ᚑᒻߒ㧘

FRP

ᚑᒻຠࠍ

⵾ㅧߔࠆᎿ⒟㧔ᚑᒻᎿ⒟㧕ߦಽߌߡ⠨߃ࠆ㧚ߘߩᎿ

⒟ࠍ

Fig. 1

ߦ␜ߔ㧚ᒝൻ❫⛽ߩᯏ᪾⊛ᕈ⾰³⁾߅ࠃ߮

᧚ᢱࠦࠬ࠻ࠍ

Table 1

ߦ㧘ࡑ࠻࡝࠶ࠢࠬ᮸⢽ߩᯏ᪾⊛

ᕈ⾰⁴⁾߅ࠃ߮ࠦࠬ࠻ࠍ

Table 2

ߦ␜ߔ㧚

Table 3

ߦฦਛ 㑆ၮ᧚ߩଔᩰࠍ␜ߔ㧚ਛ㑆ၮ᧚ߩଔᩰ߆ࠄ❫⛽ߣ᮸

⢽ߩଔᩰࠍᒁ޿ߚ߽ߩࠍਛ㑆ၮ᧚ടᎿ⾌ߣߔࠆ㧚߹

ߚ

FRP

ᚑᒻ⾌ߪੱઙ⾌ߦ⸳஻⾌ࠍട߃ߚ߽ߩߣߔࠆ㧚

ੱઙ⾌ߪᤨ⛎

1250

౞ߩ૞ᬺຬ߇ੑฬߢ૞ᬺࠍⴕ߁

߽ߩߣߒ㧘ߘࠇߙࠇߩ

FRP

ᚑᒻຠ৻ຠ޽ߚࠅߩ૞ᬺ

ᤨ㑆ಽߩੱઙ⾌ࠍ⸘▚ߔࠆ㧚߹ߚ㧘FRP㜞ㅦࡊ࡟ࠬ

ᚑᒻ㊄ဳߣࡊ࡟ࠬ⸳஻ߦ㑐ߒߡ㧘ߘࠇߙࠇߩଔᩰߣ

૶↪ᐕᢙ߆ࠄᚑᒻຠ㧝ߟ޽ߚࠅߩ

FRP㜞ㅦࡊ࡟ࠬ㊄

ဳ⾌߅ࠃ߮㧘ࡊ࡟ࠬ⸳஻⾌ࠍ⸘▚ߒ㧘㊄ဳ⾌ߦࡊ࡟

ࠬ⸳஻⾌ࠍട߃ߚ߽ߩࠍ⸳஻⾌ߣߔࠆ㧚

Table 4

ߦਛ 㑆ၮ᧚ടᎿ⾌ߣ

FRP

ᚑᒻ⾌ߩ⸘▚ߦ↪޿ߚ୯ࠍ␜ߔ㧚 ߥ߅㧘ਛ㑆ၮ᧚ߩ⒳㘃ߦࠃࠅᚑᒻߦᔅⷐߥ⸳஻ߪ⇣

ߥࠆ߇ᧄႎߢߪ◲නߩߚ߼㧘ߔߴߡߩ

FRP

ߦߟ޿ߡ 㜞ㅦࡊ࡟ࠬᚑᒻߦḰߕࠆ⸳஻ߢᚑᒻߔࠆ߽ߩߣߒ㧘

Table 4

߆ࠄ⸘▚ߒߚ

82

౞ࠍᚑᒻຠ㧝ߟ޽ߚࠅߩ⸳

஻⾌ߣߒߚ㧚

ਛ㑆ၮ᧚

ਇ❱Ꮣઃᄙጀᄙゲࠢࡠࠬ㧔0QPYQXGP 5VKVEJGF/WNVKCZKCN%NQVJ05/%㧕

ਇ❱Ꮣઃᄙጀᄙゲࠢࡠࠬ㧔

Non-woven Stitched Multi-axial Cloth: NSMC,

ࡌ࠾࡯࠻ࡗࡑ ⵾㧕ߪ㧘

Fig. 2

ߦ␜ߔࠃ߁ߦࡑ࠻࡝࠶ࠢࠬࠍਇ❱Ꮣߣߒ

ߡଏ⛎ߒ㧘ߎߩਇ❱Ꮣߣᒝൻ❫⛽ߩࡁࡦࠢ࡝ࡦࡊ ࡈࠔࡉ࡝࠶ࠢ㧔

Non-crimp stitched fabric: NCF,

Multi-axial multi-ply fabric: MMF

㧕ࠍ৻૕ߣߒߡࠬ࠹

࠶࠴ߒߚ߽ߩߢ޽ࠅ㧘⚛᧚ߩኈᤃߥࡂࡦ࠼࡝ࡦࠣࠍ ታ⃻ߒߚ᧚ᢱߢ޽ࠆ㧚ᧄႎߢߪ㧘ࡈࠖ࡜ࡔࡦ࠻ᢙ

12k

㧘 ᒢᕈ₸

24t

ࠣ࡟࡯࠼ߩ὇⚛❫⛽ࠍ↪޿ߚ

