# US 10,766,206 B2 · Manufacturing method of resin composite plate > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,766,206 B2 - Document ID: US10766206B2 - Status: Granted - Kind: B2 - Application number: 16/021,035 - Filed: 2018-06-28 - Published: 2019-01-03 - Granted: 2020-09-08 - Earliest claimed: 2017-06-29 - Assignees: Fanuc Corporation - Applicants: Fanuc Corporation - Inventors: Hajimu Kishi - Web page: https://patentgrep.com/patent/US10766206B2 ## CPC - B29C 43/003: {characterised by the choice of material} - B29B 11/16: comprising fillers or reinforcement {(non-woven fabrics per se D04H1/00, D04H3/00)} - B29C 43/18: incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles {(B29C43/206 takes precedence)} - B29C 43/203: {Making multilayered articles} - B29C 66/1142: {Single butt to butt joints} - B29C 66/12842: {comprising at least three butt joint-segments} - B29C 66/14: {the joint having the same thickness as the thickness of the parts to be joined (B29C66/1142 takes precedence)} - B29C 66/22: {said joint lines being in the form of recurring patterns (B29C66/234 takes precedence)} - B29C 66/23: {said joint lines being multiple and parallel or being in the form of tessellations} - 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)} - B29C 70/207: {arranged in parallel planes of fibres crossing at substantial angles} - B29C 70/42: for producing articles of definite length, i.e. discrete articles - B29C 70/46: using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs - C08J 5/04: Reinforcing macromolecular compounds with loose or coherent fibrous material - B29C 43/02: of articles of definite length, i.e. discrete articles {(B29C35/0227 takes precedence)} - B29C 2043/189: {the parts being joined} - B29K 2101/12: Thermoplastic materials - B29K 2105/06: containing reinforcements, fillers or inserts - 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) - B29B: PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS - C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29) - 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 ## Abstract In a manufacturing method of a resin composite plate for manufacturing a resin composite plate by heating under pressure a resin sheet group having a plurality of fiber-reinforced thermoplastic resin sheets stacked together, and thereby integrating the resin sheet group into one resin composite plate, the fiber-reinforced thermoplastic resin sheets each containing fibers arranged in one direction, the resin composite plate having a desired thickness is manufactured by stacking the plurality of fiber-reinforced thermoplastic resin sheets having different thickness. ## Claims ### Claim 1 A method of manufacturing a resin composite plate having a predetermined thickness, the method comprising: producing a plurality of resin sheet groups, wherein each of the plurality of resin sheet groups is produced by stacking at least (1) a first fiber-reinforced thermoplastic resin sheet having a first thickness on (2) a second fiber-reinforced thermoplastic resin sheet having a second thickness which is different from the first thickness, each of the first and second fiber-reinforced thermoplastic resin sheets containing fibers arranged in one direction; laying the plurality of resin sheet groups side-by-side on a plane; and manufacturing the resin composite plate having the predetermined thickness by heating, under pressure, the plurality of resin sheet groups that are laid side-by-side on the plane, to integrate the plurality of resin sheet groups into said resin composite plate, wherein at least one resin sheet group among the plurality of resin sheet groups laid on the plane requires strength and differs from another resin sheet group not requiring strength among the plurality of resin sheet groups laid on the plane in a number of fiber-reinforced thermoplastic resin sheets that are stacked, so as to increase the strength of said at least one resin sheet group and to weaken the strength of said another resin sheet group. ### Claim 2 (depends on 1) The method according to claim 1, wherein: the producing of each of the plurality of resin sheet groups comprises stacking the first fiber-reinforced thermoplastic resin sheet with the fibers thereof being oriented in a first fiber direction on the second fiber-reinforced thermoplastic resin sheet with the fibers thereof being oriented in a second fiber direction so as to cross the first fiber direction of the first fiber-reinforced thermoplastic resin sheet with the second fiber direction of the second fiber-reinforced thermoplastic resin sheet. ### Claim 3 (depends on 2) The method according to claim 2, wherein: in the producing of each of the plurality of resin sheet groups, the first fiber-reinforced thermoplastic resin sheet is adjacently-stacked on the second fiber-reinforced thermoplastic resin sheet. ### Claim 4 (depends on 1) The method according to claim 1, wherein: in each of the plurality of resin sheet groups, the first fiber-reinforced thermoplastic resin sheet differs in volume fraction of fiber from the second fiber-reinforced thermoplastic resin sheet. ### Claim 5 (depends on 1) The method according to claim 1, wherein: