Prepreg, composite molded body and method of manufacture of the composite molded body

• US 5,770,313 A
• Filed: 09/06/1996
• Issued: 06/23/1998
• Est. Priority Date: 01/25/1989
• Status: Expired due to Fees

• Current Assignee: Asahi Kasei Kogyo Kabushiki Kaisha
• Original Assignee: Asahi Kasei Kogyo Kabushiki Kaisha
• Inventors: Fujiwara, Takashi, Furumoto, Goro, Igarashi, Tsuneo
• Primary Examiner(s): NOLD, CHARLES R
• Application Number:
  US08/709,188
• Time in Patent Office: 655 Days
• Field of Search: 428/364, 428/36.91, 428/34.5, 428/413, 428/417, 428/435, 428/475.8, 428/411.1
• US Class Current: 428/411.1
• CPC Class Codes: B29C 70/086 and with one or more layers of pure plastics material, e.g. foam layers applying a non-preformed coating, e.g. a gel-coat, B29C37/0025; with foam blocks B29C70/86
• CPC Class Codes: B29L 2009/00 Layered products
• CPC Class Codes: B32B 1/08 Tubular products
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2307/54 Yield strength; Tensile strength
• CPC Class Codes: B32B 2597/00 Tubular articles, e.g. hoses, pipes
• CPC Class Codes: B32B 27/04 as impregnant, bonding, or embedding substance not used
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/281 comprising polyimides
• CPC Class Codes: B32B 27/285 comprising polyethers
• CPC Class Codes: B32B 27/34 comprising polyamides
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: B32B 27/38 comprising epoxy resins
• CPC Class Codes: B32B 27/40 comprising polyurethanes
• CPC Class Codes: B32B 33/00 Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
• CPC Class Codes: B32B 5/022 Non-woven fabric
• CPC Class Codes: B32B 5/024 Woven fabric
• CPC Class Codes: B32B 5/026 Knitted fabric
• CPC Class Codes: C08J 5/243 : using carbon fibres
• CPC Class Codes: C08J 5/246 : using polymer based synthetic fibres
• CPC Class Codes: Y10T 428/1314 : Contains fabric, fiber particle, or filament made of glass, ceramic, or sintered, fused, fired, or calcined metal oxide, or metal carbide or other inorganic compound [e.g., fiber glass, mineral fiber, sand, etc.]
• CPC Class Codes: Y10T 428/1372 : Randomly noninterengaged or randomly contacting fibers, filaments, particles, or flakes
• CPC Class Codes: Y10T 428/1393 : Multilayer [continuous layer]
• CPC Class Codes: Y10T 428/2913 : Rod, strand, filament or fiber
• CPC Class Codes: Y10T 428/31504 : Composite [nonstructural laminate]
• CPC Class Codes: Y10T 428/31511 : Of epoxy ether
• CPC Class Codes: Y10T 428/31525 : Next to glass or quartz
• CPC Class Codes: Y10T 428/31623 : Next to polyamide or polyimide
• CPC Class Codes: Y10T 428/31743 : Next to addition polymer from unsaturated monomer[s]

Abstract

The present invention relates to a novel composite material, that is, a prepreg, obtained by bonding a film (1) comprised of an organic polymer having substantially no melting point and having a high modulus of 700 kg/mm³ or more and a high strength of 35 kg/mm² or more and a resin layer (2) and/or fiber-reinforced layer (3), a composite molded body, and a method of manufacturing a composite molded body.

The composite molded body obtained by bonding the film (1) and the resin layer (2) of the present invention has superior strength, excellent pliability, and large toughness in all directions. Further, the composite molded body obtained by bonding the film (1) and the fiber-reinforced resin layer (3) has both an extremely large impact resistance which could never be obtained with conventional molded bodies and also a strength and modulus greater than in the past. The molded body can be suitably used for aerospace equipment, sports goods, leisure goods, etc. making use of its light weight, corrosion resistance, and other properties in addition to the above superior proportion.

Claims

1. A prepreg comprising at least one layer of a film comprising an organic polymer having substantially no melting point and having a tensile modulus of 700 kg/mm² or more and a tensile strength of 35 kg/mm² or more and at least one layer of a resin, said film and said resin layer being bonded to each other.

2. A prepreg according to claim 1, wherein said resin layer comprises a thermosetting resin.

3. A prepreg according to claim 1, wherein said resin layer comprises a thermoplastic resin.

4. A prepreg according to any one of claims 1 to 3, wherein a plurality of films and a plurality of resin layers are alternately bonded.

5. A prepreg according to claim 2, wherein said thermosetting resin is a resin selected from the group comprising an epoxy resin, a polyimide resin, an unsaturated polyester resin, a phenolic rosin, and a polyurethane resin.