CF(Carbon Fiber)/PA6(Polyamide 6)

㧘

GF(Glass Fiber)/PA6

㧘

GF/PP(polypropylene)ߩਃ⒳㘃ߦߟ޿ߡࠦࠬ࠻Ყセ

ࠍⴕߞߚ㧚߹ߚ㧘㜞ㅦടᾲ಄ළࠪࠬ࠹ࡓࠍ↪޿ߚ㜞 ㅦࡊ࡟ࠬᚑᒻߦࠃࠅ

FRTP

ࠍᚑᒻߒ㧘ਃὐᦛߍ⹜㛎 ߦࠃࠅᒝᐲࠍ᷹ቯߒߚ㧚ߚߛߒ㧘

GF(Glass Fiber)/PA6

㧘

GF/PP(polypropylene)ߩੑ⒳㘃ߦߟ޿ߡߪ NSMC

ߢ ߪߥߊ㧘

NCF

ߣ᮸⢽ਇ❱ᏓࠍⓍጀߒᚑᒻߦ↪޿ߚ㧚

ࡊ࡝ࡊ࡟ࠣ

ࡊ࡝ࡊ࡟ࠣߪ⥶ⓨᯏ↪᧚ᢱߥߤߩ㜞ᕈ⢻

FRP

ߩㇱ

ຠߦ↪޿ࠄࠇࠆਛ㑆ၮ᧚ߢ޽ࠆ㧚ࡑ࠻࡝࠶ࠢࠬ᮸⢽

(a) Fabrication of semi products.

(b) Molding process.

Fig.1. Manufacturing process of FRP.

Table 4. Condition values of cost evaluation.

Prepleg 7200 NSMC(CF/PA6) 320 NSMC(GF/PA6) 320 NSMC(GF/PP) 280 Working times (s)

GMT 60

Employment cost (yen/h) 1250

Mold cost (yen) 6000000

Number of molding times of one mold (times)

230000

Molding system cost (yen) 50000000 Number of molding capacity of one system

(times)

900000 Table 3. Cost of semi product.

Prepleg (GF/EP) 5000 NSMC (CF/PA6) 1840

NSMC (GF/PA6) 590

Cost of semi-product (yen/m²)

NSMC (GF/PP) 200

Cost of semi-product (yen/kg)

