Reinforcing fiber mat, and fiber-reinforced resin forming material and method of producing same
AssigneeToray Industries, Inc.
InventorsSatoshi Seike, Masaru Tateyama, Mitsuki Fuse, Hiroshi Hirano, Akihiko Matsui, Kazuma Ura
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Abstract
A reinforcing fiber mat includes reinforcing fiber bundles having an average fiber length of 5 mm to 100 mm, wherein reinforcing fiber bundles consisting of 86 or more fibers per bundle are contained at a weight content of more than 99 wt % to 100 wt % and the reinforcing fiber bundles contain single yarns by 500 fibers/mm-width or more and 1,600 fibers/mm-width or less and have a drape level of 120 mm or more and 240 mm or less.
Claims14
A reinforcing fiber mat comprising reinforcing fiber bundles having an average fiber length of 5 mm to 100 mm,
- wherein reinforcing fiber bundles consisting of 86 or more fibers per bundle are contained at a weight content of more than 99 wt % to 100 wt %, and
- the reinforcing fiber bundles contain single yarns by 500 fibers/mm-width or more and 1,600 fibers/mm-width or less and have a drape level of 120 mm or more and 240 mm or less.
A fiber-reinforced resin forming material comprising a thermoplastic resin and reinforcing fiber bundles and having a void ratio of 5 vol % or more and 30 vol % or less,
- wherein the reinforcing fiber bundles contain single yarns by 500 fibers/mm-width or more and 1,600 fibers/mm-width or less and have a drape level of 120 mm or more and 240 mm or less.
A method of producing a fiber-reinforced thermoplastic resin forming material, comprising:
- preparing a mat base material of reinforcing fiber bundles that contain single yarns by 500 fibers/mm-width or more and 1,600 fibers/mm-width or less and have a drape level of 120 mm or more and 240 mm or less;
- dispersing or layering thermoplastic resin on the mat base material;
- melting the thermoplastic resin;
- and
- cooling and solidifying the melted thermoplastic resin between plates through a gap thicker by 5% or more than a thickness of a fully resin-impregnated base material.
A reinforcing fiber mat comprising reinforcing fiber bundles having an average fiber length of 5 mm to 100 mm,
- wherein reinforcing fiber bundles consisting of 86 or more fibers per bundle are contained at a weight content of more than 99 wt % to 100 wt %, and
- the reinforcing fiber bundles have a cutting angle θ of 3° or more and 30° or less.
Dependencies are inferred from the claim text.