Toray has developed technology to improve the surface smoothness of thermosetting carbon fiber reinforced resin matrix composites (CFRP). The CFRP sunroof equipped on the new concept car “TEEWAVE AC1” uses this technology, which was revealed at the internal exhibition “Toray Advanced Materials Exhibition 2016”.
The sunroof is equipped with a resin transfer molding (RTM) molding. In the RTM method, a carbon fiber fabric is put into a mold during operation, the epoxy resin as a base material is soaked and hardened, and then the product is poured out of the mold.
In the new technology, after wetting the epoxy resin as the base material, before the stamping, the epoxy resin is injected into the mold again to increase the thickness of the surface resin and then harden. After demolding, the surface is painted and ground. According to the commentator, “the surface smoothness can be improved compared with the original method of repeatedly coating and polishing the coating agent after demolding.” In addition, new technologies can reduce workflows and therefore reduce manufacturing costs.