Random mat and fiber-reinforced composite material shaped product
AssigneeTeijin Limited
InventorsNaoaki Sonoda, Makoto Ootsubo, Takeru Ohki
Life of this patent
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Abstract
There is provided a random mat including reinforcing fibers having an average fiber length of 3 to 100 mm and a thermoplastic resin, wherein the reinforcing fibers satisfy the following i) to iii). i) The reinforcing fibers have a weight-average fiber width (Ww) which satisfies the following equation (1). 0 mm<Ww<2.8 mm (1) ii) The reinforcing fibers have an average-fiber-width dispersion ratio (Ww/Wn), which is defined as a ratio of the weight-average fiber width (Ww) to a number-average fiber width (Wn), of 1.00 or more and 2.00 or less. iii) The reinforcing fibers have a weight-average fiber thickness which is smaller than the weight-average fiber width (Ww) thereof.
Claims11
A process for producing a random mat comprising a reinforcing-fiber mat and a thermoplastic resin, the process comprising:
- widening a reinforcing fiber strand;
- and the following steps (1) to (4):
- (1) cutting off reinforcing fibers from the reinforcing fiber strand;
- (2) introducing the cut reinforcing fibers into a tube, conveying the reinforcing fibers in the tube with air and spraying the reinforcing fibers from the tube;
- (3) fixing the sprayed reinforcing fibers to obtain a reinforcing-fiber mat;
- and
- (4) adding a thermoplastic resin to the reinforcing-fiber mat to obtain a random mat, wherein
- the reinforcing fibers have an average fiber length of 3 to 100 mm;
- the weight-average fiber thickness of the reinforcing fibers is 0.01 mm or more and 0.30 mm or less;
- fiber axes of the reinforcing fibers are substantially parallel to a plane of the random mat;
- the reinforcing fibers are randomly dispersed in the plane of the random mat;
- and
- the reinforcing fibers satisfy the following i) to iii):
- i) the reinforcing fibers have a weight-average fiber width (Ww) which satisfies the following equation (1):
- 0 mm<Ww<2.8 mm (1);
- ii) the reinforcing fibers have an average-fiber-width dispersion ratio (Ww/Wn), which is defined as a ratio of the weight-average fiber width (Ww) to a number-average fiber width (Wn), of more than 1.00 and 2.00 or less;
- and
- iii) the reinforcing fibers have a weight-average fiber thickness which is smaller than the weight-average fiber width (Ww).
Dependencies are inferred from the claim text.