Self-adhesive prepreg and method for producing same

Patent metadata

Field	Value
Publication number	US-12134261-B2
Application number	US-201816496569-A
Country	US
Kind code	B2
Filing date	Mar 22, 2018
Priority date	Mar 23, 2017
Publication date	Nov 5, 2024
Grant date	Nov 5, 2024

Abstract

The present invention provides a self-adhesive prepreg which is characterized by comprising: a base prepreg that is composed of reinforcing fibers and a thermosetting resin composition (I), some or all of which is impregnated into a reinforcing fiber layer that is formed of the reinforcing fibers; an adhesive layer that is composed of a nonwoven fabric which is laminated on at least one surface of the base prepreg so as to be integrated with the base prepreg and a thermosetting resin composition (II) which is laminated on the surface of the nonwoven fabric so as to be integrated with the nonwoven fabric.

First claim

The invention claimed is:

1. A self-adhesive prepreg comprising:
a base prepreg including reinforcing fibers, and a thermosetting resin composition (I) that is partially or entirely impregnated into a reinforcing fiber layer that is formed of the reinforcing fibers; and
an adhesive layer including a nonwoven fabric that is laminated on at least one surface of the base prepreg so as to be integrated with the base prepreg, and a thermosetting resin composition (II) layer that is laminated on a surface of the nonwoven fabric so as to be integrated with the nonwoven fabric
wherein
the base prepreg contains the thermosetting resin composition (I) by 30 to 50% by mass,
the thickness of the base prepreg is 60 to 500 μm,
the content of the thermosetting resin composition (II) is 100 to 300 g/m 2 ,
the thermosetting resin composition (I) and the thermosetting resin composition (II) are compatible and are mixed at the time of pressure molding,
the thermosetting resin composition (I) and the thermosetting resin composition (II) has a minimum resin viscosity of 0.1 to 100 Poise,
the nonwoven fabric is formed of thermoplastic resin,
the thickness of the nonwoven fabric is 0.15 to 1.0 mm,
the mass per unit area of the nonwoven fabric is 10 to 50 g/m 2 , and
the nonwoven fabric has a 10% extension load of 35 N or less.

2. The self-adhesive prepreg according to claim 1 , wherein each of the thermosetting resin composition (I) and the thermosetting resin composition (II) is an epoxy resin composition.

3. The self-adhesive prepreg according to claim 1 , wherein the thermosetting resin composition (I) and the thermosetting resin composition (II) have the same composition.

4. The self-adhesive prepreg according to claim 1 , wherein in the adhesive layer, the thermosetting resin composition (II) concentrates on a side of a surface of the adhesive layer opposite to a surface thereof that is in contact with the base prepreg.

5. A method for producing the self-adhesive prepreg according to claim 1 , the method comprising:
obtaining the base prepreg by impregnating the thermosetting resin composition (I) into the reinforcing fiber layer; and
laminating the adhesive layer including the nonwoven fabric and the thermosetting resin composition (II) on the surface of the prepreg so as to be integrated with the base prepreg.

6. A method for producing a honeycomb laminated composite material, the method comprising molding a honeycomb core laminate, in which the self-adhesive prepreg according to claim 1 and a honeycomb core are laminated, by applying heat and pressure.

7. A honeycomb laminated composite material comprising a honeycomb core, and a cured body of the self-adhesive prepreg according to claim 1 that is laminated on a surface of the honeycomb core so as to be attached to the honeycomb core.

Assignees

• Teijin Ltd

Inventors

• Kawakami Atsushi
• Schubert Matthias
• Kaneko Toru

Classifications

• B32B2305/076

  Prepregs · CPC title

• B32B2305/024

  Honeycomb · CPC title

• B32B2262/106

  Carbon fibres, e.g. graphite fibres · CPC title

• B32B2262/0284

  Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT] · CPC title

• B32B2260/046

  Synthetic resin · CPC title