GMT (GF/PP) 500

ߦߪᾲน႟ᕈ᮸⢽㧘ᾲ⎬ൻᕈ᮸⢽ߩਔᣇ߇↪޿ࠄࠇ ߡ޿ࠆ߇㧘ᦨ߽ᄙߊ↪޿ࠄࠇߡ޿ࠆߩߪᾲ⎬ൻᕈ᮸

⢽ߩࠛࡐࠠࠪ᮸⢽ࠍ↪޿ߚ߽ߩߢ޽ࠆ ⁵⁾㧚ߘߩടᎿ

Ꮏ⒟ࠍ

Fig. 3

ߦ␜ߔ㧚㈩೉ߒߚ㧘޽ࠆ޿ߪ❱ࠅ޽ߍ

ߚၮ᧚❫⛽ߦ㧘ࡑ࠻࡝࠶ࠢࠬ᮸⢽ࠍ฽ᶐߐߖ㧘৻ㇱ ᮸⢽ߩ⎬ൻ෻ᔕࠍㅴ߼ߡ㧘ขࠅᛒ޿߿ߔ޿ࠪ࡯࠻⁁

ߦߒߡ޿ࠆ㧚ᧄႎߢߪࡈࠖ࡜ࡔࡦ࠻ᢙ

3k

ᒢᕈ₸

35t

ࠣ࡟࡯࠼ߩ὇⚛❫⛽ߣ

130͠⎬ൻࠛࡐࠠࠪ᮸⢽߆ࠄ

᭴ᚑߐࠇࠆ

CF/EP(Epoxy)

ࡊ࡝ࡊ࡟ࠣߦߟ޿ߡࠦࠬ

࠻⹏ଔࠍⴕߞߚ㧚

)/6

GMT(Glass Mat reinforced Thermoplastics)

ߪ㧘቟ଔ ߥ

FRP

ߦ↪޿ࠄࠇߡ޿ࠆਛ㑆ၮ᧚ߢ޽ࠅ㧘⥄േゞߩ

ࡃ࠶ࠢ࠼ࠕࠗࡦ࠽࡯߿ࡃ࠶࠹࡝࡯࠻࡟࡯ߥߤߦㆡ↪

੐଀߇޽ࠆ⁷⁾㧚GMTߩടᎿᎿ⒟ࠍ

Fig. 4

ߦ␜ߔ㧚ࠟ

࡜ࠬ❫⛽ࡈࠔࡉ࡝࠶ࠢߦ࠾࡯࠼࡞ߢ❫⛽ಽᢔಣℂࠍ ⴕ޿㧘ࡐ࡝ࡊࡠࡇ࡟ࡦ(PP)ࠍࠟ࡜ࠬࡈࠔࡉ࡝࠶ࠢߦ ቢోߦ฽ᶐߐߖ᧼⁁ߩ

FRP

ߣߒߚ߽ߩ߇

GMT

ߢ޽

ࠆ㧚ടᾲࡊ࡟ࠬᚑᒻߦࠃࠅੑᰴടᎿࠍⴕ߁ߎߣߢ⋡

⊛ߩᒻ⁁ߦߔࠆߎߣ߇ߢ߈ࠆ㧚

ᚑᒻᣇᴺ㧔㔚⏛⺃ዉᕆㅦടᾲ࡮಄ළࠪࠬ࠹ࡓ㧕

ᚑᒻᎿ⒟ߦߪ

Fig. 5

ߦ␜ߔ㔚⏛⺃ዉടᾲࠍ↪޿ߚ ᕆㅦടᾲ࡮಄ළࠪࠬ࠹ࡓ

Cage System

^®㧔

Roctool

⵾㧕 ࠍ↪޿ߚ㧚એਅ㧘ᧄࠪࠬ࠹ࡓࠍ

IH system

ߣ⒓ߔࠆ㧚 ߎࠇߪ㧘ࠦࠗ࡞ߦᵹߒߚ੤ᵹ㔚ᵹߦࠃࠅ⏛⇇ࠍ⊒↢

ߐߖ㧘ࠦࠗ࡞ߩਛߩⵍടᾲ‛ߦ᷵㔚ᵹࠍ⺃⿠ߒ㧘ࠫ

ࡘ࡯࡞ᾲߦࠃࠅ⊒ᾲߔࠆේℂࠍᔕ↪ߒߚᛛⴚߢ޽ࠆ㧚

਄ਅߩ㊄ဳߦ⚵ߺㄟ߹ࠇߚࠦࠗ࡞ߦࠃࠅ㔚⏛⺃ዉࠍ

⿠ߎߒ㧘㊄ဳ⴫㕙ߩߺࠍടᾲߔࠆߚ߼㧘⍴ᤨ㑆ߢߩ ടᾲ߇น⢻ߢ޽ࠆ㧚߹ߚ㧘಄ළߪ㧘㊄ဳ⴫㕙⋥ਅࠍ ㅢࠆࡄࠗࡊߦ಄ළ᳓ࠍㅢߔߎߣߦࠃߞߡⴕ޿㧘ടᾲ ㇱߩ૕Ⓧ߇ዊߐ޿ߚ߼㧘⍴ᤨ㑆ߢߩ಄ළ߇น⢻ߣߥ ࠆ㧚

