Method for inserting out-of-plane reinforcement threads and method for producing fiber-containing material

Patent metadata

Field	Value
Publication number	US-11241844-B2
Application number	US-201716312303-A
Country	US
Kind code	B2
Filing date	Jun 2, 2017
Priority date	Aug 1, 2016
Publication date	Feb 8, 2022
Grant date	Feb 8, 2022

Abstract

Provided are: a fiber-containing material which has improved strength in an out-of-plane direction without a decrease in strength in an in-plane direction; a method for inserting out-of-plane reinforcement threads; and a method for producing the fiber-containing material. The fiber-containing material contains a base material and out-of-plane reinforcement threads. The base material contains reinforcement fibers extending in a direction along a plane. The out-of-plane reinforcement threads are formed in the base material so as to extend in a direction intersecting the direction along the plane.

First claim

The invention claimed is:

1. A method for inserting out-of-plane reinforcement threads comprising:
a preparation step of preparing a base material including reinforcement fibers that extend in a direction along a plane and providing a protective sheet on at least one surface of the base material to form a sheet laminate;
a hole-forming step of forming a hole for inserting out-of-plane reinforcement threads in a direction inserting the direction along the plane, in which the reinforcement fibers extend, in the base material and the protective sheet, after the preparation step and before an out-of-plane reinforcement thread insertion step;
the out-of-plane reinforcement thread insertion step of inserting the out-of-plane reinforcement threads into an inside of the prepared base material and an inside of the prepared protective sheet only in the direction intersecting the direction along the plane, wherein a length of the out-of-plane reinforcement threads is the same as a total of thickness of the base material and the protective sheet forming the sheet laminate; and
a sheet removal step of removing the protective sheet after the out-of-plane reinforcement thread insertion step such that the out-of-plane reinforcement threads protrude from the base material by a length corresponding to the thickness of the protective sheet.

2. The method for inserting out-of-plane reinforcement threads according to claim 1 ,
wherein the hole-forming step is carried out using a hole-forming portion that radiates a laser to the protective sheet and the base material in the direction intersecting the direction along the plane, and
the out-of-plane reinforcement thread insertion step is carried out using a fiber fragment injection portion that injects fiber fragments which serve as the out-of-plane reinforcement threads into the protective sheet and the base material in the direction intersecting the direction along the plane.

3. A method for producing a fiber-containing material, comprising:
producing a fiber-containing material in which the out-of-plane reinforcement threads are formed in the inside of the base material including the reinforcement fibers using the method for inserting out-of-plane reinforcement threads according to claim 1 .

4. The method for producing a fiber-containing material according to claim 3 , further comprising:
an impregnation step of impregnating the reinforcement fibers with a resin.

5. The method for producing a fiber-containing material according to claim 4 , further comprising:
a curing step of curing the resin after the out-of-plane reinforcement thread insertion step and after the impregnation step.

Assignees

• Mitsubishi Heavy Ind Ltd

Inventors

• Morishima Shunichi
• Kozasa Toshio
• Hatano Masatake
• Kishimoto Kazuaki
• Takeuchi Yukio
• Yamashita Masayuki
• Ojika Hitoshi

Classifications

• C08J5/24

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

• B32B38/04

  Punching, slitting or perforating · CPC title

• B29C70/24 Primary

  oriented in at least three directions forming a three-dimensional [3D] structure · CPC title

• D04H1/45

  by forming intermeshing loops or stitches from some of the fibres · CPC title

• B32B2371/00

  Polyethers, e.g. PEEK, i.e. polyether-etherketone; PEK, i.e. polyetherketone · CPC title