Composite material, method for manufacturing composite material, and method for manufacturing molded article

Patent metadata

Field	Value
Publication number	US-10926488-B2
Application number	US-201615563922-A
Country	US
Kind code	B2
Filing date	Apr 1, 2016
Priority date	Apr 3, 2015
Publication date	Feb 23, 2021
Grant date	Feb 23, 2021

Abstract

Provided is a composite material capable of keeping a good appearance even after heat processed, a method for manufacturing a composite material and a method for manufacturing a molded article. The composite material of the present invention contains a commingled yarn that contains a continuous reinforcing fiber (A) and a continuous thermoplastic resin fiber (B) as fiber components thereof; and a thermoplastic resin fiber (C) that keeps the commingled yarn in place, a thermoplastic resin that composes the thermoplastic resin fiber (C) having a melting point 15° C. or more higher than the melting point of a thermoplastic resin that composes the continuous thermoplastic resin fiber (B).

First claim

The invention claimed is:

1. A composite material comprising:
a commingled yarn that contains a continuous reinforcing fiber (A) and a continuous thermoplastic resin fiber (B) as fiber components thereof, the continuous reinforcing fiber (A) including carbon fiber and/or glass fiber; and
a thermoplastic resin fiber (C) that keeps the commingled yarn in place,
a thermoplastic resin that composes the thermoplastic resin fiber (C) having a melting point 15° C. or more higher than the melting point of a thermoplastic resin that composes the continuous thermoplastic resin fiber (B),
wherein the commingled yarn is arranged in a base, and is stitched with the thermoplastic resin fiber (C) so as to be kept in place,
wherein the thermoplastic resin that composes the thermoplastic resin fiber (C) is a polyamide resin, and
wherein the base is a thermoplastic resin film (D).

2. The composite material of claim 1 , wherein the thermoplastic resin that composes the continuous thermoplastic resin fiber (B) is a polyamide resin.

3. The composite material of claim 1 , wherein the thermoplastic resin that composes the continuous thermoplastic resin fiber (B) is a polyamide resin that contains a diamine-derived structural unit and a dicarboxylic acid-derived structural unit, 50% by mole or more of the diamine-derived structural unit being derived from xylylenediamine.

4. The composite material of claim 1 , wherein a thermoplastic resin that composes the thermoplastic resin film (D) has a melting point 15° C. or more higher than the melting point of the thermoplastic resin that composes the continuous thermoplastic resin fiber (B).

5. The composite material of claim 1 , wherein the thermoplastic resin film (D) contains a polyamide resin.

6. The composite material of claim 1 , wherein the continuous reinforcing fiber (A) is carbon fiber.

7. The composite material of claim 1 , wherein the thermoplastic resin that composes the thermoplastic resin fiber (C) has a melting point 15 to 100° C. higher than the melting point of the thermoplastic resin that composes the continuous thermoplastic resin fiber (B).

8. The composite material of claim 1 , wherein the continuous reinforcing fiber (A) in the commingled yarn has a dispersion of 60 to 100%.

9. A composite material comprising:
a commingled yarn that contains a continuous reinforcing fiber (A) and a continuous thermoplastic resin fiber (B) as fiber components thereof, the continuous reinforcing fiber (A) including carbon fiber and/or glass fiber; and
a thermoplastic resin fiber (C) that keeps the commingled yarn in place,
a thermoplastic resin that composes the thermoplastic resin fiber (C) having a melting point 15° C. or more higher than the melting point of a thermoplastic resin that composes the continuous thermoplastic resin fiber (B),
wherein a plurality of commingled yarns are arranged in parallel in one direction to form a first layer; over the first layer of commingled yarn, a plurality of commingled yarns are arranged in parallel to form a second layer, in a direction 10° to 90° away from the parallel direction of the aforementioned commingled yarn of the first layer; and the thermoplastic resin fiber (C) keeps the first layer in place.

10. The composite material of claim 1 , wherein the composite material is a non-crimp fabric.

11. The composite material of claim 1 , wherein the commingled yarn is bundled by using a treatment agent for at least either one of the continuous reinforcing fiber (A) and the continuous thermoplastic resin fiber (B).

12. The composite material of claim 1 , used for manufacturing a medical brace.

13. A method for manufacturing a composite material, the method comprising stitching a base, and a commingled yarn arranged in the base, with a thermoplastic resin fiber (C); the commingled yarn containing, as its fiber components, a continuous reinforcing fiber (A) and a continuous thermoplastic resin fiber (B), the continuous reinforcing fiber (A) including carbon fiber and/or glass fiber; and a thermoplastic resin that composes the thermoplastic resin fiber (C) having a melting point 15° C. or more higher than the melting point of a thermoplastic resin that composes the continuous thermoplastic resin fiber (B),
wherein the continuous reinforcing fiber (A) in the commingled yarn has a dispersion of 60 to 100%.

14. A composite material comprising:
a commingled yarn that contains a continuous reinforcing fiber (A) and a continuous thermoplastic resin fiber (B) as fiber components thereof, the continuous reinforcing fiber (A) including carbon fiber and/or glass fiber; and
a thermoplastic resin fiber (C) that keeps the commingled yarn in place,
a thermoplastic resin that composes the thermoplastic resin fiber (C) having a melting point 15° C. or more higher than the melting point of a thermoplastic resin that composes the continuous thermoplastic resin fiber (B),
wherein the thermoplastic resin that composes the continuous thermoplastic resin fiber (B) is a polyamide resin that contains a diamine-derived structural unit and a dicarboxylic acid-derived structural unit, 50% by mole or more of the diamine-derived structural unit being derived from xylylenediamine; and
the thermoplastic resin that composes the thermoplastic resin fiber (C) is a polyamide resin,
wherein the commingled yarn is arranged in a base and the base is a thermoplastic resin film (D).

15. The composite material of claim 14 , wherein the thermoplastic resin that composes the thermoplastic resin fiber (C) has a melting point 15 to 100° C. higher than the melting point of the thermoplastic resin that composes the continuous thermoplastic resin fiber (B).

Assignees

• Mitsubishi Gas Chemical Co

Inventors

• Ohtani Akio
• Nakai Asami
• Kaji Masataka
• Takagi Mitsuro
• Matsumoto Nobuhiko

Classifications

• D02G3/402

  the adhesive being one component of the yarn, i.e. thermoplastic yarn · CPC title

• B27N3/12

  from fibres · CPC title

• B29C70/34

  and shaping or impregnating by compression {, i.e. combined with compressing after the lay-up operation} · CPC title

• C08J5/047

  with mixed fibrous material · CPC title

• D10B2505/02

  Reinforcing materials; Prepregs · CPC title