Thermoplastic composite material and formed body

Patent metadata

Field	Value
Publication number	US-11203673-B2
Application number	US-201815971718-A
Country	US
Kind code	B2
Filing date	May 4, 2018
Priority date	Nov 6, 2015
Publication date	Dec 21, 2021
Grant date	Dec 21, 2021

Abstract

A thermoplastic composite material comprising, a fiber bundle having a polypropylene emulsion impregnated therein and having a plurality of reinforcing fibers lined up in a predetermined direction, and satisfies the following conditions (1) to (4); and a formed body:(1) A void content of the thermoplastic composite material is 3% or less,(2) A fiber volume fraction of the thermoplastic composite material is 40% or more and 70% or less,(3) A bending strength of a laminated body, in which a plurality of layers of the thermoplastic composite material has been laminated so that the reinforcing fibers would be lined up in one direction, when bent in the fiber-axis direction and measured in conformity to JIS K7074, is 250 MPa or more, and a bending elastic modulus of the laminated body is 90 GPa or more, and(4) A variation coefficient of the bending strength, when measured at N=5 or more and calculated in conformity to JIS K7074, is within 7%.

First claim

The invention claimed is:

1. A thermoplastic composite material comprising, a fiber bundle having a polypropylene emulsion impregnated therein and having a plurality of reinforcing fibers lined up in a predetermined direction,
wherein the thermoplastic composite material satisfies the following conditions (1) to (4):

(1) A void content of the thermoplastic composite material is 3% or less,
(2) A fiber volume fraction of the thermoplastic composite material is 45% or more to 65% or less,
(3) A bending strength of a laminated body, in which a plurality of layers of the thermoplastic composite material has been laminated so that the reinforcing fibers would be lined up in one direction, when bent in the fiber-axis direction and measured in conformity to JIS K7074, is 250 MPa or more, and a bending elastic modulus of the laminated body is 90 GPa or more, and
(4) A variation coefficient of the bending strength, when measured at N=5 or more and calculated in conformity to JIS K7074, is within 7%.

2. The thermoplastic composite material as described in claim 1 , wherein the reinforcing fiber comprises a carbon fiber.

3. The thermoplastic composite material as described in claim 1 , wherein the polypropylene is graft-modified.

4. The thermoplastic composite material as described in claim 1 , wherein the thermoplastic composite material comprises at least one or more selected from the group consisting of Na, K, ammonia, and an organic amine compound.

5. The thermoplastic composite material as described in claim 1 , wherein the thermoplastic composite material does not contain any surfactant.

6. A formed body of the thermoplastic composite material as described in claim 1 .

7. A thermoplastic composite material comprising a fiber bundle having a plurality of reinforcing fibers lined up in a predetermined direction, and polypropylene,
wherein the thermoplastic composite material satisfies the following conditions (1) to (5):

(1) A void content of the thermoplastic composite material is 3% or less,
(2) A fiber volume fraction of the thermoplastic composite material is 45% or more and 65% or less,
(3) A bending strength of a laminated body, in which a plurality of layers of the thermoplastic composite material has been laminated so that the reinforcing fibers would be lined up in one direction, when bent in the fiber-axis direction and measured in conformity to JIS K7074, is 250 MPa or more and a bending elastic module of the laminated body is 90 GPa or more,
(4) A variation coefficient of the bending strength, when measured at N=5 or more and calculated in conformity to JIS K7074, is within 7%, and
(5) The thermoplastic composite material further comprises at least one or more selected from the group consisting of Na, K, ammonia, and an organic amine compound.

8. The thermoplastic composite material as described in claim 7 , wherein the reinforcing fiber comprises a carbon fiber.

9. A formed body of the thermoplastic composite material as described in claim 7 .

10. The thermoplastic composite material as described in claim 1 , wherein the fiber volume fraction of the thermoplastic composite material is 45% or more to 55% or less.

11. The thermoplastic composite material as described in claim 1 , wherein the thickness of the thermoplastic composite material is 0.05 mm or more and 0.5 mm or less.

12. The thermoplastic composite material as described in claim 7 , wherein the fiber volume fraction of the thermoplastic composite material is 45% or more to 55% or less.

13. The thermoplastic composite material as described in claim 7 , wherein the thickness of the thermoplastic composite material is 0.05 mm or more and 0.5 mm or less.

Assignees

• Furukawa Electric Co Ltd

Inventors

• Yoshizaki Motoko
• Nakano Makiko
• Ito Takayori
• Ikura Yukihiro
• Iida Takahiro
• Morishima Yasumasa
• Hara Hidekazu

Classifications

• B29C70/30 Primary

  Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core · CPC title

• C08J5/042 Primary

  with carbon fibres · CPC title

• B29B15/125

  by dipping · CPC title

• C08J5/04

  Reinforcing macromolecular compounds with loose or coherent fibrous material · CPC title

• B29C43/02

  of articles of definite length, i.e. discrete articles {(B29C35/0227 takes precedence)} · CPC title