Continuous Fiber Reinforced Thermoplastic Resin Composite Material and Method for Producing Same

Patent metadata

Field	Value
Publication number	US-2023241837-A1
Application number	US-202318133663-A
Country	US
Kind code	A1
Filing date	Apr 12, 2023
Priority date	Nov 29, 2017
Publication date	Aug 3, 2023
Grant date	—

Abstract

Disclosed is a scheme whereby a continuous fiber reinforced thermoplastic resin composite material applicable to production of a reinforcing material of various thermoplastic injection products and manufacture of a fiber reinforced thermoplastic plastic part using 3D printing can be produced by a simple method to have an excellent mechanical property. The present invention provides a continuous fiber reinforced thermoplastic composite material in which a plurality of yarns or tape intermediate materials are combined together to form a rod shape, and a method for producing the same.

First claim

What is claimed is:

1 . A method for producing a continuous fiber reinforced thermoplastic resin composite material, the method comprising the steps of:
(a) continuously introducing a plurality of yarns or tape-type intermediate materials into a heating unit; (b) heating the intermediate materials to a temperature equal to or higher than the melting point of a thermoplastic resin contained in the intermediate materials to melt at least a portion of the thermoplastic resin on the surface of the intermediate material; and (c) passing at least two of the molten intermediate materials through a nozzle to be combined together to form a rod shape.

2 . The method for producing a continuous fiber reinforced thermoplastic resin composite material of claim 1 , wherein the intermediate material has a continuous fiber content of 30-60 wt % and a thermoplastic resin content of 40-70 wt %.

3 . The method for producing a continuous fiber reinforced thermoplastic resin composite material of claim 1 , wherein the heating in step (b) is performed at a temperature higher than the melting point of the thermoplastic resin by 20-40° C.

4 . The method for producing a continuous fiber reinforced thermoplastic resin composite material of claim 1 , wherein the nozzle has a cross-sectional shape in which a bend is not formed, or one or more recess and protrusion are formed.

5 . The method for producing a continuous fiber reinforced thermoplastic resin composite material of claim 1 , wherein the rod discharged through the nozzle is rotated to form a spiral shape.

6 . The method for producing a continuous fiber reinforced thermoplastic resin composite material of claim 1 , wherein the nozzle has an outlet and wherein the nozzle is formed in multiple stages and has a reduced diameter toward the outlet.

7 . The method for producing a continuous fiber reinforced thermoplastic resin composite material of claim 1 , wherein the nozzle has an inlet end and an outlet end and wherein the nozzle has a diameter ratio of the inlet end to the diameter of the outlet end of 1.5-5 and a length ratio of the outlet end to the diameter of the outlet end of 2-10.

8 . The method for producing a continuous fiber reinforced thermoplastic resin composite material of claim 1 , wherein the yarn has a diameter of 1-3 mm and the tape has a thickness of 0.1-1.0 mm and a width of 3-30 mm.

9 . The method for producing a continuous fiber reinforced thermoplastic resin composite material of claim 1 , wherein the nozzle has an inlet end and an outlet end and wherein the nozzle has a diameter ratio of the inlet end to the diameter of the outlet end of 1.5-5 and a length ratio of the outlet end to the diameter of the outlet end of 2-10.

10 . The method for producing a continuous fiber reinforced thermoplastic resin composite material of claim 1 ,
wherein the composite material has a porosity of 1-10 vol %.

11 . The method for producing a continuous fiber reinforced thermoplastic resin composite material of claim 1 , wherein the composite material satisfies Expression 1 below on the basis of the cross-section of the composite material:
0.2 mm −1 ≤P/A≤ 5 mm −1   [Expression 1]
wherein, in Expression 1, P and A are a cross-sectional circumference length and a cross-sectional area of the composite material, respectively.

12 . The method for producing a continuous fiber reinforced thermoplastic resin composite material of claim 1 , comprising (a) continuously introducing the plurality of yarn intermediate materials having a diameter of 1-3 mm into the heating unit.

13 . A method for producing a continuous fiber reinforced thermoplastic resin composite material, the method comprising the steps of:
(a) continuously introducing a plurality of yarn intermediate materials having a diameter of 1-3 mm or tape-type intermediate materials having a thickness of 0.1-1.0 mm and a width of 3-30 mm into a heating unit; (b) heating the intermediate materials to a temperature equal to or higher than the melting point of a thermoplastic resin contained in the intermediate materials to melt at least a portion of the thermoplastic resin on the surface of the intermediate material; and (c) passing at least two of the molten intermediate materials through a nozzle having an inlet end and an outlet end and wherein the nozzle has a diameter ratio of the inlet end to the diameter of the outlet end of 1.5-5 and a length ratio of the outlet end to the diameter of the outlet end of 2-10, to be combined together to form a rod shape to produce a continuous fiber reinforced thermoplastic resin composite material, wherein the composite material has a porosity of 1-10 vol % and satisfies Expression 1 below on the basis of the cross-section of the composite material:
0.2 mm −1 ≤P/A≤ 5 mm −1   [Expression 1]

wherein, in Expression 1, P and A are a cross-sectional circumference length and a cross-sectional area of the composite material, respectively.

14 . The method for producing a continuous fiber reinforced thermoplastic resin composite material of claim 13 , wherein the intermediate material has a continuous fiber content of 30-60 wt % and a thermoplastic resin content of 40-70 wt %.

15 . The method for producing a continuous fiber reinforced thermoplastic resin composite material of claim 13 , wherein the heating in step (b) is performed at a temperature higher than the melting point of the thermoplastic resin by 20-40° C.

16 . The method for producing a continuous fiber reinforced thermoplastic resin composite material of claim 13 , wherein the nozzle has a cross-sectional shape in which a bend is not formed, or one or more recess and protrusion are formed.

17 . The method for producing a continuous fiber reinforced thermoplastic resin composite material of claim 13 , wherein the rod discharged through the nozzle is rotated to form a spiral shape.

18 . The method for producing a continuous fiber reinforced thermoplastic resin composite material of claim 13 , wherein the nozzle has an outlet and wherein the nozzle is formed in multiple stages and has a reduced diameter toward the outlet.

19 . The method for producing a continuous fiber reinforced thermoplastic resin composite material of claim 13 , comprising (a) continuously introducing the plurality of yarn intermediate materials having a diameter of 1-3 mm into the heating unit.

Assignees

• Lotte Chemical Corp

Inventors

• Kim Won Seock
• Lee Jong Wook
• Lee You Jung

Classifications

• B29C70/52

  Pultrusion, i.e. forming and compressing by continuously pulling through a die · CPC title

• B29C64/165 Primary

  using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B33Y30/00

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title

• B29C64/321

  Feeding · CPC title