# US 10,369,753 B2 · Fiber substrate stacking method, manufacturing method of roll of fiber substrate group, fiber substrate group, and aircraft

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- Number: US 10,369,753 B2
- Document ID: US10369753B2
- Status: Granted
- Kind: B2
- Application number: 14/980,034
- Filed: 2015-12-28
- Published: 2016-08-25
- Granted: 2019-08-06
- Earliest claimed: 2015-02-19
- Assignees: Mitsubishi Aircraft Corporation
- Applicants: Mitsubishi Aircraft Corporation
- Inventors: Hiromichi Akiyama; Hideki Horizono; Kazuaki Kishimoto; Masahiro Shinya; Shinya Suzukake
- Web page: https://patentgrep.com/patent/US10369753B2

## CPC

- B29C 70/443: {and impregnating by vacuum or injection}
- B29C 43/12: using bags surrounding the moulding material {or using membranes contacting the moulding material}
- B29C 70/202: {arranged in parallel planes or structures of fibres crossing at substantial angles, e.g. cross-moulding compound [XMC] (B29C70/207 takes precedence)}
- B32B 5/12: characterised by the relative arrangement of fibres or filaments of {different layers, e.g. the fibres or filaments being parallel or perpendicular to each other}
- B32B 37/0076: {characterised in that the layers are not bonded on the totality of their surfaces}
- B29K 2101/12: Thermoplastic materials
- B29K 2105/101: {Oriented}
- B29L 2009/00: Layered products
- B32B 2037/1215: {Hot-melt adhesive}
- B32B 2250/20: All layers being fibrous or filamentary
- B32B 2260/023: Two or more layers
- B32B 2260/046: Synthetic resin
- B32B 2603/00: Vanes, blades, propellers, rotors with blades
- Y02T 50/40: Weight reduction
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

The present invention aims to sufficiently impregnate each layer of a fiber substrate group composed of fiber substrates, which are used for fiber-reinforced resin molding by a resin injection method, with a resin. To successively stack a plurality of fiber substrates, each of which has arrayed fiber bundles and is a material composing a fiber-reinforced resin along with a resin, with their fiber bundles oriented in the same direction, the plurality of fiber substrates are integrated in a state where border zones between the fiber bundles adjacent to each other in an array direction are aligned with one another among the fiber substrates.

## Claims

### Claim 1

A fiber substrate stacking method for stacking a plurality of fiber substrates each of which has arrayed fiber bundles and is a material composing a fiber-reinforced resin along with a matrix resin, wherein the plurality of fiber substrates are integrated in a state where border zones between the fiber bundles adjacent to each other in an array direction are aligned with one another among the plurality of fiber substrates which are successively stacked with their fiber bundles oriented in a same direction, wherein a border zone of each of the fiber substrates includes a channel that is formed in a thickness direction of a stacked body comprising the stacked plurality of fiber substrates, the channel configured for passage of the matrix resin.

### Claim 2 (depends on 1)

The fiber substrate stacking method according to claim 1, wherein the plurality of fiber substrates are bonded together by heating and plasticizing particles of a thermoplastic resin scattered over surfaces of the fiber bundles.

### Claim 3 (depends on 1)

The fiber substrate stacking method according to claim 1, wherein the plurality of fiber substrates are bonded together by disposing a sheet, which has thermoplasticity and allows passage of the matrix resin at least in a thickness direction of the plurality of fiber substrates, between each of the plurality of fiber substrates and heating and plasticizing the sheet.

### Claim 4 (depends on 1)

The fiber substrate stacking method according to claim 1, wherein the fiber bundles are arrayed at a regular pitch.

### Claim 5 (depends on 1)

The fiber substrate stacking method according to claim 1, wherein:
each of the plurality the fiber substrates has a first fiber and a second fiber that hold together the fiber bundles in an arrayed state; and
the first fiber extends along a length direction of the fiber bundles at the position of a border zone while the second fiber extends along the array direction of the fiber bundles.

### Claim 6 (depends on 1)

The fiber substrate stacking method according to claim 1, wherein the arrayed fiber bundles of each of the plurality of fiber substrates are aligned in one direction, and the border zones of stacked adjacent plurality of fiber substrates are aligned in a stacking direction.

### Claim 7

A manufacturing method of a roll of a fiber substrate group in which a plurality of fiber substrates, each of which has arrayed fiber bundles and is a material composing a fiber-reinforced resin along with a matrix resin, are successively stacked with their fiber bundles oriented in a same direction by a fiber substrate stacking method when the plurality of fiber substrates are integrated in a state where border zones between the fiber bundles adjacent to each other in an array direction are aligned with one another among the plurality of fiber substrates which are successively stacked with their fiber bundles oriented in the same direction, the manufacturing method comprising the steps of:
obtaining a form of the plurality of fiber substrates using the fiber bundles;
integrating the plurality of fiber substrates in the state where the border zones between the fiber bundles adjacent to each other in the array direction are aligned with one another; and
rolling up the fiber substrate group including the integrated plurality of fiber substrates.

### Claim 8 (depends on 7)

The manufacturing method of a roll of a fiber substrate group according to claim 7, wherein, in the step of integrating, the plurality of fiber substrates are stitched together with fibers, which are passed between the fiber bundles adjacent to each other in the array direction, in a state where the border zones are aligned with one another.

### Claim 9 (depends on 7)

A fiber-reinforced resin molding method comprising the steps of:
forming a stack of a plurality of fiber substrates including the plurality of fiber substrates of the roll of the fiber substrate group manufactured by the manufacturing method according to claim 7; and
depressurizing an inside of a cavity, where the stack is disposed, and injecting the matrix resin into the cavity to impregnate each of the plurality of fiber substrates constituting the stack with the matrix resin.

### Claim 10

. A fiber-reinforced resin molding method comprising the steps of:
forming a stack of a plurality of fiber substrates including the plurality of fiber substrates which are stacked by a fiber substrate stacking method ; and
depressurizing an inside of a cavity, where the stack is disposed, and injecting a matrix resin into the cavity to impregnate each of the plurality of fiber substrates constituting the stack with the matrix resin, wherein
each of the plurality of fiber substrates has arrayed fiber bundles and is a material composing a fiber-reinforced resin along with the matrix resin, and
in the fiber substrate stacking method for stacking the plurality of fiber substrates, the plurality of fiber substrates are integrated in a state where border zones between the fiber bundles adjacent to each other in an array direction are aligned with one another among the plurality of fiber substrates which are successively stacked with their fiber bundles oriented in a same direction.

### Claim 11 (depends on 10)

The fiber-reinforced resin molding method according to claim 10, wherein, before impregnating each of the plurality of fiber substrates, a resin diffusion medium, which presents a lower flow resistance to the matrix resin than the plurality of fiber substrates, is disposed on top of the stack.

### Claim 12 (depends on 9)

The fiber-reinforced resin molding method according to claim 9, wherein, before impregnating each of the plurality of fiber substrates, a resin diffusion medium, which presents a lower flow resistance to the matrix resin than the plurality of fiber substrates, is disposed on top of the stack.