Toray Industries, Inc.

Yuzo Fujita

Takuya Karaki

Kentaro Adachi

Ichiro Taketa

Yuta Naito

Shiori Kawamoto

Yoshitaka Koyama

Nobuyuki Arai

Narumichi Sato

Terumasa Tsuda

Kentatro Adachi

Ichiro Takeda

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

An intermediate base material is provided that is excellent in the conformity to three-dimensional shapes and that, when formed into a fiber reinforced plastic, develops good surface quality and high mechanical properties. According to one aspect, an incised prepreg is provided that has, in at least a partial region in a prepreg that contains unidirectionally oriented reinforcing fibers and a resin, a plurality of incisions that divide reinforcing fibers, wherein, in the case where a population is made up of the numbers of incisions contained in ten small circular regions of 10 mm in diameter randomly selected in the aforementioned region, a mean value for the population is 10 or greater and a coefficient of variation therefor is within 20%.

Incised prepreg, cross-ply laminate, and production method for incised prepreg

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 substantially flat-plate-shaped laminated base material has at least a layer-shaped body &#x3b1; and a layer-shaped body &#x3b2; are layered or disposed side by side, the layer-shaped body &#x3b1; having one or more cut prepregs A in which reinforcing fibers oriented in one direction are impregnated with a resin composition, the volume fraction of fiber is 45-65%, and at least a portion of the reinforcing fibers are segmented into a fiber length of 10-300 mm by a plurality of cuts, and the layer-shaped body &#x3b2; having one or more base materials B in which reinforcing fibers having a fiber length in the range of 10-300 mm are impregnated with a resin composition.

Laminated base material and method of manufacturing fiber-reinforced plastic

An intermediate base material has high handleability and shape conformity to complicated shapes and serves to perform high-yield production, even by low pressure molding, of fiber reinforced plastic material that do not suffer from significant generation of molding defects, such as creases and voids, that can cause a decrease in strength and that has good mechanical characteristics, decreased variations therein, and high dimensional stability. The prepreg includes a layer containing reinforcement fibers impregnated with a resin composition and the impregnation rate with the resin composition in the prepreg is in a predetermined range. It is characterized by being an incised prepreg having a plurality of incisions, being at least partly formed of reinforcement fibers with a predetermined fiber length, and having a reinforcement fiber content by volume Vf in a predetermined range.

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Ehime, Japan

Yuzo Fujita