Fiber-reinforced resin material, molded article, method and device for manufacturing fiber-reinforced resin material, and fiber bundle group inspection device

Patent metadata

Field	Value
Publication number	US-11951692-B2
Application number	US-202318155773-A
Country	US
Kind code	B2
Filing date	Jan 18, 2023
Priority date	Jun 24, 2015
Publication date	Apr 9, 2024
Grant date	Apr 9, 2024

Abstract

The purpose of the present invention is to provide a fiber-reinforced resin material having minimal directionality of strength as well as excellent productivity, a method and device for manufacturing a fiber-reinforced resin material whereby a molded article is obtained, and a device for inspecting a fiber bundle group. A method for manufacturing a sheet-shaped fiber-reinforced resin material in which a paste (P 1 ) is impregnated between cut fiber bundles (CF), the method for manufacturing a fiber-reinforced resin material including a coating step applying a coating of a paste (P 1 ) on a first sheet (S 11 ) conveyed in a predetermined direction, a cutting step for cutting a long fiber bundle (CF) using a cutter ( 113 A), a scattering step for dispersing the cut fiber bundles (CF) and scattering the cut fiber bundles (CF) on the paste (P 1 ), and an impregnation step for pressing a fiber bundle group (F 1 ) and the paste (P 1 ) on the first sheet (S 11 ) and impregnating the paste (P 1 ) between the fiber bundles (CF).

First claim

The invention claimed is:

1. A sheet-shaped fiber-reinforced resin material comprising dispersed carbon fiber bundles impregnated with a thermosetting resin and having a longitudinal direction and a width direction, wherein a diffracted X-ray at a diffraction angle 2θ of 25.4° is detected by an X-ray diffraction method, and a roughness β obtained by the following Formulas (1) to (3) is in a range of 0.5 to 4.5,

β
=

∫
0
360

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f
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⁢
d
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1
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wherein:
f(ϕ i ) is a luminance obtained by subtracting an average luminance from a luminance (I(ϕ i )) at an i-th rotation angle (ϕ i ) in X-ray diffraction measurement represented by the following Formula (2),
dϕ is a step width of the X-ray diffraction measurement, I(ϕ i ) is normalized so that an integration strength represented by the following Formula (3) becomes 10000:

f
⁡
(

ϕ
i

)

=

I
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(

ϕ
i

)

-

∑

i
=
1

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⁢

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(

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N

(
2
)

∫
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I
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ϕ
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⁢
d
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ϕ

Assignees

• Mitsubishi Chem Corp

Inventors

• Iwata Hiroshi
• Yamamoto Nobuyuki
• Okutsu Hajime
• Ishikawa Ryuichi
• Akiyama Koichi
• Kobayashi Takayuki

Classifications

• B29C70/12 Primary

  using fibres of short length, e.g. in the form of a mat {(non-woven fabrics per se D04H1/00)} · CPC title

• B29B11/16

  comprising fillers or reinforcement {(non-woven fabrics per se D04H1/00, D04H3/00)} · CPC title

• B29B15/08

  of reinforcements or fillers (chemical aspects C08J, C08K) · CPC title

• B29B15/122

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

• B29C43/48

  Endless belts · CPC title