Method for manufacturing FRP precursor and method for manufacturing FRP

Patent metadata

Field	Value
Publication number	US-11446845-B2
Application number	US-201816497127-A
Country	US
Kind code	B2
Filing date	Mar 28, 2018
Priority date	Mar 28, 2017
Publication date	Sep 20, 2022
Grant date	Sep 20, 2022

Abstract

In the method for adhering a resin film with an aggregate under an atmospheric pressure in which workability is excellent and spouting of the resin from an edge portion of the aggregate can be suppressed, the present invention provides a method for producing an FRP precursor with excellent resin filling property into bulk voids of the aggregate as well as a method for producing an FRP. Specifically, provided is the method for producing the FRP precursor by adhering a thermosetting resin film to one surface of an aggregate that is in a form of a sheet under an atmospheric pressure, wherein the method includes a process in which the thermosetting resin film and the aggregate are press-adhered by heating by means of a pressure roll having a temperature in a range of +5° C. to +35° C. relative to a temperature at which a minimum melt viscosity of the film is exhibited.

First claim

The invention claimed is:

1. A method for producing an FRP precursor, comprising:
providing an aggregate that is in a form of a sheet, and
heating and press-adhering a thermosetting resin film to a surface of the aggregate by pressing the thermosetting resin film to the surface of the aggregate with a pressure roll at a roll pressure in a range of 0.5 to 1.0 MPa, wherein the pressure roll has a temperature in a range of +30° C. to +35° C. relative to a temperature at which a minimum melt viscosity of the thermosetting resin film is exhibited, wherein the heating and press-adhering are conducted while the aggregate, the thermosetting resin film and the pressure roll are under an atmospheric pressure.

2. A method for producing an FRP, comprising:
providing an aggregate that is in a form of a sheet,
heating and press-adhering a thermosetting resin film to a surface of the aggregate by pressing the thermosetting resin film to the surface of the aggregate with a pressure roll at a roll pressure in a range of 0.5 to 1.0 MPa, wherein the pressure roll has a temperature in a range of +30° C. to +35° C. relative to a temperature at which a minimum melt viscosity of the thermosetting resin film is exhibited to form an FRP precursor, wherein the heating and press-adhering are conducted while the aggregate, the thermosetting resin film and the pressure roll are under an atmospheric pressure; and
curing the FRP precursor.

3. A method for producing an FRP precursor, comprising:
providing an aggregate that is in a form of a sheet, and
heating and press-adhering thermosetting resin films to each of opposing surfaces of the aggregate by pressing each of the thermosetting resin films to each of the opposing surfaces of the aggregate with pressure rolls at a roll pressure in a range of 0.5 to 1.0 MPa, wherein the pressure rolls have a temperature in a range of +30° C. to +35° C. relative to temperature at which a minimum melt viscosity of the thermosetting resin films is exhibited, wherein the heating and press-adhering are conducted while the aggregate, the thermosetting resin films and the pressure rolls are under an atmospheric pressure.

4. A method for producing an FRP, comprising:
providing an aggregate that is in a form of a sheet, and
heating and press-adhering thermosetting resin films to each of opposing surfaces of the aggregate by pressing each of the thermosetting resin films to each of the opposing surfaces of the aggregate with pressure rolls at a roll pressure in a range of 0.5 to 1.0 MPa, wherein the pressure rolls have a temperature in a range of +30° C. to +35° C. relative to the temperature at which a minimum melt viscosity of the thermosetting resin films is exhibited, wherein the heating and press-adhering are conducted while the aggregate, the thermosetting resin films and the pressure rolls are under an atmospheric pressure to form an FRP precursor; and
curing the FRP precursor.

Assignees

• Hitachi Chemical Co Ltd
• Showa Denko Materials Co Ltd

Inventors

• Sasaki Ryohta
• Nakamura Yukio
• Danjoubara Kazutoshi
• Saitoh Takeshi
• Hashimoto Shintaro

Classifications

• B29C70/506 Primary

  and impregnating by melting a solid material, e.g. sheet, powder, fibres (B29C70/508 takes precedence) · CPC title

• B29B15/122

  with a matrix in liquid form, e.g. as melt, solution or latex · CPC title

• B29B15/12 Primary

  of reinforcements of indefinite length · CPC title

• B29C70/06

  Fibrous reinforcements only · CPC title

• B29B11/12 Primary

  Compression moulding · CPC title