Stitched reinforcing-fiber base material, preform material, fiber-reinforced composite material, and methods for producing same

Patent metadata

Field	Value
Publication number	US-2025387953-A1
Application number	US-202318879081-A
Country	US
Kind code	A1
Filing date	Jun 29, 2023
Priority date	Jun 30, 2022
Publication date	Dec 25, 2025
Grant date	—

Abstract

The present invention provides a stitched reinforcing-fiber base material comprising a reinforcing-fiber base material composed of reinforcing fiber and a stitching thread comprising polyethersulfone fiber, the stitched reinforcing-fiber base material being characterized in that the reinforcing-fiber base material is stitched with the stitching thread.

First claim

1 . A stitched reinforcing-fiber base material comprising:
a reinforcing-fiber base material composed of reinforcing fibers; and a stitching thread including a polyethersulfone fiber, wherein the reinforcing-fiber base material is stitched with the stitching thread.

2 . The stitched reinforcing-fiber base material according to claim 1 , wherein the reinforcing-fiber base material is a reinforcing-fiber base material composed of a reinforcing-fiber sheet composed of reinforcing fibers aligned in uni-direction.

3 . The stitched reinforcing-fiber base material according to claim 2 , wherein the reinforcing-fiber base material is a multiaxial base material formed by laminating a plurality of the reinforcing-fiber sheets while mutually changing angles of fiber axes.

4 . The stitched reinforcing-fiber base material according to claim 1 , wherein the reinforcing-fiber base material is a reinforcing-fiber base material formed by placed a resin material on a surface of the reinforcing-fiber base material and/or between layers composed of reinforcing fibers.

5 . The stitched reinforcing-fiber base material according to claim 1 , wherein a single yarn fineness of the stitching thread is 1 to 10 dtex/filament.

6 . The stitched reinforcing-fiber base material according to claim 1 , wherein a total fineness of the stitching thread is 1 to 250 dtex.

7 . The stitched reinforcing-fiber base material according to claim 1 , wherein the number of filaments of the stitching thread is 1 to 60.

8 . The stitched reinforcing-fiber base material according to claim 1 , wherein the polyethersulfone fiber is a polyethersulfone fiber composed of polyethersulfone having a glass transition point of 160 to 250° C.

9 . The stitched reinforcing-fiber base material according to claim 1 , wherein a content ratio of the stitching thread is 0.1 to 30 mass % with respect to a mass of the stitched reinforcing-fiber base material.

10 . A method for producing the stitched reinforcing-fiber base material according to claim 1 , the method comprising stitching a reinforcing-fiber base material composed of reinforcing fibers with a stitching thread including a polyethersulfone fiber.

11 . A preform material comprising:
the stitched reinforcing-fiber base material according to claim 1 ; and 1 to 20 parts by mass of a binder resin with respect to 100 parts by mass of the stitched reinforcing-fiber base material.

12 . A method for producing a preform material, the method comprising heating, under pressure,
the stitched reinforcing-fiber base material according to claim 1 and 1 to 20 parts by mass of a binder resin with respect to 100 parts by mass of the stitched reinforcing-fiber base material.

13 . A fiber-reinforced composite material comprising:
the stitched reinforcing-fiber base material according to claim 1 ; and a matrix resin impregnated into the stitched reinforcing-fiber base material.

14 . A method for producing a fiber-reinforced composite material, the method comprising impregnating a matrix resin into the stitched reinforcing-fiber base material according to claim 1 .

15 . A method for producing a fiber-reinforced composite material, the method comprising impregnating a matrix resin into the preform material according to claim 11 .

Assignees

• Teijin Ltd

Inventors

• Nakagawa Hiroki
• Osaki Kohei

Classifications

• D04H3/115

  by applying or inserting filamentary binding elements · CPC title

• D04H3/002

  Inorganic yarns or filaments · CPC title

• B29B11/16 Primary

  comprising fillers or reinforcement {(non-woven fabrics per se D04H1/00, D04H3/00)} · CPC title

• B32B2307/30

  having particular thermal properties · CPC title

• B32B5/06

  characterised by a fibrous {or filamentary} layer {mechanically connected, e.g. by needling} to another layer, e.g. of fibres, of paper · CPC title