Fiber-reinforced composite material

Patent metadata

Field	Value
Publication number	US-9580568-B2
Application number	US-201314052935-A
Country	US
Kind code	B2
Filing date	Oct 14, 2013
Priority date	Apr 14, 2011
Publication date	Feb 28, 2017
Grant date	Feb 28, 2017

Abstract

There is provided a fiber-reinforced composite material is constituted by reinforcing fibers with an average fiber length of 5 mm to 100 mm and a thermoplastic resin, in which in a viscoelastic characteristic that is defined by following formulas (1) and (2), an average value in a range of −25° C. of the melting point of a matrix resin to +25° C. of the melting point of a matrix resin satisfies following formula (3):

tan δ= G″/G′   (1)

tan δ′= Vf ×tan δ/(100− Vf )  (2)

0.01≦tan δ′≦0.2  (3)
wherein G′ represents a storage modulus (Pa) of the fiber-reinforced composite material, G″ represents a loss modulus (Pa) of the fiber-reinforced composite material, and Vf represents a volume fraction (%) of the reinforcing fibers in the fiber-reinforced composite material.

First claim

The invention claimed is:

1. A fiber-reinforced composite material comprising:
reinforcing fibers with a fiber length of 5 mm to 100 mm; and
a thermoplastic resin,
wherein in tan δ′ that exhibits a viscoelastic characteristic as defined by formulas (1) and (2), an average value of the tan δ′ in a range of −25° C. to +25° C. of a melting point of a matrix resin satisfies formula (3):
tan δ= G″/G′   (1)

tan δ′= Vf ×tan δ/(100 −Vf )  (2)

0.01≦tan δ′≦0.2  (3)

wherein G′ represents a storage modulus (Pa) of the fiber-reinforced composite material,
G″ represents a loss modulus (Pa) of the fiber-reinforced composite material, and
Vf represents a volume fraction (%) of the reinforcing fibers in the fiber-reinforced composite material;
wherein the reinforcing fibers in the fiber-reinforce composite material are carbon fibers and the carbon fibers includes a reinforcing fiber bundle (A) constituted by the carbon fibers of a critical single fiber number or more, the critical single fiber number defined by formula (4), and a reinforcing fiber bundle constituted by the carbon fibers less than the critical single fiber number:
Critical single fiber number =600/ D   (4)

wherein D represents an average fiber diameter (μm) of single carbon fibers;
the carbon fibers are two-dimensionally oriented; and
the carbon fibers are deposited in a mat form.

2. The fiber-reinforced composite material according to claim 1 ,
wherein the thermoplastic resin is at least one kind selected from the group consisting of a polyamide 6 resin and a polypropylene resin.

3. The fiber-reinforced composite material according to claim 1 ,
wherein a content of the thermoplastic resin is 50 parts to 1000 parts by weight based on 100 parts by weight of the reinforcing fibers.

4. The fiber-reinforced composite material according to claim 1 ,
wherein the reinforcing fibers have an average fiber length of 10 mm to 100 mm.

5. The fiber-reinforced composite material according to claim 1 ,
wherein a ratio of the reinforcing fiber bundle (A) constituted by the reinforcing fibers of a critical single fiber number or more, to a total amount of the reinforcing fibers in the fiber-reinforced composite material is 20 Vol % or more and less than 90 Vol %.

6. The fiber-reinforced composite material according to claim 5 ,
wherein the ratio of the reinforcing fiber bundle (A) constituted by the reinforcing fibers of the critical single fiber number or more, to the total amount of the reinforcing fibers in the fiber-reinforced composite material is from 20 Vol % to 40 Vol %.

7. The fiber-reinforced composite material according to claim 5 ,
wherein the ratio of the reinforcing fiber bundle (A) constituted by the reinforcing fibers of the critical single fiber number or more, to the total amount of the reinforcing fibers in the fiber-reinforced composite material is from 70 Vol % to 90 Vol %.

Assignees

• Teijin Ltd

Inventors

• Hagihara Katsuyuki
• Konagai Yuhei
• Sonoda Naoaki
• Teshima Masatomo

Classifications

• C08J2300/22

  Thermoplastic resins · CPC title

• C08K3/04 Primary

  Carbon · CPC title

• C08J5/042

  with carbon fibres · CPC title

• C08J2377/02

  Polyamides derived from omega-amino carboxylic acids or from lactams thereof (C08J2377/10 takes precedence) · CPC title

• B29C43/222 Primary

  characterised by the shape of the surface · CPC title