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Prepreg, intermediate material for forming frp, and method for production thereof and method for production of fiber-reinforced composite material

a technology of intermediate materials and composite materials, which is applied in the direction of synthetic resin layered products, applications, weaving, etc., can solve the problems of ineffective inability to produce larger products, limited size of molded products, and high cost of autoclave facilities, so as to improve the specific strength and inelasticity, reduce the viscosity of resin, and improve the effect of cost performan

Inactive Publication Date: 2011-06-23
MITSUBISHI RAYON CO LTD
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The solution enables the production of FRP composites with excellent external appearance and no internal voids or surface pinholes, maintaining workability similar to conventional prepregs, while eliminating the need for autoclave pressure.

Problems solved by technology

However, autoclave facilities are extremely expensive, which not only acts as a large barrier to new entrants, but also means that once autoclave facilities are purchased, the size of the molded products is restricted by the size of the autoclave, meaning the production of larger products is effectively impossible.
However, because these processes do not involve the application of pressure, residual voids tend to remain within the molded product, the strength of the molded product is inferior to that of a molded product produced in an autoclave, and pinhole formation is also a problem.
However, with this technology, almost all of the resin is impregnated during molding, and depending on the molding conditions, portions of the resin that display unsatisfactory impregnation can occur, leading to the occurrence of internal voids and surface pinholes.
Furthermore, because the surface is almost free from resin and is extremely dry, workability problems such as difficulty in bonding the product to the molding die can also be a concern.

Method used

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  • Prepreg, intermediate material for forming frp, and method for production thereof and method for production of fiber-reinforced composite material
  • Prepreg, intermediate material for forming frp, and method for production thereof and method for production of fiber-reinforced composite material
  • Prepreg, intermediate material for forming frp, and method for production thereof and method for production of fiber-reinforced composite material

Examples

Experimental program
Comparison scheme
Effect test

example 1

[0140]The matrix resin was applied uniformly to a release sheet at a resin weight of 430 g / m2, thus forming a resin film. This resin film was supplied to a piece of carbon fiber cloth TRK510, manufactured by Mitsubishi Rayon Co., Ltd. (fiber weight 646 g / m2, 2 / 2 twill) from the bottom surface of the cloth, thus impregnating the carbon fiber cloth with the resin. The temperature during impregnation was 60° C., and the pressure was adjusted to complete the preparation of a prepreg. When the resin impregnation ratio of the thus produced prepreg was measured, the result was 90%, thus confirming the prepreg as conforming to the present invention.

[0141]Next, using the release sheet side of the thus produced prepreg of the present invention as the tool side (a stainless steel plate), a 4-ply laminate was formed at 0° C. The layers from the second layer up were arranged so that the release sheet side of the prepreg faced the opposite side of the previous layer. Vacuum bag molding was conduc...

example 4

[0150]An epoxy resin composition #830 manufactured by Mitsubishi Rayon Co., Ltd. was used as the matrix resin. Using this resin, a resin film was prepared in the same manner as the example 1, and this was then impregnated into a TRK510. The impregnation temperature was set to 50° C. When the resin impregnation ratio of the thus obtained prepreg was measured, the result was 60%, thus confirming the prepreg as conforming to the present invention. Using this prepreg, a molded product of the shape shown in FIG. 3 was molded. A wooden female mold was used as the molding die. An 8-ply laminate was formed using an alignment pattern of [0° / 45° / 90° / −45° / −45° / 90° / 45° / 0°], with the release sheet side of the prepreg facing the tool surface, and subsequently prepregs arranged so that the release sheet side faced the opposite side of the previous layer. The operation of laminating the prepregs presented absolutely no problems.

