US10933563B2 · US · B2
| Field | Value |
|---|---|
| Publication number | US-10933563-B2 |
| Application number | US-201815973919-A |
| Country | US |
| Kind code | B2 |
| Filing date | May 8, 2018 |
| Priority date | Dec 24, 2015 |
| Publication date | Mar 2, 2021 |
| Grant date | Mar 2, 2021 |
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Provided is a fiber-reinforced resin material molding in which fluctuations of the dispersion state of the fiber bundle in the molding is small, the generation of a resin pool is suppressed, and fluctuations in physical properties such as tensile strength and modulus of elasticity are suppressed; a method for manufacturing the same; and a method for manufacturing a fiber-reinforced resin material. Provided is a fiber-reinforced resin material molding comprising: a fiber bundle comprising a plurality of reinforcing fibers; and a matrix resin, wherein a coefficient of variation in fiber content of the reinforcing fibers per unit zone of 0.1 mm square on a cut face along a thickness direction is 40% or less.
Opening claim text (preview).
The invention claimed is: 1. A fiber-reinforced resin material molding comprising: a fiber bundle comprising a plurality of reinforcing fibers; and a matrix resin, wherein a coefficient of variation in fiber content of the reinforcing fibers per unit zone of 0.1 mm square on a cut face along a thickness direction of the fiber-reinforced resin material molding is 40% or less, wherein a ratio of respective flexural moduluses of elasticity along respective directions of two orthogonal directions in the fiber-reinforced resin material molding is from 0.8:1 to 1:0.8 and coefficients of variation in flexural moduluses of elasticity along the respective directions are both from 5 to 15. 2. The fiber-reinforced resin material molding according to claim 1 , wherein an average fiber length of the reinforcing fibers is from 5 to 100 mm. 3. The fiber-reinforced resin material molding according to claim 1 , wherein a direction of a fiber axis of the fiber bundle on a cut face along a plane direction is substantially randomly distributed. 4. The fiber-reinforced resin material molding according to claim 1 , wherein the coefficient of variation is 10% or more. 5. The fiber-reinforced resin material molding according to claim 1 , wherein an average value of fiber contents of the reinforcing fibers per unit zone of 0.1 mm square on a cut face along a thickness direction of the fiber-reinforced resin material molding is from 50% to 60%. 6. The fiber-reinforced resin material molding according to claim 1 , wherein the matrix resin is a thermosetting resin. 7. A method for manufacturing the fiber-reinforced resin material molding according to claim 1 , the method comprising: molding the fiber reinforced resin material molding from a sheet-shaped fiber-reinforced resin material wherein a matrix resin has penetrated between dispersed carbon fiber bundles, and of which a degree of roughness β determined by the following Equations (1) to (3) is from 0.5 to 4.5 when a diffracted X-ray having a diffraction angle 2θ of 25.4° is detected by an X-ray diffraction method: β = ∫ 0 360 f ( ϕ ) d ϕ × 1 360 = ( ∑ i = 2 N ( f ( ϕ i ) + f ( ϕ i - 1 ) ) × d ϕ × 1 2 ) × 1 360 ( 1 ) in Equation (1), f(ϕ i ) is a brightness which is represented by the following Equation (2) and obtained by subtracting an average brightness from a brightness (I(ϕ i )) at an i-th rotation angle (ϕ i ) in X-ray diffraction measurement and dϕ is a step size in the X-ray diffraction measurement, I(ϕ i ) is normalized so that an integrated intensity represented by the following Equation (3) is 10,000, f ( ϕ i ) = I ( ϕ i )
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