# US 9,873,242 B2 · Method for preparing continuous carbon fiber-reinforced thermoplastic prepreg

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- Number: US 9,873,242 B2
- Document ID: US9873242B2
- Status: Granted
- Kind: B2
- Application number: 14/654,835
- Filed: 2013-12-24
- Published: 2015-11-26
- Granted: 2018-01-23
- Earliest claimed: 2012-12-27
- Assignees: Posco; Research Institute of Industrial Science & Technology
- Applicants: Posco; Research Institute of Industrial Science & Technology
- Inventors: Il-Joon Bae; Ik-Pyo Hong; Sei-Min Park; Sung-Young Lee
- Web page: https://patentgrep.com/patent/US9873242B2

## CPC

- B32B 38/1808: {characterised by the laying up of the layers}
- B29C 65/1425: {Microwave radiation}
- B29C 70/506: {and impregnating by melting a solid material, e.g. sheet, powder, fibres (B29C70/508 takes precedence)}
- B32B 27/08: of synthetic resin
- B32B 37/04: characterised by the partial melting of at least one layer
- B32B 37/06: characterised by the heating method
- B32B 38/0012: {Mechanical treatment, e.g. roughening, deforming, stretching}
- C08J 5/243: {using carbon fibres}
- B29K 2105/0872: {Prepregs}
- B29K 2105/0881: {unidirectional}
- B29K 2307/04: Carbon
- B32B 2260/021: Fibrous or filamentary layer
- B32B 2260/046: Synthetic resin
- B32B 2262/106: Carbon fibres, e.g. graphite fibres
- B32B 2305/076: Prepregs
- B32B 2305/20: in the form of a non-woven mat
- B32B 2305/74: Partially cured
- B32B 2309/02: Temperature
- B32B 2309/12: Pressure
- B32B 2310/0806: using electromagnetic radiation
- B32B 2310/0825: using IR radiation
- B32B 2310/0862: using microwave
- B32B 2313/04: Carbon
- C08J 2300/22: Thermoplastic resins
- C08J 2323/12: Polypropene
- C08J 2367/02: Polyesters derived from dicarboxylic acids and dihydroxy compounds; (C08J2367/06 takes precedence)
- C08J 2371/00: Characterised by the use of polyethers obtained by reactions forming an ether link in the main chain; Derivatives of such polymers
- C08J 2377/00: Characterised by the use of polyamides obtained by reactions forming a carboxylic amide link in the main chain; Derivatives of such polymers
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- 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)
- 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

The present invention relates to a method for preparing a continuous carbon fiber-reinforced thermoplastic prepreg, and more specifically, to a method for preparing a continuous carbon fiber-reinforced thermoplastic semi-prepreg or prepreg, comprising the steps of: providing a plurality of carbon fibers having an increased width; preparing a layered product by arranging a thermoplastic film on at least a part of the upper and lower portions of the carbon fibers having an increased width; and preparing a joined product by joining the thermoplastic film and the carbon fibers comprising the layered body.

## Claims

### Claim 1

A method for preparing a continuous carbon fiber reinforced thermoplastic prepreg, the method comprising:
preparing widely spread filaments of carbon fiber;
forming a stack by disposing a thermoplastic film on at least one side of upper and lower sides of the widely spread filaments of carbon fiber; and
forming a bonded material by bonding the thermoplastic film and the carbon fiber of the stack by radiating microwaves,
wherein the preparing of the widely spread filaments of carbon fiber comprises coating the filaments of carbon fiber with a bonding resin having a melting point lower than that of the thermoplastic film.

### Claim 2 (depends on 1)

The method of claim 1, wherein the widely spread filaments of carbon fiber are arranged at regular intervals.

### Claim 3 (depends on 1)

The method of claim 1, wherein the thermoplastic film is formed of a material selected from the group consisting of polypropylene (PP), polyamide (PA), polyetheretherketone (PEEK), and polyethyleneterephthalate (PET).

### Claim 4 (depends on 1)

The method of claim 1, wherein the thermoplastic film has a thickness of 10 μm to 100 μm.

### Claim 5 (depends on 1)

The method of claim 1, further comprising pressing the bonded material by using a pair of rollers under a vacuum or atmospheric pressure conditions.

### Claim 6 (depends on 5)

The method of claim 5, after the pressing is performed, further comprising:
heating the bonded material; and
additionally pressing the bonded material by using a pair of rollers under a vacuum or atmospheric pressure conditions.

### Claim 7 (depends on 6)

The method of claim 6, wherein the heating of the bonded material is performed using at least one heat source selected from the group consisting of halogen lamps and infrared lamps.

### Claim 8 (depends on 1)

The method of claim 1, wherein forming a stack is performed by disposing a thermoplastic film on both upper and lower sides of the widely spread filaments of carbon fiber.