Prepreg, laminate, and molding

Patent metadata

Field	Value
Publication number	US-12492289-B2
Application number	US-202017608237-A
Country	US
Kind code	B2
Filing date	May 15, 2020
Priority date	May 23, 2019
Publication date	Dec 9, 2025
Grant date	Dec 9, 2025

Abstract

An object of the present invention is to provide a prepreg and a laminate for producing a laminate suitable as a structural material, which have excellent joining strength and interlaminar fractural toughness values and can be firmly integrated with another structural member by welding. The present invention provides a prepreg including the following structural components, [A] reinforcing fibers, [B] an epoxy resin, and [C] a thermoplastic resin, wherein all epoxy resins included in [B] have an average epoxy value of 2.0 meq./g or more and 5.0 meq./g or less, [C] is present in a surface of the prepreg, and the reinforcing fibers [A] are present, which are included in a resin area including [B] and a resin area including [C] across an interface between the two resin areas.

First claim

The invention claimed is:

1 . A prepreg comprising the following structural components [A], [B], and [C], wherein
all epoxy resins included in [B] have an average epoxy value of 2.0 meq./g or more and 5.0 meq./g or less, [C] is present in a surface of the prepreg, and reinforcing fibers [A] are present, which are included in a resin area including [B] and a resin area including [C] across an interface between the two resin areas: [A] reinforcing fibers; [B] an epoxy resin; and [C] a thermoplastic resin, wherein, in a planar view, when a cross-section vertical to a plane of the prepreg including [A] is obtained from a direction of an angle different by 45 degrees to a direction of any fiber [A] included in the two resin areas, a cross-sectional curve, formed by the interface between the two resin areas closely adhering to each other, in the cross-section, has an average roughness length RSm, defined in accordance with JIS B0601 (2001), of 100 μm or less, and an average roughness height Rc of 3.5 μm or more, and wherein the resin area including [B] and the resin area including [C] are adjacent to each other in a layered state to form the interface.

2 . The prepreg according to claim 1 , wherein the all epoxy resins included in the structural component [B] have an average epoxy value of 2.5 meq./g or more and 4.0 meq./g or less.

3 . The prepreg according to claim 1 , wherein the structural component [B] includes a bisphenol type epoxy resin having an epoxy equivalent of 400 or more and 3000 or less in an amount of 20 parts by mass or more and 50 parts by mass or less based on 100 parts by mass of the all epoxy resins included therein.

4 . The prepreg according to claim 3 , wherein the structural component [B] includes a bisphenol type epoxy resin having an epoxy equivalent of 1000 or more and 3000 or less in an amount of 20 parts by mass or more and 50 parts by mass or less based on 100 parts by mass of the all epoxy resins included therein.

5 . The prepreg according to claim 1 , wherein the structural component [B] has a bending fractural strain of 8% or more in a state in which a degree of cure is 90% or more.

6 . The prepreg according to claim 1 , wherein the structural component [A] includes a carbon fiber having a strand tensile strength of 5.5 GPa or more.

7 . The prepreg according to claim 1 , wherein the average roughness height Rc is 10 μm or more.

Assignees

• Toray Industries

Inventors

• Misumi Jun
• Honma Masato
• Shinohara Kyoko
• Hirano Noriyuki

Classifications

• C08J2377/02

  Polyamides derived from omega-amino carboxylic acids or from lactams thereof (C08J2377/10 takes precedence) · CPC title

• C08J2371/10

  from phenols · CPC title

• C08J2367/02

  Polyesters derived from dicarboxylic acids and dihydroxy compounds; (C08J2367/06 takes precedence) · CPC title

• C08J2363/00

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

• C08J2323/12

  Polypropene · CPC title