UNIDIRECTIONALLY-ORIENTED TAPE-SHAPED PREPREG, AND MOLDED ARTICLE THEREOF

• US 20200131325A1
• Filed: 05/15/2018
• Published: 04/30/2020
• Est. Priority Date: 07/18/2017
• Status: Abandoned Application

• Current Assignee: Toray Industries Incorporated
• Original Assignee: Toray Industries Incorporated
• Inventors: Yamada, Mayuka, Konno, Eita, Ueda, Taito
• Application Number:
  US16/629,193
• Publication Number:
  US 20200131325A1
• Time in Patent Office: Days
• CPC Class Codes: B29B 15/122 with a matrix in liquid form, e.g. as melt, solution or latex
• CPC Class Codes: B29K 2077/00 Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2307/04 Carbon
• CPC Class Codes: C08J 2377/00 Characterised by the use of polyamides obtained by reactions forming a carboxylic amide link in the main chain; Derivatives of such polymers
• CPC Class Codes: C08J 5/042 with carbon fibres
• CPC Class Codes: C08J 5/243 using carbon fibres

Abstract

A tape-shaped prepreg includes unidirectionally-oriented reinforcing fibers, and a thermoplastic resin, which prepreg has a good and uniform tape thickness and tensile strength, and which allows for producing a final product at a low cost. The tape-shaped prepreg includes unidirectionally-oriented reinforcing fibers and a thermoplastic resin composition, and has an average thickness of 0.2 mm or more and 1.5 mm or less, a void content of 5% by volume or less, and a degree of dispersity of reinforcing fibers of 0.5 or less.

Claims

1-10. -10. (canceled)

11. A tape-shaped prepreg comprising unidirectionally-oriented reinforcing fibers, and a thermoplastic resin composition,

wherein said tape-shaped prepreg has:

an average thickness of 0.2 mm or more and 1.5 mm or less;

a void content of 5% by volume or less; and

a degree of dispersity of reinforcing fibers of 0.5 or less.

12. The tape-shaped prepreg according to claim 11, having a fiber volume content of 30 to 70% by volume.

13. The tape-shaped prepreg according to claim 11, having a tensile strength as measured in accordance with ASTM D3039/D3039-07 of 1,500 to 3,500 MPa.

14. The tape-shaped prepreg according to claim 11, wherein the coefficient of variation (%) of a thickness of said tape-shaped prepreg is 2.0% or less.

15. The tape-shaped prepreg according to claim 11, wherein the coefficient of variation (%) of said degree of dispersity of reinforcing fibers in a length direction of said tape-shaped prepreg is 5.0% or less.

16. The tape-shaped prepreg according to claim 11, wherein said thermoplastic resin has a melt viscosity of 200 Pa'"'"'s or less, at a temperature 50°

C. or more higher than the melting point of said thermoplastic resin.

17. The tape-shaped prepreg according to claim 11, wherein said reinforcing fibers are carbon fibers.

18. The tape-shaped prepreg according to claim 11, wherein said thermoplastic resin composition is a polyamide resin composition.

19. A molded article formed using a tape-shaped prepreg, said tape-shaped prepreg comprising unidirectionally-oriented reinforcing fibers, and a thermoplastic resin composition,

wherein said tape-shaped prepreg has:

an average thickness of 0.2 mm or more and 1.5 mm or less;

a void content of 5% by volume or less; and

a degree of dispersity of reinforcing fibers of 0.5 or less.

20. A method of producing a tape-shaped prepreg, said tape-shaped prepreg comprising unidirectionally-oriented reinforcing fibers, and a thermoplastic resin composition, the method comprising:

providing a fixed guide(s) in a die for impregnating said reinforcing fibers with said thermoplastic resin composition, and

providing at least a pair of projection parts on each of the surface(s) of said fixed guide(s) above and/or under which said reinforcing fibers pass,

wherein the direction of a straight line having the shortest distance between said pair of projection parts, is substantially vertical to the direction of orientation of said reinforcing fibers, and

the widening of said tape-shaped prepreg is restricted by defining the interval between said pair of projection parts.