ᚑᒻਛߩ

IH system

㊄ဳ⴫㕙ߦ߅ߌࠆ᷷ᐲጁᱧࠍ

Fig.7

ߦ␜ߔ㧚ቶ᷷߆ࠄ㧘⚂

60

⑽㑆ߢ

250qC

߹ߢ਄

᣹ߐߖࠆߎߣ߇ߢ߈㧘⚂

120

⑽㑆ߢ಄ළߔࠆߎߣ߇ น⢻ߢ޽ࠆ㧚

ᚑᒻ᧦ઙ

ᚑᒻຠߪ

250mm˜400mm㧘ෘߐ 2mm

ߩ⭯᧼ߣߒ ߚ㧚ᚑᒻᤨ㑆ߦߟ޿ߡߪ

Table 4

ߦ␜ߒߚࠃ߁ߦࡊ࡝

ࡊ࡟ࠣߢߪ৻⥸⊛ߥ⎬ൻᤨ㑆ߢ޽ࠆ

2

ᤨ㑆ࠍᚑᒻᤨ

㑆ߣߒ㧘

NSMC

ߦߟ޿ߡߪߘࠇߙࠇߩ᮸⢽ߩⲢὐ߆ ࠄᚑᒻ᷷ᐲࠍ⸳ቯߒ㧘ᚑᒻ᷷ᐲ߹ߢߩടᾲ಄ළᤨ㑆

ࠍ

Fig. 6

ߦ␜ߔ㊄ဳ᷷ᐲጁᱧࠃࠅ᳞߼ߘࠇߦ଻ᜬᤨ

㑆ࠍട߃ߚᤨ㑆ࠍᚑᒻᤨ㑆ߣߒߚ㧚NSMC(CF/PA6) ߣ

NSMC(GF/PA6)

ߦߟ޿ߡߪᚑᒻ᷷ᐲࠍ

250

͠㧘଻

ᜬᤨ㑆ࠍ

90s

ߣ⸳ቯߒ㧘NSMC(GF/PP)ߦߟ޿ߡߪᚑ ᒻ᷷ᐲࠍ

230

͠㧘଻ᜬᤨ㑆ࠍ

90s

ߣ⸳ቯߒߚ㧚

GMT

ߦߟ޿ߡߪࠬ࠲ࡦࡇࡦࠣᚑᒻᤨ㑆

60s

ࠍ⸳ቯߒߚ

(42 ߩᒝᐲ

Table 5

ߦ␜ߔᒝᐲ㧘૕Ⓧ❫⛽฽᦭㊂ߣ

Table 1,2

ߦ␜ߔ᧚ᢱߩኒᐲࠃࠅᲧᒝᐲࠍ᳞߼ߚ㧚NSMCߦߟ Fig. 2. Fabricating process of NSMC.

Fig. 3. Fabricating process of prepreg.

Fig. 4. Fabricating process of GMT.

