Carbon-fiber-reinforced thermoplastic-resin composite material and molded body using the same

Patent metadata

Field	Value
Publication number	US-2016009054-A1
Application number	US-201414771990-A
Country	US
Kind code	A1
Filing date	Mar 6, 2014
Priority date	Mar 7, 2013
Publication date	Jan 14, 2016
Grant date	—

Abstract

The invention is intended to obtain a composite material suitable for mass production or the like by shortening the molding time while obtaining the advantages of the composite materials described above, and intended to provide a composite material which has a short molding time by the use of a thermoplastic resin as a matrix and is excellent in balance among stiffness, strength, and thermal conductivity. A carbon-fiber-reinforced thermoplastic-resin composite material comprising: a layer (I) containing a carbon fiber (A) aligned in one direction and a thermoplastic resin (C-1); and a layer (II) containing a carbon fiber (B) aligned in one direction and a thermoplastic resin (C-2), wherein the carbon fiber (A) has a higher elastic modulus than the carbon fiber (B).

First claim

1 . A carbon-fiber-reinforced thermoplastic-resin composite material, comprising:
a first layer comprising a first carbon fiber aligned in one direction and a first thermoplastic resin; and a second layer comprising a second carbon fiber aligned in one direction and a second thermoplastic resin, wherein the first carbon fiber has a higher elastic modulus than the second carbon fiber.

2 . The carbon-fiber-reinforced thermoplastic-resin composite material according to claim 1 ,
wherein an elastic modulus of the first carbon fiber is 350 GPa or more and an elastic modulus of the second carbon fiber is 200 GPa or more and less than 350 GPa.

3 . The carbon-fiber-reinforced thermoplastic-resin composite material according to claim 1 ,
wherein the first layer accounts for ⅓ or less of a thickness of the carbon-fiber-reinforced thermoplastic-resin composite material.

4 . The carbon-fiber-reinforced thermoplastic-resin composite material according to claim 1 ,
wherein the first layer accounts for ⅓ or more of a thickness of a region which accounts for 10% of a thickness of the carbon-fiber-reinforced thermoplastic-resin composite material from a surface of at least one side of the carbon-fiber-reinforced thermoplastic-resin composite material.

5 . The carbon-fiber-reinforced thermoplastic-resin composite material according to claim 4 ,
wherein the first layer accounts for ⅓ or more of each of thicknesses of regions which account for 10% of a thickness of the carbon-fiber-reinforced thermoplastic-resin composite material from surfaces of both sides of the carbon-fiber-reinforced thermoplastic-resin composite material.

6 . The carbon-fiber-reinforced thermoplastic-resin composite material according to claim 1 ,
wherein the second carbon fiber is a polyacrylonitrile-based carbon fiber.

7 . The carbon-fiber-reinforced thermoplastic-resin composite material according to claim 1 ,
wherein the first carbon fiber is a pitch-based carbon fiber.

8 . The carbon-fiber-reinforced thermoplastic-resin composite material according to claim 1 ,
wherein the first carbon fiber is a pitch-based carbon fiber and the second carbon fiber is a polyacrylonitrile-based carbon fiber.

9 . The carbon-fiber-reinforced thermoplastic-resin composite material according to claim 1 ,
wherein a thickness of the first layer is from 0.1 to 0.3 mm.

10 . The carbon-fiber-reinforced thermoplastic-resin composite material according to claim 1 ,
wherein a thermal conductivity of the first carbon fiber is 20 W/mK or more and 600 W/mK or less and a thermal conductivity of the second carbon fiber is 3 W/mK or more and less than 20 W/mK.

11 . The carbon-fiber-reinforced thermoplastic-resin composite material according to claim 1 ,
wherein the first carbon fiber is a continuous carbon fiber and an average fiber length of the second carbon fiber is from 10 to 50 mm.

12 . The carbon-fiber-reinforced thermoplastic-resin composite material according to claim 1 ,
wherein an elastic modulus after applying a load corresponding to 70% of the maximum load to the carbon-fiber-reinforced thermoplastic-resin composite material is from 20 to 60% of an elastic modulus before applying the load in a three-point bending test.

13 . The carbon-fiber-reinforced thermoplastic-resin composite material according to claim 1 ,
wherein an equivalent stiffness weight that is a weight of a sample plate having a size of 200 mm×320 mm when a shift of a region to which a load of 10 N is applied in the case of applying the load to a substantially central portion of the sample plate is 0.88 mm is from 80 to 92 g.

14 . The carbon-fiber-reinforced thermoplastic-resin composite material according to claim 1 ,
wherein at least one layer of the second layer is sandwiched between at least two layers of the first layer.

15 . The carbon-fiber-reinforced thermoplastic-resin composite material according to claim 14 ,
wherein two or more layers of the second layer are sandwiched between at least two layers of the first layer.

16 . The carbon-fiber-reinforced thermoplastic-resin composite material according to claim 1 ,
wherein the first layer and the second layer are overlapped, and fiber directions of carbon fibers contained in respective two layers consisting of the first layer and the second layer which are directly overlapped are substantially orthogonal to each other.

17 . A molded body obtained by thermoforming the carbon-fiber-reinforced thermoplastic-resin composite material according to claim 1 .

18 . The molded body according to claim 17 , comprising a convex portion having a height of 3 mm or more on a surface of either side.

19 . A member for electronic device housing comprising the molded body according to claim 17 .

Assignees

• Mitsubishi Rayon Co

Inventors

• Okunaka Osamu

Classifications

• B32B2260/023

  Two or more layers · CPC title

• B32B2262/106

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

• C08J2369/00

  Characterised by the use of polycarbonates; Derivatives of polycarbonates · CPC title

• C08J2323/26

  modified by chemical after-treatment · CPC title

• B32B2457/00

  Electrical equipment · CPC title