Molded body and method for manufacturing same

Patent metadata

Field	Value
Publication number	US-12502846-B2
Application number	US-202118245292-A
Country	US
Kind code	B2
Filing date	Sep 9, 2021
Priority date	Sep 17, 2020
Publication date	Dec 23, 2025
Grant date	Dec 23, 2025

Abstract

The present invention addressed the problem of providing a molded body which has a high performance of reducing energy caused by the application of a load, and which is obtained from a fiber-reinforced resin containing reinforcing fibers arranged while aligned in one direction. To solve the problem, the present invention relates to a molded body, including a reinforced layer formed by layering fiber-reinforced resin layers containing a plurality of reinforcing fibers arranged while aligned in one direction and a matrix resin impregnated with the reinforcing fibers. In the molded body, the reinforced layer has a plurality of alignment shifted layers, which are fiber-reinforced resin layers in which the shift angle, i.e., the angle formed by the reinforcing fibers with respect to the longitudinal direction of the reinforced layer, is 25° to 65° or −65° to −25°.

First claim

The invention claimed is:

1 . A molded body comprising a reinforced layer including stacked fiber reinforced resin layers, each of the fiber reinforced resin layers including a set of a plurality of reinforcing fibers oriented and arranged in one direction and a matrix resin impregnated in the plurality of the reinforcing fibers, wherein
the reinforced layer is composed only of a plurality of thin-film shaped fiber reinforced resin including a plurality of reinforcing fibers oriented and arranged in one direction and a matrix resin impregnated in the reinforcing fibers, that are fused with each other, thereby each of the thin-film shaped fiber reinforced resin forming each layer of the stacked fiber reinforced resin layers, the reinforced layer includes a matrix resin rich region between adjacent sets of a plurality of the reinforcing fibers that are continuously placed in a lamination direction, each set of the adjacent plurality of the reinforcing fibers being contained in two adjacent fiber-reinforced resin layers that are continuously disposed in a lamination direction, the reinforced layer includes a plurality of orientation shifted layers, the orientation shifted layers being at least a part of the fiber reinforced resin layers arranged with a shifted angle of 25 degrees to 65 degrees or −65 degrees to −25 degrees, the shifted angle being an angle of the plurality of the reinforcing fibers with respect to a longitudinal axial direction of the reinforced layer, the plurality of the orientation shifted layers includes a positive orientation shifted layer where the shifted angle is 25 degrees to 65 degrees; and a negative orientation shifted layer where the shifted angle is −65 degrees to −25 degrees, the plurality of the orientation shifted layers includes a pair of the orientation shifted layers continuously disposed in a lamination direction, and the molded body does not include a non-orientation shifted layer adjacent to an orientation shifted layer among the plurality of the orientation shifted layers, the non-orientation shifted layer being a layer including a plurality of the reinforcing fibers arranged in an orientation of an angle greater than −25 degrees and smaller than 25 degrees, with respect to the longitudinal axial direction of the reinforced layer, and the matrix resin impregnated in the plurality of the reinforcing fibers and fused with the matrix resin of the orientation shifted layer.

2 . The molded body according to claim 1 , wherein a difference between absolute values of the shifted angles is 10 degrees or smaller in all pairs of the orientation shifted layers.

3 . The molded body according to claim 2 , wherein the pair of orientation shifted layers continuously disposed is composed of:
a positive orientation shifted layer where the shifted angle is 25 degrees to 65 degrees; and a negative orientation shifted layer where the shifted angle is −65 degrees to −25 degrees.

4 . The molded body according to claim 1 , wherein between an orientation shifted layer with a largest absolute value of the shifted angle and an orientation shifted layer with a smallest absolute value of the shifted angle in the reinforced layer, a difference between absolute values of the shifted angles is 10 degrees or smaller.