޿ߡߪ

IH system

ࠍ↪޿ߡ

FRP

ߩᚑᒻࠍⴕ޿㧘

JIS-K7017

ߦၮߠ޿ߚᦛߍ⹜㛎߆ࠄᓧࠄࠇߚᦛߍᒝ

ᐲࠍᒝᐲߣߒߚ㧚ࡊ࡝ࡊ࡟ࠣߣ

GMT

ߩᒝᐲߦߪᢥ

₂୯ ^{8, 9㧕}ࠍ↪޿ߚ㧚

⚿ᨐ߅ࠃ߮⠨ኤ ਛ㑆ၮ᧚ߩࠦࠬ࠻

Fig. 7

ߦ὇⚛❫⛽ࠍᒝൻ❫⛽ߣߒߚࡊ࡝ࡊ࡟ࠣߣ

NSMC

ߩ᧚ᢱ

1kg

޽ߚࠅߩࠦࠬ࠻ࠍ␜ߔ㧚

NSMC

ߩ

ࠦࠬ࠻ߪࡊ࡝ࡊ࡟ࠣߩࠦࠬ࠻ߩ⚂

40%

ߣߥߞߚ㧚ࡊ

࡝ࡊ࡟ࠣߩࠦࠬ࠻ߩਛߢᦨ߽ᄢ߈ߥഀวࠍ␜ߒߚߩ ߪਛ㑆ၮ᧚ടᎿ⾌ߢ޽ߞߚ㧚৻ᣇ

NSMC

ߢᦨ߽ᄢ߈ ߥഀวࠍ␜ߒߚߩߪ❫⛽ߢ޽ࠅ㧘NSMCߩਛ㑆ၮ᧚ ടᎿ⾌߇ࡊ࡝ࡊ࡟ࠣߩਛ㑆ၮ᧚ടᎿ⾌ߦᲧߴߡᄢ᏷

ߦ೥ᷫߢ߈ࠆߎߣ߆ࠄૐࠦࠬ࠻ߥਛ㑆ၮ᧚ߣߥߞߡ

޿ࠆߎߣ߇᣿ࠄ߆ߢ޽ࠆ㧚

Fig. 8

ߦࠟ࡜ࠬ❫⛽ࠍᒝൻ❫⛽ߦ↪޿ߚ

NSMC

ߣ

GMT

ߩ᧚ᢱ

1kg

޽ߚࠅߩࠦࠬ࠻ࠍ␜ߔ㧚 ߤߜࠄߩ ਛ㑆ၮ᧚ߦ߅޿ߡ߽ో૕ߩࠦࠬ࠻ߩᄢㇱಽࠍਛ㑆ၮ

᧚ടᎿ⾌߇භ߼ߡ޿ࠆߎߣ߇ࠊ߆ࠆ㧚߹ߚ

NSMC

ߢ

PA6

ࠍ↪޿ߚ‛ߣ

PP

ࠍ↪޿ߚ߽ߩߦߪਛ㑆ၮ᧚ో

૕ߩࠦࠬ࠻ߦߪᄢ߈ߥᏅߪߥߊ㧘᮸⢽ߩଔᩰ߇ਛ㑆 ၮ᧚ߩࠦࠬ࠻ߦ෸߷ߔᓇ㗀ߪዋߥ޿㧚߹ߚ

GMT

ߦ Ყߴߡ

NSMC

ߪ୚⒟ᐲߩࠦࠬ࠻ߣߥߞߡ߅ࠅ㧘ਛ㑆 ၮ᧚ടᎿ⾌ߩᏅ߇ᄢ߈ߊᓇ㗀ߒߡ޿ࠆ㧚

ᚑᒻຠ޽ߚࠅߩࠦࠬ࠻

Fig. 9

ߦ὇⚛❫⛽ࠍᒝൻ❫⛽ߣߒߚࡊ࡝ࡊ࡟ࠣߣ

NSMC

ߩᚑᒻຠߩࠦࠬ࠻ࠍ␜ߔ㧚

NSMC

ߩࠦࠬ࠻ߪ ࡊ࡝ࡊ࡟ࠣߩࠦࠬ࠻ߩ⚂

30

㧑ߣߥߞߚ㧚ߤߜࠄߩ႐ ว߽ਛ㑆ၮ᧚ടᎿ⾌ߣ❫⛽ߩ᧚ᢱ⾌߇ᄢ߈ߥഀวࠍ භ߼ߡ޿ࠆ㧚৻ᣇ㧘ࡊ࡝ࡊ࡟ࠣߢߪᚑᒻ⾌߇ో૕ߩ

35㧑⒟ᐲࠍභ߼ߡ޿ࠆߩߦኻߒ㧘 NSMC

ߢߪ

10㧑⒟

ᐲߒ߆ߥ޿㧚ᾲน႟ᕈ᮸⢽ࠍࡑ࠻࡝࠶ࠢࠬߦߔࠆߎ

0 50 100 150 200

0 50 100 150 200 250 300

Temperature C

Time s

Fig. 6. Temperature history of mould surface.

