US 11,873,376 B2
Fiber-reinforced resin material and production method therefor
Mitsuki Fuse, Nagoya (JP); Satoshi Seike, Nagoya (JP); Akihiko Matsui, Nagoya (JP); and Kazuma Ura, Nagoya (JP)
Assigned to Toray Industries, Inc., Tokyo (JP)
Appl. No. 17/287,171
Filed by Toray Industries, Inc., Tokyo (JP)
PCT Filed Oct. 17, 2019, PCT No. PCT/JP2019/040831
§ 371(c)(1), (2) Date Apr. 21, 2021,
PCT Pub. No. WO2020/090488, PCT Pub. Date May 7, 2020.
Claims priority of application No. 2018-205380 (JP), filed on Oct. 31, 2018.
Prior Publication US 2021/0388165 A1, Dec. 16, 2021
Int. Cl. C08J 5/06 (2006.01); B29B 15/10 (2006.01); C08J 5/04 (2006.01)
CPC C08J 5/06 (2013.01) [B29B 15/105 (2013.01); C08J 5/042 (2013.01)] 9 Claims
OG exemplary drawing
 
1. A fiber-reinforced resin material used for molding a fiber-reinforced resin that comprises a matrix resin and reinforcing fiber bundles A comprising chopped fiber bundles each including 100 or more single fibers, wherein a product of an average porosity within fiber bundles Pfav (−) represented by equation (1) and an average fiber bundle thickness tfav (mm) represented by equation (2) is 0 mm or more and 0.01 mm or less and a porosity of composite Pc (−) represented by equation (3) is 0.02 or more and 0.4 or less:

OG Complex Work Unit Math
wherein, i=1, 2, . . . n, j=1, 2, . . . k, x=1, 2, . . . l, which are integers, and n, k, l represent, respectively, the number of all fiber bundles A, the number of voids, and the number of fibers other than the fiber bundles A included in a photographed sectional view, each parameter is:
vf1: area occupied by fibers other than fiber bundles A (mm2)
vf2: area occupied by fibers in fiber bundles A (mm2)
vm1: resin layer area (mm2)
vm2: resin area in fiber bundles A (mm2)
p1: area of voids present in resin layer (mm2)
p2: area of voids present in fiber bundles A (mm2)
tf: thickness of fiber bundle A (mm),
and each parameter is a value calculated from image analysis after binarization of a sectional view prepared by observing a section of a cut surface of the fiber-reinforced resin material in its thickness direction with an optical microscope, and photographing it at effective pixels of 1,600 (H)×1,200 (V) and a photograph magnification of 300 times.