[0151]Under the molding conditions used, the temperature was raised fro...

example 5

[0153]Using the resin used in the example 1, and using a non-crimped fabric Quadraxial-Carbon-Gelege (+45°: Carbon 267 g / m2, 0°: Carbon 268 g / m2, −45°: Carbon 267 g / m2, 90°: Carbon 268 g / m2, stitching: PES 6 g·m2, weight 1076 g / m2) manufactured by Saertex Co., Ltd. as a sheet-like reinforcing fiber substrate, a prepreg was prepared in the same manner as the example 1. However, the resin weighting was 717 g / m2. When the resin impregnation ratio was measured, the result was 75%, thus confirming the prepreg as conforming to the present invention. A 2-ply laminate was prepared with the prepreg surfaces facing in the same direction, and a FRP was then molded. The molding was conducted under the same molding conditions as the example 1. The thus obtained molded product displayed no internal voids and no surface pinholes.

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Abstract

An FRP is produced using a prepreg comprising reinforcing fiber, a sheet-like reinforcing fiber substrate containing reinforcing fiber, and a matrix resin, wherein the matrix resin is impregnated into the sheet-like reinforcing fiber substrate and also covers one surface of the sheet-like reinforcing fiber substrate, and the matrix resin impregnation ratio is within a range of 35% to 95%; a prepreg comprising reinforcing fiber, a sheet-like reinforcing fiber substrate containing reinforcing fiber, and a matrix resin, wherein the matrix resin exists on both surfaces of the sheet-like reinforcing fiber substrate, and the portion inside the sheet-like reinforcing fiber substrate into which the matrix resin has not been impregnated is continuous; or a prepreg comprising reinforcing fiber, a sheet-like reinforcing fiber substrate containing reinforcing fiber, and a matrix resin, wherein at least one surface exhibits a sea-and-island-type pattern comprising resin-impregnated portions (island portions) where the matrix resin is present at the surface and fiber portions (sea portions) where the matrix resin is not present at the surface, the surface coverage ratio of the matrix resin on those surfaces with said a sea-and-island-type pattern is within a range of 3% to 80%, and the weave intersection coverage ratio for the island portions, represented by a formula (1) shown below, is at least 40%, displays excellent external appearance, with no internal voids or surface pinholes, even when molded is conducted using only vacuum pressure.Island portions weave intersection coverage ratio (%)=(T / Y)×100  (1)(wherein, T represents a number of island portions that cover weave intersections, and Y represents a number of weave intersections within said reinforcing fiber woven fabric on said surface with said sea-and-island-type pattern).

Description

TECHNICAL FIELD[0001]The present invention relates to a prepreg that functions as an intermediate material for FRP molding.BACKGROUND ART[0002]Fiber-reinforced composite materials (hereafter also abbreviated as FRP) are lightweight, while offering good strength and high rigidity, and are consequently widely used in a variety of applications from sports and leisure through to industrial applications such as vehicles and aircraft. In recent years, with the fall in the cost of carbon fiber, the use of carbon fiber reinforced composite materials (hereafter abbreviated as CFRP), which are even more lightweight and offer even higher levels of strength and rigidity, within industrial applications has also become more widespread.[0003]Amongst these potential industrial applications, CFRPs used for structural members within train bodies and aircraft frames are typically produced by autoclave molding, using an intermediate material known as a prepreg. The reason for this preference is that by...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): B32B5/02B32B37/00B32B3/10B32B7/02B32B27/04B29C70/44B29C70/46B29C70/54
CPCB29B15/122Y10T428/2495B29C70/086B29C70/22B29C70/342B29C70/465B29C70/546B29K2063/00B29K2101/10B29K2101/12B32B5/022B32B5/26C08J5/24B32B2260/023B32B2262/106B32B2305/076B32B2363/00D06M15/55Y10T156/10Y10T428/2481B29C70/081Y10T428/249921Y10T442/2861Y10T442/2951Y10T442/2992Y10T442/20Y10T442/2984Y10T442/2361Y10T442/2139Y10T442/2926Y10T442/3854Y10T442/2008Y10T442/2049C08J5/243
Inventor GOTO, KAZUYAKOGA, KAZUKISAITOU, TADAYOSHIITO, AKIHIROTAKANO, TSUNEOWAKABAYASHI, KOUKI
Owner MITSUBISHI RAYON CO LTD
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