Carbon-fiber-reinforced plastic and process for producing same

Patent metadata

Field	Value
Publication number	US-9469740-B2
Application number	US-201214122501-A
Country	US
Kind code	B2
Filing date	Apr 18, 2012
Priority date	May 31, 2011
Publication date	Oct 18, 2016
Grant date	Oct 18, 2016

Abstract

A carbon-fiber-reinforced plastic prepared by impregnating a matrix resin into a sheet-like base material includes discontinuous carbon fibers, wherein a content ratio of carbon fibers having lengths of 10 mm or longer in the base material is 60 wt % or more relative to a total amount of the carbon fibers, and an average value of orientation degrees of carbon fibers contained in the base material is 2-10.

First claim

The invention claimed is:

1. A carbon-fiber-reinforced plastic prepared by impregnating a matrix resin into a sheet-like base material composed of discontinuous carbon fibers, wherein the content of carbon fibers having lengths of 10 mm or longer in said base material is 60 wt % or more relative to the total amount of carbon fibers, an average value of orientation degrees of carbon fibers contained in said base material is 2-10, and with respect to carbon fibers contained in said sheet-like base material, the ratio of bundle-like fiber aggregates each gathered with 80 or more carbon fibers relative to the total amount of carbon fibers contained in said sheet-like base material is 3 wt % or more and 40 wt % or less.

2. The carbon-fiber-reinforced plastic according to claim 1 , wherein the maximum value σMax of tensile elastic moduli determined in different tensile directions is 10 GPa or more.

3. The carbon-fiber-reinforced plastic according to claim 1 , wherein the ratio of the maximum tensile elastic moduli of the carbon-fiber-reinforced plastic to the minimum tensile elastic moduli of the carbon-fiber-reinforced plastic (σMax/σMin) determined in different tensile directions is 2-10.

4. The carbon-fiber-reinforced plastic according to claim 1 , wherein said matrix resin comprises a thermoplastic resin.

5. The carbon-fiber-reinforced plastic according to claim 2 , wherein the ratio of the maximum tensile elastic moduli of the carbon-fiber-reinforced plastic to the minimum tensile elastic moduli of the carbon-fiber-reinforced plastic (σMax/σMin) determined in different tensile directions is 2-10.

6. The carbon-fiber-reinforced plastic according to claim 2 , wherein said matrix resin comprises a thermoplastic resin.

7. The carbon-fiber-reinforced plastic according to claim 3 , wherein said matrix resin comprises a thermoplastic resin.

8. A carbon-fiber-reinforced plastic prepared by impregnating a matrix resin into a sheet-like base material composed of discontinuous carbon fibers, wherein the content of carbon fibers having lengths of 10 mm or longer in said base material is 60 wt % or more relative to the total amount of carbon fibers, an average value of orientation degrees of carbon fibers contained in said base material is 2-10, and
the maximum value Wax of tensile elastic moduli determined in different tensile directions is 10 GPa or more, and with respect to carbon fibers contained in said sheet-like base material, the ratio of bundle-like fiber aggregates each gathered with 80 or more carbon fibers relative to the total amount of carbon fibers contained in said sheet-like base material is 3 wt % or more and 40 wt % or less.

9. A carbon-fiber-reinforced plastic prepared by impregnating a matrix resin into a sheet-like base material composed of discontinuous carbon fibers, wherein the content ratio of carbon fibers having lengths of 10 mm or longer in said base material is 60 wt % or more relative to the total amount of carbon fibers, an average value of orientation degrees of carbon fibers contained in said base material is 2-10, and
the ratio of the maximum tensile elastic moduli of the carbon-fiber-reinforced plastic to the minimum tensile elastic moduli of the carbon-fiber-reinforced plastic (σMax/σMin) determined in different tensile directions is 2-10, and with respect to carbon fibers contained in said sheet-like base material, the ratio of bundle-like fiber aggregates each gathered with 80 or more carbon fibers relative to the total amount of carbon fibers contained in said sheet-like base material is 3 wt % or more and 40 wt % or less.

10. A carbon-fiber-reinforced plastic prepared by impregnating a matrix resin into a sheet-like base material composed of discontinuous carbon fibers, wherein the content of carbon fibers having lengths of 10 mm or longer in said base material is 60 wt % or more relative to the total amount of carbon fibers, an average value of orientation degrees of carbon fibers contained in said base material is 2-10, and said matrix resin comprises a thermoplastic resin, and with respect to carbon fibers contained in said sheet-like base material, the ratio of bundle-like fiber aggregates each gathered with 80 or more carbon fibers relative to the total amount of carbon fibers contained in said sheet-like base material is 3 wt % or more and 40 wt % or less.

Assignees

• Hashimoto Takafumi
• Minowa Hirohito
• Shimada Takashi
• Hashimoto Masahiro
• Miyoshi Katsuhiro
• Naruse Yoshihiro
• Toray Industries

Inventors

• Hashimoto Takafumi
• Minowa Hirohito
• Shimada Takashi
• Hashimoto Masahiro
• Miyoshi Katsuhiro
• Naruse Yoshihiro

Classifications

• B29C70/14

  oriented · CPC title

• B29C70/06

  Fibrous reinforcements only · CPC title

• C08J2300/22

  Thermoplastic resins · CPC title

• C08K3/04 Primary

  Carbon · CPC title

• C08J5/24

  Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs · CPC title