US 11,951,692 B2Granted

Fiber-reinforced resin material, molded article, method and device for manufacturing fiber-reinforced resin material, and fiber bundle group inspection device

AssigneeMitsubishi Chemical Corporation

InventorsHiroshi Iwata, Nobuyuki Yamamoto, Hajime Okutsu, Ryuichi Ishikawa, Koichi Akiyama, Takayuki Kobayashi

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Abstract

The purpose of the present invention is to provide a fiber-reinforced resin material having minimal directionality of strength as well as excellent productivity, a method and device for manufacturing a fiber-reinforced resin material whereby a molded article is obtained, and a device for inspecting a fiber bundle group. A method for manufacturing a sheet-shaped fiber-reinforced resin material in which a paste (P1) is impregnated between cut fiber bundles (CF), the method for manufacturing a fiber-reinforced resin material including a coating step applying a coating of a paste (P1) on a first sheet (S11) conveyed in a predetermined direction, a cutting step for cutting a long fiber bundle (CF) using a cutter (113A), a scattering step for dispersing the cut fiber bundles (CF) and scattering the cut fiber bundles (CF) on the paste (P1), and an impregnation step for pressing a fiber bundle group (F1) and the paste (P1) on the first sheet (S11) and impregnating the paste (P1) between the fiber bundles (CF).

Claims8

Dependent claims

A sheet-shaped fiber-reinforced resin material comprising dispersed carbon fiber bundles impregnated with a thermosetting resin and having a longitudinal direction and a width direction, wherein a diffracted X-ray at a diffraction angle 2θ of 25.4° is detected by an X-ray diffraction method, and a roughness β obtained by the following Formulas (1) to (3) is in a range of 0.5 to 4.5,

β
=
∫
0
360
❘
"\[LeftBracketingBar]"
f
(
ϕ
)
❘
"\[RightBracketingBar]"
⁢
d
⁢
ϕ
×
1
360
=
(
∑
i
=
2
N
(
❘
"\[LeftBracketingBar]"
f
(
ϕ
i
)
❘
"\[RightBracketingBar]"
+
❘
"\[LeftBracketingBar]"
f
(
ϕ
i
-
1
)
❘
"\[RightBracketingBar]"
)
×
d
⁢
ϕ
×
1
2
)
×
1
360
(
1
)
wherein:
f(ϕi) is a luminance obtained by subtracting an average luminance from a luminance (I(ϕi)) at an i-th rotation angle (ϕi) in X-ray diffraction measurement represented by the following Formula (2),
dϕ is a step width of the X-ray diffraction measurement, I(ϕi) is normalized so that an integration strength represented by the following Formula (3) becomes 10000:
f
⁡
(
ϕ
i
)
=
I
⁡
(
ϕ
i
)
-
∑
i
=
1
N
⁢
I
⁡
(
ϕ
i
)
N
(
2
)
∫
0
360
I
⁡
(
ϕ
)
⁢
d
⁢
ϕ
=
∑
i
=
2
N
(
I
⁡
(
ϕ
i
)
+
I
⁡
(
ϕ
i
-
1
)
)
×
d
⁢
ϕ
×
1
2
=
10000.
(
3
)

141 more elements

A sheet-shaped fiber-reinforced resin material comprising dispersed carbon fiber bundles impregnated with a thermosetting resin and having a longitudinal direction and a width direction, wherein, when the longitudinal direction of the fiber-reinforced resin material is defined as a 0° direction and the width direction is defined as a 90° direction, a diffracted X-ray at a diffraction angle 2θ of 25.4° is detected by an X-ray diffraction method, and a sum of an average value and a standard deviation of a degree of crystal orientation fa of the fiber bundle based on the 0° direction obtained by the following Formulas (4) to (6) is in a range of 0.05 to 0.13,

fa=2a-1 (4)
a
=
∑
í
=
1
N
⁢
I
⁡
(
ϕ
i
)
⁢
cos
2
⁢
ϕ
i
∑
i
=
1
N
⁢
I
⁡
(
ϕ
i
)
(
5
)
∫
0
3
⁢
6
⁢
0
I
⁡
(
ϕ
)
⁢
d
⁢
ϕ
=
∑
i
=
2
N
(
I
⁡
(
ϕ
i
)
+
I
⁡
(
ϕ
i
-
1
)
)
×
d
⁢
ϕ
×
1
2
=
10000
(
6
)
wherein:
“aa” is an orientation coefficient represented by Formula (5), and
I(ϕi) is a luminance at an i-th rotation angle (ϕi) in X-ray diffraction measurement and is normalized so that an integration strength represented by Formula (6) becomes 10000.

87 more elements

Dependencies are inferred from the claim text.

Facts

Application: 18/155,773Filed 18 Jan 2023 · division
Priority: JP 2015-12681424 Jun 2015
Published: US 2023/0150210 A118 May 2023
Granted: 9 Apr 2024
Term ends: Not estimatedThe source records don’t support an estimate.

Classification21 codes

B29C 70/12
Characterised by the structure of fibrous reinforcements , e.g. hollow fibres: using fibres of short length, e.g. in the form of a mat
B29B 11/16
Characterised by structure or composition: comprising fillers or reinforcement
B29B 15/08
Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00: of reinforcements or fillers
B29B 15/122
Of reinforcements of indefinite length: with a matrix in liquid form, e.g. as melt, solution or latex

Family

PCT/JP2016/068862Parent of this division · filed 24 Jun 2016
Application16/374,875Parent of this division · filed 4 Apr 2019
US 10,343,352 B2Parent of this division · filed 9 Jul 2019
US 2023/0150210 A1Pre-grant publication · published 18 May 2023
US 11,597,165 B2Parent of this division
Application15/738,380Parent of this division
US 10,300,666 B2Related patent
US 2018/0162070 A1Published application
US 2019/0224926 A1Published application
US 11,951,692 B2This patent

From the US filing history. Foreign family members aren’t listed.