(a) Mould with IH system.

Heated surface Cold waterElectrical current Inductors

Electrical current

Heated surface Cold waterElectrical current Inductors

Electrical current

(b) Schematic drawing of IH system.

Fig. 5. Mould and schematic drawing of IH system.

Table 5. Strength of FRP.

Strength (MPa)

Fiber volume fraction (㧑)

Fiber orientation

Prepreg(CF/EP) 1414⁽⁵⁾ 50 0/90

NSMC(CF/PA6) 802 50 0/90

NSMC(GF/PA6) 435 50 0/90

GMT(GF/PP) 63⁽⁶⁾ 35(40wt㧑) Random ᴾ

0 2000 4000 6000 8000 10000

Prepreg NSMC (CF/EP) (CF/PA6)

Cost of molded part yen

Fiber Matrix Fabrication of Molding semi–product

Fig. 9. Cost of the molded part using carbon fiber.

ߣߢᚑᒻᤨ㑆ࠍᄢ᏷ߦ⍴❗ߢ߈㧘ᚑᒻຠో૕ߩࠦࠬ

࠻ࠍᄢ߈ߊ೥ᷫߢ߈ࠆߎߣ߇ࠊ߆ࠆ㧚

Fig. 10

ߦᒝൻ❫⛽ߦࠟ࡜ࠬ❫⛽ࠍ↪޿ߚ

NSMC

ߣ

GMT

ߩᚑᒻຠߩࠦࠬ࠻ࠍ␜ߔ㧚 ߤߜࠄߩਛ㑆ၮ᧚ ߦ߅޿ߡ߽ో૕ߩࠦࠬ࠻ߩᄢㇱಽࠍਛ㑆ၮ᧚ടᎿ⾌

ߣᚑᒻ⾌߇භ߼ߡ޿ࠆ㧚὇⚛❫⛽ࠍᒝൻ❫⛽ߣߔࠆ

CFRP

ߢߪࡊ࡝ࡊ࡟ࠣ㧘

NSMC

౒ߦ❫⛽ߣࡑ࠻࡝࠶

ࠢࠬࠍ฽߼ߚ᧚ᢱ⾌ߪో૕ߩ⚂

40㧑ߢ޽ߞߚߩߦ

ኻߒ㧘ࠟ࡜ࠬࠍᒝൻ❫⛽ߣߒߚ

FRP

ߢߪ

22

㧑એਅߢ

޽ߞߚ㧚ࠟ࡜ࠬ❫⛽ߪ㧘὇⚛❫⛽ߦኻߒߡ᧚ᢱ⾌ߩ ὐߢఝ૏ߢ޽ࠆߎߣ߇ࠊ߆ࠆ㧚߹ߚ

PP

ࠍ↪޿ߚ

NSMC

ߩࠦࠬ࠻ߪ㧘PA6ࠍ↪޿ߚ߽ߩߦᲧߴߡ㧘ᚑ ᒻ᷷ᐲߩ㆑޿ߦࠃࠆᚑᒻᤨ㑆ߩ⍴❗ൻߣ㧘

PP

᮸⢽ࠍ

↪޿ࠆߎߣߦࠃࠆ᧚ᢱ⾌ߩ೥ᷫߦࠃߞߡ

5㧑⒟ᐲ೥

ᷫߐࠇߚ㧚ߒ߆ߒ㧘

GMT

ߣᲧセߔࠆߣ

