Toray Industries, Inc.

Takuya Karaki

Yuzo Fujita

Kentaro Adachi

Akihiko Kitano

Ichiro Taketa

Tomoyuki Shinoda

Shoji Murai

Maurice Geli

Terumasa Tsuda

Hitoshi Nishiyama

Kentatro Adachi

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).

Incised prepreg and method for producing incised prepreg

A random mat material including fiber bundles, said fiber bundles including fibers having an average fiber length of 5 to 100 mm, and having an average number N of fibers in the fiber bundle that satisfies: wherein D is the average diameter of fibers in the fiber bundle, expressed in micrometers, and the standard deviation SDof the number of fibers in a fiber bundle satisfies:1,000&#x3c;SD&#x3c;6,000wherein at an end of the fiber bundle, the number of the fibers in a fiber bundle becomes less from center to edge of the fiber bundle in a fiber direction.

Carbon fiber random mat and carbon fiber composite material

This invention is an impact energy absorption device, in which a long part () made of a high strength material is disposed with its lengthwise direction kept different from an impact direction, and both terminals of the long part () are connected with columns () through upper platens () covering the upper faces of the columns () kept standing apart from each other with a predetermined distance (L), comprising a structural system, in which a deformation of the long part () caused by the impact force applied to it, causes the upper platens () to move for compressing or deflecting the columns (), thereby absorbing the impact energy. The conventional column type energy absorption member is weak against an impact applied in a direction within a wide angle (&#x3b8;) such as an impact applied in an oblique direction. However, the energy absorption device of this invention can exhibit an impact energy absorption capability even against an impact applied in the direction within such a wide angle, equivalent or superior to that in the case where it fails in the axial direction. Furthermore, even if the parts used are damaged, they can be easily exchanged to allow restoration as an energy absorption device.

Impact energy absorption device

The present invention is an impact energy absorption member that is characterized by comprising a long member of fiber reinforced resin having a lengthwise direction and a thickness direction, wherein the ratio of the thickness t (mm) of the long member to the length L (mm) thereof is within the range of 1/11000 to 6/1000 as well as the direction of an external force is substantially in agreement with the thickness direction of the impact member. The member of the present invention sufficiently absorbs impact energy from a moving body when collision occurs and greatly increases safety to collision of transportation equipment, for example, a motor car and the like as well as is light in weight and compact, whereby the member can improve resistance against environment and saves energy. Further, when this member is applied to a house and a building against which the transportation equipment may collide, it can reduce the loss of social properties.

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Ehime, Japan

Takuya Karaki