Fiber-reinforced resin material molding, method for manufacturing fiber-reinforced resin material molding, and method for manufacturing fiber-reinforced resin material

Patent metadata

Field	Value
Publication number	US-11660783-B2
Application number	US-202017108230-A
Country	US
Kind code	B2
Filing date	Dec 1, 2020
Priority date	Dec 24, 2015
Publication date	May 30, 2023
Grant date	May 30, 2023

Abstract

Provided is a fiber-reinforced resin material molding in which fluctuations of the dispersion state of the fiber bundle in the molding is small, the generation of a resin pool is suppressed, and fluctuations in physical properties such as tensile strength and modulus of elasticity are suppressed; a method for manufacturing the same, and a method for manufacturing a fiber-reinforced resin material. Provided is a fiber-reinforced resin material molding comprising: a fiber bundle comprising a plurality of reinforcing fibers; and a matrix resin, wherein a coefficient of variation in fiber content of the reinforcing fibers per unit zone of 0.1 mm square on a cut face along a thickness direction is 40% or less.

First claim

The invention claimed is:

1. A molding material comprising a thermosetting resin and a sheet-shaped carbon fiber bundle group impregnated with the thermosetting resin,
wherein such a molded product that has a coefficient of variation of 40% or less in fiber content per unit zone of 0.1 mm square on a cut face along a thickness direction is obtainable by heating and pressing the molding material using a panel molding die of 300 mm×300 mm×2 mm at 140° C. and 8 MPa for 5 minutes.

2. The molding material according to claim 1 , wherein the sheet-shaped carbon fiber bundle group comprises carbon fibers having an average fiber length of from 5 to 100 mm.

3. The molding material according to claim 1 , wherein fiber axis directions of carbon fiber bundles are substantially randomly distributed on a cut face along a plane direction in the molded product.

4. The molding material according to claim 1 , wherein the coefficient of variation is 10% to 40%.

5. The molding material according to claim 1 , wherein the molded product has an average value of fiber content per unit zone of 0.1 mm square on a cut face along a thickness direction of from 50% to 60%.

6. The molding material according to claim 1 , wherein a ratio of respective flexural moduluses of elasticity along respective directions of two orthogonal directions in the molded product is from 0.8:1 to 1:0.8 and coefficients of variation in flexural moduluses of elasticity along the respective directions are both from 5 to 15.

7. The molding material according to claim 1 , of which a degree of roughness β determined by the following Equations (1)to (3) is from 0.5 to 4.5 when a diffracted X-ray having a diffraction angle 2θ of 25.° is detected by an X-ray diffraction method:

β
=

∫
0
360

⁢



f
⁡

(
ϕ
)



⁢
d
⁢

⁢
ϕ
×

1
360

=

(

∑

i
=
2

N

⁢

(



f
⁡

(

ϕ
i

)



+



f
⁡

(

ϕ

i
-
1

)



)

×
d
⁢

⁢
ϕ
×

1
2

)

×

1
360

(
1
)

in Equation ( 1 ), f(ϕ i ) is a brightness which is represented by the following Equation (2) and obtained by subtracting an average brightness from a brightness (I(ϕ i )) at an i-th rotation angle (ϕ i ) in X-ray diffraction measurement and dϕ is a step size in the X-ray diffraction measurement. I(ϕ i ) is normalized so that an integrated intensity represented by the following Equation (3) is 10,000,

f
⁡

(

ϕ
i

)

=

I
⁡

(

ϕ
i

)

-

∑

i
=
1

N

⁢

Assignees

• Mitsubishi Chem Corp

Inventors

• Mizutori Yukihiro
• Samejima Tadao
• Watanabe Yasushi
• KANEHAGI Junji
• Kobayashi Takayuki

Classifications

• B29B15/122 Primary

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

• B29C70/504

  using rollers or pressure bands (for corrugating B29C53/22) · CPC title

• B29C70/06 Primary

  Fibrous reinforcements only · CPC title

• C08J5/04 Primary

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

• C08J2363/00

  Characterised by the use of epoxy resins; Derivatives of epoxy resins · CPC title