5 . The molded body according to claim 1 , wherein a difference between an absolute value of the shifted angle in the orientation shifted layer, and an absolute value of an angle of a plurality of reinforcing fibers with respect to the longitudinal axial direction of the reinforced layer in a fiber reinforced resin layer including the plurality of reinforcing fibers and a matrix resin impregnated in the plurality of reinforcing fibers and fused with a matrix resin of the orientation shifted layer, is 10 degrees or smaller for all of the orientation shifted layer.

6 . The molded body according to claim 1 , wherein the molded body does not include a non-orientation shifted layer, the non-orientation shifted layer being a layer including a plurality of the reinforcing fibers arranged in an orientation of an angle greater than 65 degrees and equal to or smaller than 90 degrees or an angle equal to or greater than −90 degrees and smaller than −65 degrees with respect to the longitudinal axial direction of the reinforced layer, and the matrix resin impregnated in the plurality of reinforcing fibers and fused with a matrix resin of the orientation shifted layer.

7 . The molded body according to claim 1 , wherein the matrix resin is a thermoplastic resin.

8 . The molded body according to claim 7 , wherein the matrix resin contains coloring matter that absorbs light of any wavelength between 300 nm to 3000 nm.

9 . The molded body according to claim 1 , wherein the plurality of reinforcing fibers is a carbon fiber or a glass fiber.

10 . The molded body according to claim 1 , wherein the reinforced layer has a tensile elastic modulus of 5.0 GPa or greater and a breaking strain of 7.0%.

11 . The molded body according to claim 1 , comprising the reinforced layer and a base material, wherein the base material including the reinforced layer at a surface, provided that in the case where the molded body includes a portion where the plurality of fiber reinforced resin layers is stacked and the matrix resin is fused, the entirety of the plurality of fiber reinforced resin layers is a reinforced layer.

12 . The molded body according to claim 11 ,
wherein the base material has an elongated shape; and wherein an angle difference between a longitudinal axial direction of the base material and a longitudinal axial direction of the reinforced layer is 0 degree to 10 degrees.

13 . The molded body according to claim 1 , wherein the molded body is composed only of the reinforced layer.

14 . The molded body according to claim 1 ,
wherein the reinforced layer does not contain a layer which is produced by assembling the reinforcing fiber, and impregnating the matrix resin in the reinforcing fiber that is assembled.

15 . The molded body according to claim 1 ,
wherein the molded body includes fused portions between adjacent layers.

16 . A method of manufacturing the molded body according to claim 1 , comprising:
forming a reinforced layer by stacking a plurality of fiber reinforced resins and welding the plurality of fiber reinforced resins with each other, each of the plurality of fiber reinforced resins having a thin-film shape and including a plurality of reinforcing fibers oriented and arranged in one direction and a matrix resin impregnated in the plurality of reinforcing fibers, wherein the reinforced layer is formed by fusing the plurality of fiber reinforced resins having the thin-film shape, wherein a positive orientation shifted layer where a positive orientation shifted layer where a shifted angle of 25 degrees to 65 degrees and a negative orientation shifted layer where −65 degrees to −25 degrees, the shifted angle being an angle of the plurality of reinforcing fibers with respect to a longitudinal axial direction of the reinforced layer, are stacked, wherein at least two layers selected from the group of the positive orientation shifted layer and the negative orientation shifted layer are stacked continuously, and wherein a non-orientation shifted layer being a layer including a plurality of reinforcing fibers arranged in an orientation of an angle greater than −25 degrees and smaller than 25 degrees, with respect to the longitudinal axial direction of the reinforced layer, and a matrix resin impregnated in the plurality of reinforcing fibers and fused with a

Assignees

• Mitsui Chemicals Inc

Inventors

• Mizumoto Kazuya
• Isaki Takeharu
• Miyata Atsushi
• Kanda Yoshihiko
• Fujihara Kazutoshi

Classifications

• B32B2262/106

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

• B32B2262/101

  Glass fibres · CPC title

• B32B5/26

  another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)} · CPC title

• B29K2995/0077

  Yield strength; Tensile strength · CPC title

• B29K2309/08

  Glass · CPC title