US 11,951,695 B2
Method for producing fiber-reinforced plastic
Yuzo Fujita, Ehime (JP); Kentaro Adachi, Ehime (JP); and Takuya Karaki, Ehime (JP)
Assigned to Toray Industries, Inc., Tokyo (JP)
Appl. No. 16/482,434
Filed by Toray Industries, Inc., Tokyo (JP)
PCT Filed Jan. 19, 2018, PCT No. PCT/JP2018/001527
§ 371(c)(1), (2) Date Jul. 31, 2019,
PCT Pub. No. WO2018/142962, PCT Pub. Date Aug. 9, 2018.
Claims priority of application No. 2017-017328 (JP), filed on Feb. 2, 2017.
Prior Publication US 2020/0001550 A1, Jan. 2, 2020
Int. Cl. B29C 70/30 (2006.01); B29C 43/34 (2006.01); B29C 70/34 (2006.01); B29C 70/46 (2006.01); B32B 5/10 (2006.01); B32B 37/02 (2006.01)
CPC B29C 70/30 (2013.01) [B29C 43/34 (2013.01); B29C 70/34 (2013.01); B29C 70/46 (2013.01); B32B 5/10 (2013.01); B32B 37/02 (2013.01)] 10 Claims
OG exemplary drawing
 
1. A method for producing a rigid fiber-reinforced plastic having a three-dimensional shape using a tape-shaped substrate A and a sheet substrate B,
the tape-shaped substrate A comprising 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 comprising randomly oriented reinforcing fibers and a resin, wherein
the method for producing a fiber-reinforced plastic comprises:
a placement step (A) of placing a plurality of tape-shaped substrates A on a mold such that each of the tape-shaped substrates A forms an overlapping portion in which the tape substrate A overlaps one or more other tape-shaped substrates A and a non-overlapping portion in which the tape-shaped substrate A does not overlap any other tape-shaped substrates A;
a placement step (B) of placing a sheet substrate B; and
a molding step of heating and pressing the tape-shaped substrates A and the sheet substrate B placed,
(Condition 1)
the average length xa (mm) of the incisions and the average length ya (mm) of the reinforcing fibers divided by the incisions satisfy ya>6.0xa+10;
wherein in the placement step (A), the ratio of the total of the area of the overlapping portion to the total of the area of the non-overlapping portion is 0.05 to 0.8;
thereby producing the rigid fiber-reinforced plastic having a three-dimensional shape.