6. A prepreg according to claim 3, wherein said thermoplastic resin is a resin selected from the group comprising a polyphenylene sulfide, a polyether ketone, a polyether ether ketone, a polyether sulfone, a polyether imide, and a polyamide imide.

7. A prepreg according to claim 1, wherein said film is a film comprising an aromatic polyamide.

8. A prepreg comprising at least one layer of a film comprising an organic polymer having substantially no melting point and having a tensile module of 700 kg/mm² or more and a tensile strength of 35 kg/mm² or more and at least one layer of a fiber-reinforced resin layer, said film and said fiber-reinforced resin layer being bonded to each other.

9. A prepreg according to claim 8, wherein a resin used in the fiber-reinforced resin layer comprises a thermosetting resin.

10. A prepreg according to claim 8, wherein a resin used in the fiber-reinforced resin layer comprises a thermoplastic resin.

11. A prepreg according to any one of claims 8 to 10, wherein at least one layer of film is laminated on an inner layer or an outer layer of at least one laminated fiber-reinforced resin layer.

12. A prepreg according to any one of claims 8 to 10, wherein the film and the fiber-reinforced resin layer are alternately laminated every other layer or every plurality of layers.

13. A prepreg according to any one of claims 8 to 10, wherein a fiber-reinforced layer reinforced by a fiber selected from the group comprising carbon fiber, glass fiber, aromatic polyamide fiber, boron fiber, alumina fiber, silicon carbide fiber, polybenzimidazole fiber, and polybenzothiazole fiber is used.

14. A prepreg according to any one of claims 8 to 10, wherein the reinforcing fibers in the fiber-reinforced resin layer consist of a unidirectionally fiber-arranged sheet.

15. A prepreg according to any one of claims 8 to 10, wherein the reinforcing fibers of the fiber-reinforced resin layer consist of a sheet selected from a group of a woven fabric, a knitted fabric, a nonwoven fabric, and a mat sheet.

16. A prepreg according to claim 8, wherein a fiber-reinforced resin layer with a thermosetting resin which is a resin selected from the group comprising an epoxy resin, a polyimide resin, an unsaturated polyester resin, a phenolic resin, and a polyurethane resin is used.

17. A prepreg according to claim 10, wherein a fiber-reinforced resin layer with a thermoplastic resin which is a resin selected from the group comprising a polyphenylene sulfide, a polyether ketone, a polyether ether ketone, a polyethyl sulfone, a polyether imide, and a polyamide imide is used.

18. A prepreg according to claim 8, wherein said film in a film comprising an aromatic polyamide.

19. A plate molded body comprising at least one layer of a film and at least one layer of a resin and/or a fiber-reinforced resin layer, wherein said film comprises an organic polymer having substantially no melting point and has a tensile module of 700 kg/mm² or more and a tensile strength of 35 kg/mm² or more, said film, said resin layer, or said fiber-reinforced resin being bonded to each other.

20. A plate molded body according to claim 19, wherein a resin used in the resin layer and fiber-reinforced resin layer comprises a thermosetting resin.

21. A plate molded body according to claim 19, wherein a resin used in the resin layer and fiber-reinforced resin layer consists of a thermoplastic resin.

22. A plate molded body according to claim 20, wherein the thermosetting resin is a resin selected from a group comprising an epoxy resin, a polyimide resin, an unsaturated polyester resin, a phenolic resin, and a polyurethane resin.

23. A plate molded body according to claim 21, wherein the thermoplastic resin is a resin selected from a group comprising a polyphenylene sulfide, a polyether ketone, a polyether other ketone, a polyethyl sulfone, a polyether imide, and a polyamide imide.

24. A plate molded body according to any one of claims 19 to 21, wherein at least one layer of film is laminated on an inner layer or an outer layer of the at least one laminated fiber-reinforced resin layers.

25. A plate molded body according to any one of claims 19 to 21, wherein the film and the fiber-reinforced resin layer are alternately laminated every other layer or every plurality of layers.

26. A plate molded body according to any one of claims 19 to 21, wherein a fiber-reinforced layer reinforced by a fiber selected from a group comprising carbon fiber, glass fiber, aromatic polyamide fiber, boron fiber, alumina fiber, silicon carbide fiber, polybenzimidazole fiber, and polybenzothiazole fiber is used.

27. A plate molded body according to any one of claims 19 to 21, wherein the reinforcing fibers in the fiber-reinforced resin layer consist of a unidirectionally fiber-arranged sheet.

28. A plate molded body according to any one of claims 19 to 21, wherein the reinforcing fibers of the fiber-reinforced resin layer consist of a sheet selected from a group of a woven fabric, a knitted fabric, a nonwoven fabric, and a mat sheet.

29. A plate molded body according to claim 19 wherein said film in a film comprising an aromatic polyamide.