Thermoplastic prepreg and laminate

Patent metadata

Field	Value
Publication number	US-10604633-B2
Application number	US-201414915866-A
Country	US
Kind code	B2
Filing date	Sep 9, 2014
Priority date	Sep 10, 2013
Publication date	Mar 31, 2020
Grant date	Mar 31, 2020

Abstract

A prepreg formed from a resin and unidirectionally aligned reinforcement fibers, characterized in that: the prepreg is sheet-shaped; the prepreg has cutouts of a depth for cutting the reinforcement fibers, and includes reinforcement fibers (A) cut by the cutouts to a length of 10 to 50 mm and reinforcement fibers (B) having a length of equal to or more than 50% of the sheet length of the prepreg in the alignment direction of the reinforcement fibers; the surface area of a band section including the reinforcement fibers (B) in a plan view is 1.4% to 35.0% of the entire surface area of the prepreg in a plan view; and at least one end of the reinforcement fibers (B) is positioned at an end portion of the prepreg in the alignment direction of the reinforcement fibers.

First claim

The invention claimed is:

1. A prepreg comprising a resin and unidirectionally aligned reinforcement fibers,
wherein
the prepreg is sheet-shaped;
the prepreg has slits with a depth capable of cutting off the reinforcement fibers;
the reinforcement fibers of the prepreg comprise reinforcement fibers A cut by the slits to a length of 10 to 50 mm; and reinforcement fibers B having a length equivalent to 50% or more of the sheet length of the prepreg in the alignment direction of the reinforcement fibers;
the surface area in a plan view of a band section containing the reinforcement fibers B is from 1.4% to 35.0% relative to the total surface in a plan view of the prepreg,
at least one end of the reinforcement fibers B is positioned at an edge of the prepreg in the alignment direction of the reinforcement fibers, and
at least two band sections formed from the reinforcement fibers A cut by the slits and band sections containing the reinforcement fibers B are alternately arranged in a repeating pattern over the entire surface of the prepreg, and
the prepeg comprises at least one band section containing the reinforcement fibers B between two band sections formed from the reinforcement fibers A cut by the slits.

2. The prepreg according to claim 1 , wherein a band section containing the reinforcement fibers B is disposed between one band section formed from the reinforcement fibers A cut by the slits and another band section formed from the reinforcement fibers A cut by the slits.

3. The prepreg according to claim 1 , wherein a width Wn of a band section containing the reinforcement fibers B is from 0.5 mm to 10.0 mm, and a distance Wp between one band section containing the reinforcement fibers B and another band section containing the reinforcement fibers B, is from 5 mm to 150 mm.

4. The prepreg according to claim 1 , wherein widths Wn of the band sections containing the reinforcement fibers B are all of the same length.

5. The prepreg according to claim 1 , wherein the reinforcement fibers B are reinforcement fibers that are not cut over the length from one side to the other side of the prepreg.

6. The prepreg according to claim 1 , wherein one side of the prepreg is parallel to the alignment direction of the reinforcement fibers.

7. The prepreg according to claim 1 , wherein the sum total of the cutting lengths formed by the slits in a surface area in a plan view of 1 m 2 of the prepreg, is from 20 m to 150 m.

8. The prepreg according to claim 1 , wherein an angle formed by the slits and the reinforcement fibers is from 30° to 60°.

9. The prepreg according to claim 1 , wherein a thickness of the prepreg is from 50 μm to 200 μm.

10. The prepreg according to claim 1 , wherein the reinforcement fibers are carbon fibers.

11. The prepreg according to claim 1 , wherein the resin that forms the prepreg is a thermoplastic resin.

12. The prepreg according to claim 1 , wherein at least one side of the prepreg is from 500 mm to 2000 mm in length.

13. A laminated base material formed by laminating plural sheets of prepregs, wherein the laminated base material comprises at least one sheet of the prepreg according to claim 1 .

14. The laminated base material according to claim 13 , further comprising at least one layer which is formed from a thermoplastic resin and does not contain the reinforcement fibers.

15. The laminated base material according to claim 13 , wherein a volume fraction of the reinforcement fibers included in the laminated base material is from 15% by volume to 55% by volume relative to the total volume of the laminated base material.

16. A molded article obtained by molding the laminated base material according to claim 13 by a process comprising heating and pressurization.

Assignees

• Mitsubishi Chem Corp

Inventors

• Ogasawara Hayato
• Nagasaka Masahiko
• Nabeshima Yasuhiko
• Ishikawa Takeshi
• Sasaki Akinobu

Classifications

• Y10T428/24314

  Slit or elongated · CPC title

• C08J2323/26

  modified by chemical after-treatment · CPC title

• C08J2377/02

  Polyamides derived from omega-amino carboxylic acids or from lactams thereof (C08J2377/10 takes precedence) · CPC title

• C08J2323/14

  Copolymers of propene (C08J2323/16 takes precedence) · CPC title

• C08J5/24 Primary

  Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs · CPC title