Method for producing FRP precursor

Patent metadata

Field	Value
Publication number	US-12466946-B2
Application number	US-202118025456-A
Country	US
Kind code	B2
Filing date	Sep 10, 2021
Priority date	Sep 11, 2020
Publication date	Nov 11, 2025
Grant date	Nov 11, 2025

Abstract

Provided is a production method of an FRP precursor. The method includes: a pre-coating step of applying a resin varnish having a filler content of 5 vol % or less in a solid content thereof, to a sheet-shaped aggregate, and a melt-pasting step of melt-pasting a pair of resin films, each having a filler content of 30 vol % or more, to both surfaces of the aggregate, after the pre-coating step.

First claim

The invention claimed is:

1 . A method of producing an FRP precursor, the method comprising:
pre-coating a resin varnish having a filler content of 5 vol % or less in a solid content thereof, to a sheet-shaped aggregate; providing a pair of resin films, each having a filler content of 30 vol % or more; and melt-pasting the pair of resin films, each having a filler content of 30 vol % or more, to respective sides of the aggregate, after the pre-coating, wherein in the pre-coating, an volume of solids in the resin varnish to be used is determined by the following formula (1):

0.05
≤

Volume
⁢

of
⁢

solid
⁢

content
⁢

of
⁢

applied
⁢

resin
⁢

varnish
⁢

(

cm
3

/

cm
2

)

Bulk
⁢

volume
⁢

of
⁢

aggregate
⁢

(

cm
3

/

cm
2

)

-

⁢

True
⁢

volume
⁢

of
⁢

aggregate
⁢

(

cm
3

/

cm
2

)

≤

0.6
.

(
1
)

2 . The method according to claim 1 , wherein the melt-pasting includes a film pressure-welding, and
the film pressure-welding comprises: a first pressure welding one resin film of the pair of resin films to side of the aggregate; and a second pressure-welding one surface of the other of the pair of resin films to the other side of the aggregate.

3 . The method according to claim 2 , further comprising preheating the one surface to be subjected to the first pressure-welding of the one resin film and one surface to be subjected to the second pressure-welding of the other resin film, prior to the film pressure-welding.

4 . The method according to claim 2 , further comprising preheating both sides of the aggregate, prior to the film pressure-welding.

5 . The method according to claim 1 , wherein a bulk thickness of the aggregate is 30 μm or more.

6 . The method according to claim 1 , wherein an average particle size of a filler contained in the resin varnish is 0.1 to 10 μm.

7 . The method according to claim 1 , wherein the resin film is a thermosetting resin film.

8 . The method according to claim 1 , wherein the resin varnish has a filler content of 3 vol % or less in a solid content thereof.

9 . The method according to claim 1 , wherein the resin varnish has a filler content of 2.5 vol % or less in a solid content thereof.

10 . The method according to claim 1 , wherein the resin varnish has a filler content of 2.0 vol % or less in a solid content thereof.

11 . The method according to claim 1 , wherein the resin varnish has a filler content of 0.2 vol % or more and 5 vol % or less in a solid content thereof.

12 . The method according to claim 1 , wherein the resin varnish has a filler content of 0.5 vol % or more and 5 vol % or less in a solid content thereof.

13 . The method according to claim 1 , wherein the resin varnish has a filler content of 1.0 vol % or more and 5 vol % or less in a solid content thereof.

14 . The method according to claim 1 , wherein the resin varnish has a filler content of 1.3 vol % or more and 5 vol % or less in a solid content thereof.

15 . The method according to claim 1 , wherein the resin varnish has a filler content of 0.2 vol % or more and 3 vol % or less in a solid content thereof.

16 . The method according to claim 1 , wherein the resin varnish has a filler content of 0.2 vol % or more and 2.5 vol % or less in a solid content thereof.

17 . The method according to claim 1 , wherein the resin varnish has a filler content of 0.2 vol % or more and 2.0 vol % or less in a solid content thereof.

18 . The method according to claim 1 , wherein an average particle size of a filler contained in the resin varnish is 0.3 to 7 μm.

19 . The method according to claim 1 , wherein an average particle size of a filler contained in the resin varnish is 0.5 to 5 μm.

Assignees

• Resonac Corp

Inventors

• Tosaka Yuji
• Saitoh Takeshi
• Yamaguchi Masaki
• Iwakura Tetsuro
• Shimayama Yuichi
• Murai Kosuke
• Oji Masashi

Classifications

• C08J2463/00

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

• C08J2363/00

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

• C08J5/18

  Manufacture of films or sheets · CPC title

• B29K2105/16

  Fillers · CPC title

• B29K2101/10

  Thermosetting resins · CPC title