NSMC

ߢߪ ߤߜࠄߩ᮸⢽ࠍ↪޿ߚ႐วߦ߽୚એ਄ߩࠦࠬ࠻ߣߥ ߞߡ߅ࠅ㧘

NSMC

ߩਛ㑆ၮ᧚ടᎿ⾌ߩ೥ᷫ߇ᦸ߹ࠇ ࠆ㧚

(42 ߩᲧᒝᐲ޽ߚࠅߩࠦࠬ࠻

Fig. 11

ߦฦᚑᒻຠߩᲧᒝᐲࠍ␜ߔ㧚

Fig. 12

ߦ␜ߔ න૏Ყᒝᐲ޽ߚࠅߩࠦࠬ࠻ߪ㧘ᚑᒻຠߩࠦࠬ࠻ࠍᲧ ᒝᐲߢ㒰ߒߚ୯ߢ޽ࠆ㧚

Fig. 10

ߦ␜ߒߚࠃ߁㧘

NSMC

ߪ

GMT

ߦᲧߴߡ㜞޿ᚑᒻຠࠦࠬ࠻ߣߥߞߡ޿ࠆ߇㧘 න૏Ყᒝᐲ޽ߚࠅߩࠦࠬ࠻ߢߪ

NSMC(GF/PA6)

ߪ

GMT

ࠃࠅૐߊߥࠅ㧘NSMC(CF/PA6)ߢ߽

GMT

ߣห

╬ߣߥߞߚ㧚ߎߩߎߣࠃࠅ

NSMC

ߪᲧᒝᐲ޽ߚࠅߢ

⠨߃ࠆߣࠟ࡜ࠬ❫⛽ࠍᒝൻ᧚ߣߒߚ

GMT

ߦ඘ᢜߔ

0 4000 8000 12000 16000 20000

Prepreg NSMC (CF/EP) (CF/PA6)

Cost of semi–product yen

Fiber Matrix Fabrication of semi–product

Fig. 7. Cost of semi-product using carbon fiber.

0 400 800 1200 1600 2000

NSMC NSMC

(GF/PP) (GF/PA6)

Cost of semi–product yen

Fiber Matrix Fabrication of

GMT (GF/PP) semi–product

Fig. 8. Cost of semi-product using glass fiber.

0 200 400 600 800 1000

NSMC NSMC

(GF/PP) (GF/PA6)

Cost of molded part yen

Fiber Matrix Fabrication of

GMT (GF/PP) Molding semi–product

Fig. 10. Cost of the molded part using glass fiber.

ࠆ߶ߤ㧘ૐࠦࠬ࠻ࠍታ⃻ߒߚఝࠇߚਛ㑆ၮ᧚ߢ޽ࠆ ߎߣ߇ࠊ߆ࠆ㧚

⚿⸒

ਇ❱Ꮣઃᄙゲᄙጀࠢࡠࠬ㧔

NSMC

㧕ࠍਛ㑆ၮ᧚ߣ ߒߡ㧘

IH system

ߦࠃࠅᚑᒻߒߚ

FRTP

ߩࠦࠬ࠻⹏ଔ ࠍⴕ޿㧘ࡊ࡝ࡊ࡟ࠣߣ

GMT

ࠍਛ㑆ၮ᧚ߣߒߡᚑᒻ ߒߚ

FRP

ߣߩᲧセࠍⴕߞߚ㧚ᓧࠄࠇߚ⍮⷗ࠍએਅߦ

␜ߔ㧚

(1)

