Toray Industries, Inc.

Kentaro Adachi

Masato Honma

Takashi Fujioka

Yuzo Fujita

Takuya Karaki

Yuta Naito

Terumasa Tsuda

Hiroaki Matsutani

An object is to provide an incised prepreg having desired formability stably, wherein the incised prepreg contains unidirectionally oriented reinforcing fibers and matrix resin and has an incised region containing a plurality of incisions made to divide reinforcing fibers, wherein the incised region includes a plurality of incision rows, each containing a plurality of incisions having nearly equal fiber-directionally projected lengths and aligned at substantially constant intervals in the fiber direction and wherein the distance L, measured at right angles to the fiber direction, between two incision rows located on either side of an arbitrarily selected incision row and the fiber-directionally projected length Lof the latter incision row satisfy the following relation: −1.0<L/L<0.5.

Incised prepreg and fiber-reinforced plastic

Provided are methods for producing a fiber-reinforced plastic having high mechanical properties and high productivity during molding of a complicated shape. In one aspect, the method produces a fiber-reinforced plastic using a tape substrate A and a sheet substrate B, the tape substrate A being a tape-shaped substrate including one or more sheets of incised prepreg a; the incised prepreg a being a prepreg including unidirectionally oriented reinforcing fibers and a resin and having a plurality of incisions dividing the reinforcing fibers formed in the prepreg, and satisfying the following condition 1; the sheet substrate B being a substrate including randomly oriented reinforcing fibers and a resin. In another aspect, the method for producing a fiber-reinforced plastic includes: a placement step \ (A) of placing a plurality of tape substrates A on a mold such that each of the sheet substrates A forms an overlapping portion in which the sheet substrate A overlaps one or more other sheet substrates A and a non-overlapping portion in which the sheet substrate A does not overlap any other sheet substrates A, a placement step (B) of placing a sheet substrate B, and a molding step of heating and pressing the tape substrates A and the sheet substrate B placed. Condition 1 is: the average length xa of the incisions and the average length ya of the reinforcing fibers divided by the incisions satisfy ya>6.0xa+10.

Method for producing fiber-reinforced plastic

Provided is a method for manufacturing a fiber-reinforced plastic composite containing a fiber-reinforced plastic part having a plate-like portion and a rib protruding from one surface of the plate-like portion, and a metal part, having an average thickness of 0.5-3.0 mm, laminated on part of or all of the plate-like portion of the fiber-reinforced plastic part, comprising:

Manufacturing method for fiber-reinforced plastic composite

A prepreg laminate is provided which includes: a woven fabric prepreg on at least one surface layer; and a discontinuous fiber prepreg; the woven fabric prepreg including reinforcing fibers Rhaving a woven structure, and a thermosetting resin A, the discontinuous fiber prepreg including unidirectionally oriented discontinuous reinforcing fibers Rand a thermosetting resin B, the thermosetting resin A and the thermosetting resin B satisfying the following calorific value condition: calorific value condition: when each of the thermosetting resin A and the thermosetting resin B is heated using a differential scanning calorimeter from 50° C. to 130° C. at 700° C./min under a nitrogen atmosphere followed by retention at 130° C. until completion of thermal curing reaction, Tb−Ta>30, wherein Ta (s): time required for the calorific value of the thermosetting resin A to reach 50% of the gross calorific value of the thermosetting resin A; Tb (s): time required for calorific value of the thermosetting resin B to reach 50% of gross calorific value of the thermosetting resin B.

Prepreg laminate, method for manufacturing fiber-reinforced plastic using prepreg laminate, and fiber-reinforced plastic

Provided is a method for producing a fiber-reinforced plastic having high mechanical properties and high productivity during molding of a complicated shape. A method for producing a fiber-reinforced plastic using a sheet substrate A is provided, the sheet substrate A being a substrate including one or more sheets of incised prepreg a, the incised prepreg a being a prepreg including unidirectionally oriented reinforcing fibers and a resin and having a plurality of incisions dividing the reinforcing fibers formed in the prepreg, wherein the method for producing a fiber-reinforced plastic includes a placement step (A) of placing a plurality of sheet substrates A in a mold such that each of the sheet substrates A forms an overlapping portion in which the sheet substrate A overlaps one or more other sheet substrates A and a non-overlapping portion in which the sheet substrate A does not overlap any other sheet substrates A, and a molding step of heating and pressing the plurality of sheet substrates A, and the total area of the overlapping portion and the non-overlapping portion is 50 to 100% relative to the area of a mold surface.

Provided is an intermediate base material (incised prepreg) which has exceptional surface quality and mechanical properties when solidified and with which it is possible to obtain a fiber-reinforced plastic having excellent three-dimensional shape conformance properties. This incised prepreg has, in a prepreg that includes a resin and reinforcing fibers oriented in one direction, incisions substantially parallel to the orientation direction of the reinforcing fibers (the incisions substantially parallel to the orientation direction of the reinforcing fibers are referred to as parallel incisions) and incisions that cut across the reinforcing fibers (the incisions that cut across the reinforcing fibers are referred to as intersecting incisions).

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Ehime, Japan

Kentaro Adachi