Fiber-reinforced composite material and sandwich structure

Patent metadata

Field	Value
Publication number	US-12076943-B2
Application number	US-202017778073-A
Country	US
Kind code	B2
Filing date	Nov 16, 2020
Priority date	Nov 29, 2019
Publication date	Sep 3, 2024
Grant date	Sep 3, 2024

Abstract

An object of the present invention is to obtain a fiber-reinforced composite material achieving both lightweight properties and mechanical properties at a high level. The present invention is a fiber-reinforced composite material including: a resin (A); and a reinforcing fiber (B), and including: a fiber-reinforced structure portion including an in-plane orientation portion having an average fiber orientation angle of the reinforcing fiber (B) of 0° or more and 45° or less and an out-of-plane orientation portion having an average fiber orientation angle of the reinforcing fiber (B) of more than 45° and 90° or less; and a cavity portion defined by the in-plane orientation portion and the out-of-plane orientation portion of the fiber-reinforced structure portion.

First claim

The invention claimed is:

1. A The fiber-reinforced composite material comprising:
a resin (A), wherein the resin (A) is a thermoplastic resin; and
a reinforcing fiber (B), wherein the reinforcing fiber (B) is a discontinuous fiber having a number average fiber length of 1 mm or more and 50 mm or less, and including:
a fiber-reinforced structure portion including an in-plane orientation portion having an average fiber orientation angle of the reinforcing fiber (B) of 0° or more and 45° or less and an out-of-plane orientation portion having an average fiber orientation angle of the reinforcing fiber (B) of more than 45° and 90° or less; and
a tunnel-shaped cavity portion defined by the in-plane orientation portion and the out-of-plane orientation portion of the fiber-reinforced structure portion,
wherein the tunnel-shaped cavity portion extends in an in-plane direction of the fiber reinforced composite material, and
wherein the in-plane direction is orthogonal to a thickness direction of the fiber reinforced composite material.

2. The fiber-reinforced composite material according to claim 1 , wherein in a cross section orthogonal to an extending direction of the tunnel-shaped cavity portion, a cross-sectional area of an out-of-plane orientation portion with respect to a cross-sectional area of an in-plane orientation portion is 0.5 times or more and 10 times or less.

3. The fiber-reinforced composite material according to claim 1 , wherein the tunnel-shaped cavity portion is defined by an in-plane orientation portion having an average fiber orientation angle of 0° or more and 30° or less and an out-of-plane orientation portion having an average fiber orientation angle of 60° or more and 90° or less.

4. The fiber-reinforced composite material according to claim 1 , wherein the thermoplastic resin is at least one thermoplastic resin selected from the group consisting of polyolefin, polycarbonate, polyester, polyarylene sulfide, polyamide, polyoxymethylene, polyetherimide, polyethersulfone, and polyarylene ether ketone.

5. The fiber-reinforced composite material according to claim 1 , wherein reinforcing fibers (B) are randomly dispersed in the fiber-reinforced structure portion.

6. The fiber-reinforced composite material according to claim 1 , wherein a reinforcing fiber (B) is carbon fiber.

7. The fiber-reinforced composite material according to claim 1 , wherein the fiber-reinforced structure portion has micropores with an average pore diameter of 500 μm or less.

8. The fiber-reinforced composite material according to claim 1 , wherein a specific gravity of the fiber-reinforced structure portion is 0.3 g/cm 3 or more and 0.8 g/cm 3 or less.

9. The fiber-reinforced composite material according to claim 1 , wherein an average value of maximum lengths of cross-sectional opening portion of the tunnel-shaped cavity portion is 1000 μm or more and 10000 μm or less.

10. The fiber-reinforced composite material according to claim 1 , wherein a specific gravity of the fiber-reinforced composite material is 0.001 g/cm 3 or more and 0.2 g/cm 3 or less.

11. The fiber-reinforced composite material according to claim 1 , wherein a thickness of the entire fiber-reinforced composite material is 0.1 mm or more and 5 mm or less.

12. The fiber-reinforced composite material according to claim 1 , comprising a laminated structure formed by laminating a plurality of layers in which opening portions of tunnel-shaped cavity portions are aligned in an in-plane direction in a cross section orthogonal to an extending direction of the tunnel-shaped cavity portion.

13. A sandwich structure comprising a skin layer disposed on both surfaces of the fiber-reinforced composite material according to claim 1 .

14. The sandwich structure according to claim 13 , wherein the skin layer has a structure in which a fiber-reinforced resin layer with reinforcing fibers arranged in one direction is laminated in a plurality of layers while changing a lamination angle, that is, while changing an arrangement direction of the reinforcing fibers in each layer.

15. The fiber-reinforced composite material according to claim 1 , wherein the tunnel-shaped cavity portion is defined by an out-of-plane orientation portion having an average fiber orientation angle of 75° or more and 90° or less.

16. The fiber-reinforced composite material according to claim 7 , wherein the average pore diameter is 10 μm or more and 150 μm or less.

17. The fiber-reinforced composite material according to claim 1 , wherein the fiber-reinforced composite material is molded by using a folded prepreg of resin-impregnated sheet-shaped reinforcing fiber.

18. The fiber-reinforced composite material according to claim 17 , wherein the tunnel-shaped cavity portion extends in an in-plane direction of the folded prepreg.

19. The fiber-reinforced composite material according to claim 1 , wherein the reinforcing fiber (B) is a reinforced fiber substrate (B′) and the reinforced fiber substrate (B′) has a folded structure including a substantially triangular structure formed in such a manner that a first fold is adjacent to one of fourth folds when a certain fold is the first fold in the cross section, wherein two folds adjacent to both sides of the first fold are a second fold, two folds further adjacent to the outside of the second fold are a third fold, and two folds further adjacent to the outside of the third fold are the fourth fold.

20. The fiber-reinforced composite material according to claim 1 , wherein the cavity portion has a structure in which a pair of adjacent folds of the reinforcing fibers (B) are bonded to each other by the resin (A).

Assignees

• Toray Industries

Inventors

• Imai Naokichi
• Shinohara Kotaro
• Honma Masato

Classifications

• B32B2260/021

  Fibrous or filamentary layer · CPC title

• B32B2250/20

  All layers being fibrous or filamentary · CPC title

• B32B2305/076

  Prepregs · CPC title

• B32B2305/026

  Porous · CPC title

• B32B2260/046

  Synthetic resin · CPC title