# US 10,864,699 B2 · Composite material member, method for producing composite material member, and molding die for same

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- Number: US 10,864,699 B2
- Document ID: US10864699B2
- Status: Granted
- Kind: B2
- Application number: 16/484,855
- Filed: 2017-03-10
- Published: 2020-02-20
- Granted: 2020-12-15
- Earliest claimed: 2017-03-10
- Assignees: Nissan Motor Co., Ltd.
- Applicants: Nissan Motor Co., Ltd.
- Inventors: Yukihiro Hamada; Hiroshi Ookubo
- Web page: https://patentgrep.com/patent/US10864699B2

## CPC

- B29C 45/14786: {Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material}
- 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}
- B26F 1/12: to notch margins of work
- B26F 1/26: Perforating by non-mechanical means, e.g. by fluid jet
- B29C 39/10: incorporating preformed parts or layers, e.g. casting around inserts or for coating articles {(coating a surface by casting in general B05D1/30, B29C39/126 takes precedence)}
- B29C 43/02: of articles of definite length, i.e. discrete articles {(B29C35/0227 takes precedence)}
- B29C 45/14336: {Coating a portion of the article, e.g. the edge of the article (B29C45/14573 and B29C45/14598 take precedence)}
- B29C 70/48: and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM] {, e.g. by vacuum}
- B29C 70/545: {Perforating, cutting or machining during or after moulding}
- B29C 70/74: Moulding material on a relatively small portion of the preformed part, e.g. outsert moulding {(B29C70/845 takes precedence)}
- B32B 3/06: for securing layers together; for attaching the product to another member, e.g. to a support {, or to another product, e.g. groove/tongue, interlocking}
- B32B 3/08: characterised by added members at particular parts {(layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18)}
- B32B 3/266: {characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12}
- B32B 5/02: characterised by structural features of a {fibrous or filamentary} layer {(layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02)}
- B32B 5/024: {Woven fabric}
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 7/00: Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B 7/022: Mechanical properties
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 38/04: Punching, slitting or perforating
- B29C 2045/0058: {removing material}
- B32B 5/145: {Variation across the thickness of the layer}
- B32B 2250/20: All layers being fibrous or filamentary
- B32B 2250/40: Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
- B32B 2250/44: Number of layers variable across the laminate
- B32B 2260/021: Fibrous or filamentary layer
- B32B 2260/023: Two or more layers
- B32B 2260/046: Synthetic resin
- B32B 2605/08: Cars
- Y10T 428/24273: including aperture
- Y10T 428/24322: Composite web or sheet
- 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
- B26F: PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING (marking-out, perforating or making buttonholes A41H25/00; shoemaking A43D; surgery A61B; punching metal B21D; drilling metal B23B; cutting of metal by applying heat locally, e.g. flame cutting, B23K; cutting by abrasive fluid jets B24C5/02; details common to machines for severing B26D; drilling wood B27C; drilling stone B28D; working of plastics or substances in a plastic state B29; making boxes, cartons, envelopes or bags, of paper or similarly worked materials, e.g. metal foil, B31B; of glass C03B; of leather C14B; of textile materials D06H; for light guides G02B6/25; of tickets G07B)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A composite material member having an FRP layer made of fiber-reinforced plastic, and a resin-rich layer that has a fiber content that is 5% or less of the fiber content of the FRP layer. The resin-rich layer is formed in at least a partial region of a surface of the FRP layer, and is formed from the same resin as a matrix resin of the fiber-reinforced plastic. A hole is bored so as to penetrate the FRP layer and the resin-rich layer.

## Claims

### Claim 1

A composite material member comprising:
an FRP layer made of fiber-reinforced plastic;
a resin-rich layer that has a fiber content that is greater than zero and less than or equal to 5% of the fiber content of the FRP layer, that is formed in at least a partial region of a surface of the FRP layer, and that is formed from the same resin as a matrix resin of the fiber-reinforced plastic; and
a hole that is bored so as to penetrate the FRP layer and the resin-rich layer.

### Claim 2 (depends on 1)

The composite material member according to claim 1, wherein
the resin-rich layer is formed on surfaces on both sides of the FRP layer, and
the hole penetrates the FRP layer and the resin-rich layers formed on the surfaces on both sides of the FRP layer.

### Claim 3 (depends on 1)

The composite material member according to claim 1, wherein
the reinforcing fibers of the FRP layer is made of continuous fibers.

### Claim 4 (depends on 1)

The composite material member according to claim 1, wherein
a thickness of the resin-rich layer is at least 0.5 mm.