ࡊ࡝ࡊ࡟ࠣߦᲧߴߡ

NSMC

ߪૐࠦࠬ࠻ߢ

CFRP

⵾ຠࠍᓧࠆߎߣ߇น⢻ߢ޽ࠆ㧚

(2) NSMC

ߪᲧᒝᐲ޽ߚࠅߢ⠨߃ࠆߣࠟ࡜ࠬ❫⛽ࠍ

ᒝൻ᧚ߣߒߚ

GMT

ߦ඘ᢜߔࠆ߶ߤ㧘ૐࠦࠬ࠻ࠍታ

⃻ߒߚఝࠇߚਛ㑆ၮ᧚ߢ޽ࠆ㧚

ᧄ⎇ⓥߩ৻ㇱߪ㧘ᢥㇱ⑼ቇ⋭⑳┙ᄢቇ⎇ⓥ㜞ᐲൻផ ㅴ੐ᬺޟవㅴⶄว᧚ᢱߩ㐿⊒ߣߘߩᔕ↪ ̆వ┵ⶄ ว᧚ᢱᛛⴚߦࠃࠆ⥄േゞ㐿⊒̆㧔หᔒ␠ᄢቇ㧕ޠߩᡰ

េࠍฃߌߚ㧚ߎߎߦ⸥ߒߡ⻢ᗧࠍ⴫ߔࠆ㧚

ෳ⠨ᢥ₂

1) ଻⼱ᢘᄦ㧘̌ゞਔ↪᮸⢽᧚ᢱߩ⃻⁁ߣ੹ᓟߩേะ̍㧘⥄

േゞᛛⴚ㧘63, No.1, 82-87, (2009).

2) ↰ਛ๺ੱ㧘ዊᯅೣᄦ㧘ᧁਅ㓁ᐔ㧘 ጊொ↢㧘ቝ㊁๺ቁ㧘

̌᮸⢽ਇ❱Ꮣઃᄙゲᄙጀࠢࡠࠬࠍ↪޿ߚCFRTPߩ㔚

⏛⺃ዉടᾲࡊ࡟ࠬᚑᒻ̍㧘᧚ᢱ㧘58, No.7, 642-648 (2009).

3) ᐔ㊁㓁ਃ㧘ࡊ࡜ࠬ࠴࠶ࠢᯏ⢻ᕈ㜞ಽሶ᧚ᢱ੐ౖ㧘㧔↥

ᬺ⺞ᩏળ ੐ౖ಴ ࠮ࡦ࠲࡯㧘᧲੩㧘2004㧕㧘p.556-571.

4) ᐔ㊁㓁ਃ㧘ࡊ࡜ࠬ࠴࠶ࠢᯏ⢻ᕈ㜞ಽሶ᧚ᢱ੐ౖ㧘㧔↥

ᬺ ⺞ ᩏ ળ ੐ ౖ ಴   ࠮ ࡦ ࠲ ࡯ 㧘 ᧲ ੩ 㧘2004㧕㧘 p.34,220,486.

5) ᩙේ⽵ᄦ㧘⍹ਣ⑓↵㧘ࡊ࡜ࠬ࠴࠶ࠢ♽వ┵ⶄว᧚ᢱ̆

⚛᧚߆ࠄᔕ↪߹ߢ̆㧘㧔␠࿅ᴺੱᒝൻࡊ࡜ࠬ࠴࠶ࠢද ળ㧘᧲੩㧘1989㧕㧘p.70-78.

6) Quadrant Plastic Composites Japan Ltdࡎ࡯ࡓࡍ࡯ࠫ㧘 http://www.jgmt.net/pro_gmt.html.

7) ጤ↰ノᒾ㧘౉ญ೰ౖ㧘ᷰㄝஜੑ㧘㋈ᧁ❥↢㧘̌⥄േゞ

↪᮸⢽ࡃ࠶ࠢ࠼ࠕࡕࠫࡘ࡯࡞̍㧘ᣣ┙ൻᚑ࠹ࠢ࠾ࠞ࡞

࡟ࡐ࡯࠻㧘No.44, 21-24 (2005).

8) M. Kawai, N. Maki, “Fatigue strengths of cross-ply CFRP laminates at room andhigh temperatures and its phenomenological modeling”, International Journal of Fatigue, 28, 1297ῒ1306, (2006).

9) F. Henning, H. Ernst and R. Brussel. ” LFTs for automotive applications”, REINFORCEDplastics, 2, 24-33, ( 2005).

0 20 40 60 80 100 120 140

NSMC NSMC

(PA6) (PA6)

Specific strength m

GMT (PP) CF

GF GF x10³

CF

Prepreg

(EP)

Fig. 11. Specific strength.

0 20 40 60 80 100

NSMC NSMC

(PA6) (PA6) Cost of molded part per 10– 3

GMT (PP) CF

GF GF CF

Prepreg (EP)

xspecific strength yen/(m )

Fig. 12. Cost of molded part per specific strength.