US 11,938,655 B2
Tape-shaped prepreg and a method for production thereof
Eita Konno, Nagoya (JP); Taito Ueda, Nagoya (JP); and Mayuka Yamada, Nagoya (JP)
Assigned to TORAY INDUSTRIES, INC., Tokyo (JP)
Appl. No. 16/772,502
Filed by TORAY INDUSTRIES, INC., Tokyo (JP)
PCT Filed Dec. 13, 2018, PCT No. PCT/JP2018/045826
§ 371(c)(1), (2) Date Jun. 12, 2020,
PCT Pub. No. WO2019/124203, PCT Pub. Date Jun. 27, 2019.
Claims priority of application No. 2017-245913 (JP), filed on Dec. 22, 2017; and application No. 2017-245914 (JP), filed on Dec. 22, 2017.
Prior Publication US 2020/0385540 A1, Dec. 10, 2020
Int. Cl. C08J 5/24 (2006.01); B29B 11/16 (2006.01); B29B 15/12 (2006.01); B29C 70/20 (2006.01); B29C 70/52 (2006.01); B32B 5/26 (2006.01); B32B 5/28 (2006.01); B29K 77/00 (2006.01); B29K 101/12 (2006.01); B29K 105/08 (2006.01); B29K 307/04 (2006.01)
CPC B29B 15/122 (2013.01) [B29B 11/16 (2013.01); B29C 70/20 (2013.01); B29C 70/52 (2013.01); B29C 70/521 (2013.01); B29C 70/528 (2013.01); B32B 5/26 (2013.01); C08J 5/243 (2021.05); B29B 15/12 (2013.01); B29K 2077/00 (2013.01); B29K 2101/12 (2013.01); B29K 2105/0872 (2013.01); B29K 2105/0881 (2013.01); B29K 2307/04 (2013.01); B32B 2307/538 (2013.01); C08J 2377/00 (2013.01); Y10T 428/24994 (2015.04); Y10T 428/249942 (2015.04); Y10T 428/249944 (2015.04); Y10T 428/249945 (2015.04); Y10T 428/31 (2015.01)] 20 Claims
OG exemplary drawing
 
1. A tape-shaped prepreg comprising unidirectionally oriented reinforcing fibers and a thermoplastic resin composition, wherein the tape-shaped prepreg has
an arithmetic average roughness (Ra) of 0.1 to 10 μm in a direction perpendicular to the orientation direction of the reinforcing fibers, as measured according to JIS B 0601: 2013, and
a warpage rate of 5% or less as determined by the procedure specified in (i) to (iii) below:
(i) a test piece of the above tape-shaped prepreg having a length of 100 mm is placed in the fiber orientation direction on a plane in such manner that the end portions curl upward,
(ii) the vertical distance from the highest position at the right end of the curled tape to the plane, which is denoted by a, and the vertical distance from the highest position at the left end to the plane, which is denoted by b, are measured and the arithmetic average of a and b is calculated, which is defined as the warpage distance, and
(iii) the warpage rate is calculated based on the following equation:
warpage rate (%)=warpage distance (mm)/100 (mm)×100,
wherein
the tape-shaped prepreg has a thickness of 0.20 to 15 mm and
the tape-shaped prepreg exhibits a waviness curve having a maximum cross-sectional height (Wt) of 80 μm or less in a direction perpendicular to the orientation direction of the reinforcing fibers, as measured according to JIS B 0601: 2013.