Fiber-reinforced thermoplastic resin filament and shaped product of same

Patent metadata

Field	Value
Publication number	US-11566114-B2
Application number	US-201816759252-A
Country	US
Kind code	B2
Filing date	Nov 5, 2018
Priority date	Nov 7, 2017
Publication date	Jan 31, 2023
Grant date	Jan 31, 2023

Abstract

A fiber-reinforced thermoplastic resin filament is obtained by impregnating a continuous reinforcing fiber with a thermoplastic resin, and satisfies all of conditions (a) to (c).(a) The volume ratio of a reinforcing fiber in a fiber-reinforced thermoplastic resin filament is 30 to 80%; and the volume ratio of a thermoplastic resin in a fiber-reinforced thermoplastic resin filament is 70 to 20%.(b) The thickness of a fiber-reinforced thermoplastic resin filament is 0.01 to 3 mm.(c) The length of a filament contained in a fiber-reinforced thermoplastic resin filament is 1 m or more.

First claim

The invention claimed is:

1. A fiber-reinforced thermoplastic resin 3D printing filament of continuous reinforcing fiber impregnated with a thermoplastic resin, having
(a) a volume content of the reinforcing fiber of 30 to 80 vol % and a volume content of the thermoplastic resin filament of 70 to 20 vol %,
(b) a thickness of 0.01 to 3 mm,
(c) a filament length of 1 m or more, and
(d) a circular filament cross section.

2. The fiber-reinforced thermoplastic resin 3D printing filament according to claim 1 , having a void rate of 5% or less.

3. The fiber-reinforced thermoplastic resin 3D printing filament according to claim 1 , having a flexural rigidity of 1 N·m 2 or less.

4. The fiber-reinforced thermoplastic resin 3D printing filament according to claim 1 , wherein the reinforcing fiber is made of at least one selected from a group consisting of a carbon fiber, a glass fiber and an aramid fiber.

5. The fiber-reinforced thermoplastic resin 3D printing filament according to claim 1 , wherein the thermoplastic resin is made of at least one selected from a group consisting of polyphenylene sulfide resin (PPS), polyarylene ether ketone resin (PAEK), polyetherimide resin (PEI), polyether sulfone resin (PES) and a liquid crystalline polymer resin (LCP).

6. The fiber-reinforced thermoplastic resin 3D printing filament according to claim 1 , wherein the reinforcing fiber has 90% or more of an average value D of a dispersion parameter d calculated by steps (i) to (iv):
(i) taking an image of a cross section of the fiber-reinforced thermoplastic resin filament perpendicular to an orientation direction;
(ii) dividing the image of the cross section into square units having a side length t within a range of Formula (1);
(iii) calculating the dispersion parameter d by Formula (2);
(iv) calculating the average value D of the dispersion parameter d by repeating a plurality of sets of steps (i) to (iii),
1.5 a≤t≤ 2.5 a   (1), where:

a: fiber diameter; and
t: side length of unit,
Dispersion parameter d =100×(the number of units including reinforcing fibers within range)/(the number of all units)  (2).

7. The fiber-reinforced thermoplastic resin 3D printing filament according to claim 1 , wherein the average value D of the dispersion parameter d has 4% or more of a coefficient of variance.

8. The fiber-reinforced thermoplastic resin 3D printing filament according to claim 1 , further comprising an outer most layer coated with the thermoplastic resin.

9. A shaped product, comprising the fiber-reinforced thermoplastic resin 3D printing filament according to claim 1 .

Assignees

• Toray Industries

Inventors

• Koshi Masayuki
• Naruse Yoshihiro
• ISHIDA Shoma

Classifications

• C08J2381/04

  Polysulfides · CPC title

• C08J5/042 Primary

  with carbon fibres · CPC title

• D06M2101/30

  Synthetic polymers consisting of macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds · CPC title

• D06M15/63 Primary

  containing sulfur in the main chain, e.g. polysulfones · CPC title

• D06M15/647

  containing polyether sequences · CPC title