at least one of the plurality of resin sheet groups laid on the plane differs from another of the plurality of resin sheet groups laid on the plane in thickness. ### Claim 6 (depends on 1) The method according to claim 1, wherein: a joint surface between adjacent resin sheet groups among the plurality of resin sheet groups laid on the plane is in a form of (i) a curved surface, (ii) plural planes, or (iii) a combination of a curved surface and a plane. ### Claim 7 (depends on 1) The method according to claim 1, wherein: the plurality of resin sheet groups laid on the plane each have a polygonal shape. ### Claim 8 (depends on 1) The method according to claim 1, wherein: at least one of the plurality of resin sheet groups laid on the plane differs from another of the plurality of resin sheet groups laid on the plane in content of fiber. ### Claim 9 (depends on 1) The method according to claim 1, wherein: at least one of the plurality of resin sheet groups laid on the plane differs from another of the plurality of resin sheet groups laid on the plane in volume fraction of fiber. ### Claim 10 A method of manufacturing a resin composite plate, the method comprising: laying a plurality of fiber-reinforced thermoplastic resin sheet groups having different thicknesses side-by-side on a plane, each of the plurality of fiber-reinforced thermoplastic resin sheet groups containing fibers arranged in one direction, wherein: a joint surface between adjacent fiber-reinforced thermoplastic resin sheet groups among the plurality of fiber-reinforced thermoplastic resin sheets laid on the plane is in a form of (i) a curved surface, (ii) plural planes, or (iii) a combination of a curved surface and a plane; and manufacturing the resin composite plate by heating, under pressure, the plurality of fiber-reinforced thermoplastic resin sheet groups that are laid side-by-side on the plane, to integrate the plurality of fiber-reinforced thermoplastic resin sheet groups into said resin composite plate, wherein at least one resin sheet group among the plurality of resin sheet groups laid on the plane requires strength and differs from another resin sheet group not requiring strength among the plurality of resin sheet groups laid on the plane in a number of fiber-reinforced thermoplastic resin sheets that are stacked, so as to increase the strength of said at least one resin sheet group and to weaken the strength of said another resin sheet group. ### Claim 11 A method of manufacturing a three-dimensional formed article, the method comprising: manufacturing a plurality of resin composite plates each having a predetermined thickness, wherein each of the plurality of resin composite plates is manufactured by producing a plurality of resin sheet groups, wherein each of the plurality of resin sheet groups is produced by stacking at least (1) a first fiber-reinforced thermoplastic resin sheet having a first thickness on (2) a second fiber-reinforced thermoplastic resin sheet having a second thickness which is different from the first thickness, each of the first and second fiber-reinforced thermoplastic resin sheets containing fibers arranged in one direction; laying the plurality of resin sheet groups side-by-side on a plane; and manufacturing each of said resin composite plates having the predetermined thickness by heating, under pressure, the plurality of resin sheet groups that are laid side-by-side on the plane, to integrate the plurality of resin sheet groups into a respective one of said resin composite plates; and manufacturing the article by heating, under pressure, at least one resin composite plate of the plurality of resin composite plates stacked together, with the at least one resin composite plate being clamped between dies, wherein the at least one resin composite plate (i) is one resin composite plate of the plurality of resin composite plates, or (ii) includes several resin composite plates of the plurality of resin composite plates stacked together, and in manufacturing the at least one resin composite plate, at least one resin sheet group among the plurality of resin sheet groups laid on the plane requires strength and differs from another resin sheet group not requiring strength among the plurality of resin sheet groups laid on the plane in a number of fiber-reinforced thermoplastic resin sheets that are stacked, so as to increase the strength of said at least one resin sheet group and to weaken the strength of said another resin sheet group. ### Claim 12 (depends on 11) The method according to claim 11, wherein: in manufacturing the at least one resin composite plate, at least one resin sheet group of the plurality of resin sheet groups laid on the plane differs from another of the plurality of resin sheet groups laid on the plane in at least one of thickness and content of fiber. ### Claim 13 (depends on 11) The method according to claim 11, wherein: in manufacturing the at least one resin composite plate, at least one resin sheet group of the plurality of resin sheet groups laid on the plane differs from another of the plurality of resin sheet groups laid on the plane in thickness, content of fiber, or volume fraction of fiber.