Structure material and manufacturing method therefor

Patent metadata

Field	Value
Publication number	US-10947352-B2
Application number	US-201716471949-A
Country	US
Kind code	B2
Filing date	Dec 20, 2017
Priority date	Dec 22, 2016
Publication date	Mar 16, 2021
Grant date	Mar 16, 2021

Abstract

Provided is a mountain-shaped structure material being excellent in stiffness and lightness. The present invention is a structure material including a resin, reinforced fibers and voids. The structure material has a specific bending stiffness represented as Ec1/3·ρ−1 being 2.5 or more where a bending modulus is Ec and a density is ρ. The structure material has a mountain shape.

First claim

The invention claimed is:

1. A structure material having a mountain shape, the structure material comprising a resin, reinforced fibers and voids,
wherein
the structure material has a specific bending stiffness represented as Ec 1/3 ·ρ −1 being 2.5 or more where a bending modulus is Ec and a density is ρ; and
a ratio of S 1 to S 2 (S 1 /S 2 ) is 0.3 to 1.7, wherein S 1 is the area of a vertical plane of a projection of the structure material, and S 2 is the area of a triangle formed by a vertex of the vertical plane of a projection of the structure material and the structure material bottom surface.

2. The structure material according to claim 1 , wherein a concentric circles homogeneity in the mountain shape is 20% or less.

3. The structure material according to claim 1 , wherein the mountain shape is a shape selected from the group consisting of a cone shape, a hemispherical shape, a polygonal pyramid shape, a truncated cone shape, a truncated hemispherical shape, and a truncated polygonal pyramid shape.

4. The structure material according to claim 1 , wherein the bending modulus (Ec) is 3 GPa or more.

5. The structure material according to claim 1 , wherein a radial homogeneity in the mountain shape is 20% or less.

6. The structure material according to claim 1 , wherein a thickness of the structure material is 0.2 mm or more.

7. The structure material according to claim 1 , satisfying the following (1) to (3):
(1) a volume content of the resin is 2.5 to 85% by volume;
(2) a volume content of the reinforced fibers is 0.5 to 55% by volume; and
(3) a volume content of the voids is 10 to 97% by volume.

8. The structure material according to claim 1 , wherein the reinforced fibers are in a nearly monofilament form, are dispersed in the structure material in a random manner, and have a non-woven form composed of discontinuous reinforced fibers having a longer of a mass mean fiber length of 1 to 15 mm.

9. The structure material according to claim 1 , wherein the reinforced fibers are any one selected from the group consisting of metal fibers, pitch-based carbon fibers, and PAN-based carbon fibers.

10. A method for manufacturing a structure material having a mountain shape, the structure material comprising a resin, reinforced fibers and voids,
wherein
the structure material has a specific bending stiffness represented as Ec 1/3 ·ρ −1 being 2.5 or more where a bending modulus is Ec and a density is ρ; and
a ratio of S 1 to S 2 (S 1 /S 2 ) is 0.3 to 1.7, wherein S 1 is the area of a vertical plane of a projection of the structure material, and S 2 is the area of a triangle formed by a vertex of the vertical plane of a projection of the structure material and the structure material bottom surface, and

wherein the method comprises at least the following steps in this order:
Step [1]: a step of heating a fiber-reinforced plastic (structure precursor) containing at least a resin and reinforced fibers until a tensile strength of the resin becomes 10 MPa or less;
Step [2]: a step of applying pressure in a state where the fiber-reinforced plastic (structure precursor) is heated until the tensile strength of the resin becomes 10 MPa or less to shape a shape; and
Step [3]: a step of expanding the fiber-reinforced plastic (structure precursor) by adjusting a thickness thereof.

Assignees

• Toray Industries

Inventors

• Fujioka Takashi
• Takebe Yoshiki
• Honma Masato

Classifications

• C08J5/0405 Primary

  with inorganic fibres · CPC title

• C08K7/04

  inorganic · CPC title

• C08J9/0085

  Use of fibrous compounding ingredients (C08J9/0076 takes precedence) · CPC title

• B29C70/40

  Shaping or impregnating by compression (B29C70/34 takes precedence){not applied} · CPC title

• B29C70/16

  using fibres of substantial or continuous length {(non-woven fabrics per se D04H3/00)} · CPC title