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AssigneeToray Industries, Inc.
InventorsIchiro Taketa, Narumichi Sato, Eisuke Wadahara
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A laminated base material includes a lamination and integration of prepreg base materials each of which includes many reinforcing fibers arranged substantially in one direction and a matrix resin adhered to the reinforcing fibers, wherein at least one of the laminated prepreg base materials is formed with a prepreg base material having, throughout its whole surface, many incisions each extending in a direction crossing the reinforcing fibers, substantially all of the reinforcing fibers divided by incisions, and wherein a length L of each of reinforcing fiber segments formed by the incisions is 10 to 100 mm, a thickness H of the prepreg base material is 30 to 300 μm, and a fiber volume content Vf of the reinforcing fibers is 45 to 65% and arranging directions of the reinforcing fibers between one and another laminated prepreg base materials have at least two directions different each other.
A laminated base material comprising a lamination and integration of prepreg base materials each of which comprises a multiplicity of reinforcing fibers arranged substantially in one direction and a matrix resin adhered to said reinforcing fibers, wherein at least one of said laminated prepreg base materials is formed with a prepreg base material having, throughout its whole surface, a multiplicity of incisions each extending in a direction crossing the reinforcing fibers, substantially all of the reinforcing fibers are divided by incisions, and wherein a length L of each of reinforcing fiber segments formed by the incisions is 10 to 100 mm, a thickness H of the prepreg base material is 30 to 300 μm, and a fiber volume content Vf of the reinforcing fibers is 45 to 65%, and arranging directions of said reinforcing fibers between one and another laminated prepreg base materials have at least two directions different from each other.
A laminated base material comprising a lamination and integration of prepreg base materials each of which comprises a multiplicity of reinforcing fibers arranged substantially in one direction and a matrix resin adhered to said reinforcing fibers, wherein at least two of said laminated prepreg base materials are formed with prepreg base materials having, throughout its whole surface, a multiplicity of incisions each extending in a direction crossing the reinforcing fibers, substantially all of the reinforcing fibers are divided by incisions, wherein a length L of each of reinforcing fiber segments formed by the incisions is 10 to 100 mm, a thickness H of the prepreg base material is 30 to 300 μm, and a fiber volume content Vf of the reinforcing fibers is 45 to 65%, wherein each of said incisions is in the form of a slit segment having a certain length, and when said slit segment is projected in the arranging direction of said reinforcing fibers, a projected length Ws of said slit segment in a direction perpendicular to the arranging direction of said reinforcing fibers is 1 to 10 mm and said thickness H of said prepreg base material is 30 to 150 μm adjacent to each other and arranging directions of said reinforcing fibers in said adjacent prepreg base materials have substantially the same direction, and wherein arranging intervals in the arranging direction of said reinforcing fibers of said slit segments in said two adjacent prepreg base materials are the same and the positions of said slit segments in one of said two adjacent prepreg base material are shifted in the arranging direction of said reinforcing fibers relative to positions of said slit segments in the other prepreg base material.
A fiber reinforced plastic comprises a laminate comprising a plurality of reinforcing fiber layers each of which comprises reinforcing fibers arranged substantially in one direction and a matrix resin, wherein at least two of said reinforcing fiber layers are laminated with their reinforcing fibers arranged in different directions, a fiber volume content Vf is 45 to 65%, and wherein at least one of the fiber-resin layers, each comprising one of said reinforcing fiber layers and said matrix resin accompanying thereto, has incised openings in an entire surface of said fiber-resin layer, each of which comprises a region in which said matrix resin exists without said reinforcing fibers or said reinforcing fibers in the adjacent fiber-resin layer exist, said reinforcing fibers are cut by said incised openings, a length L of the reinforcing fiber segments of said cut reinforcing fibers is 10 to 100 mm, a surface area of said incised openings on the surface of said layer is 0.1 to 10% of the surface area of said layer, and an average thickness Hc of said layer is 15 to 300 μm.
A prepreg base material which comprises many reinforcing fibers arranged substantially in one direction and a matrix resin existing between a multiplicity of reinforcing fibers, wherein the prepreg base material has, throughout its whole surface, a multiplicity of incisions each extending in a direction crossing the reinforcing fibers, substantially all of the reinforcing fibers are divided by incisions, wherein a length L of each of reinforcing fiber segments formed by the incisions is 10 to 100 mm, a thickness H of the prepreg base material is 30 to 300 μm, and a fiber volume content Vf of the reinforcing fibers is 45 to 65%, wherein the absolute value of an oblique angle Θb of each of said incisions in a face of said prepreg base material from the arranging direction of said reinforcing fibers is 2 to 25° which comprises a step of preparing a preliminary prepreg by arranging many reinforcing fibers in one direction and impregnating them with a matrix resin and a step of incising said preliminary prepreg by pressing a rotary blade roller having a helical blade provided on the external surface of a roller against said prepared preliminary prepreg.
Dependencies are inferred from the claim text.