	US 12,291,612 B2
	Fiber-reinforced resin base material
Naoya Ouchiyama, Nagoya (JP); Masayuki Koshi, Nagoya (JP); and Yoshihiro Naruse, Nagoya (JP)
Assigned to Toray Industries, Inc., Tokyo (JP)
Appl. No. 17/441,930
Filed by Toray Industries, Inc., Tokyo (JP)
PCT Filed Mar. 17, 2020, PCT No. PCT/JP2020/011802 § 371(c)(1), (2) Date Sep. 22, 2021, PCT Pub. No. WO2020/196109, PCT Pub. Date Oct. 1, 2020.
Claims priority of application No. 2019-058157 (JP), filed on Mar. 26, 2019.
Prior Publication US 2022/0162408 A1, May 26, 2022
Int. Cl. C08J 5/04 (2006.01); C08J 5/24 (2006.01); C08L 81/02 (2006.01)

CPC C08J 5/042 (2013.01) [C08J 5/243 (2021.05); C08L 81/02 (2013.01); C08J 2381/02 (2013.01); C08J 2471/12 (2013.01); C08J 2479/08 (2013.01); C08J 2481/06 (2013.01)]

3 Claims

1. A fiber-reinforced resin base material comprising carbon fibers oriented in one direction, said carbon fibers being impregnated with a polyphenylene sulfide resin composition, wherein said fiber-reinforced resin base material has a glass-transition temperature, as measured by the DMA method (bending mode), of 115° C. or higher;

wherein said polyphenylene sulfide resin composition:

has a melt viscosity measured at an orifice length of 5 mm, an orifice diameter of 0.5 mm, a temperature of 320° C., and a shear rate of 9,728 sec⁻¹of 120 Pa·s or less;

comprises 99 to 60% by weight of a polyphenylene sulfide resin (A) and 1 to 40% by weight of a thermoplastic resin (B) having a glass-transition temperature of 100° C. or higher, with respect to 100% by weight of the total amount of said polyphenylene sulfide resin (A) and said thermoplastic resin (B) having a glass-transition temperature of 100° C. or higher;

wherein said thermoplastic resin (B) having a glass-transition temperature of 100° C. or higher forms island phases; and

said thermoplastic resin (B) having a glass-transition temperature of 100° C. or higher has a number average particle size of 10 μm or less;

wherein said thermoplastic resin (B) having a glass-transition temperature of 100° C. or higher is at least one amorphous resin selected from the group consisting of a polyetherimide resin, a polyethersulfone resin, a polyphenyl sulfone and a polysulfone resin; and

wherein said polyphenylene sulfide resin composition further comprises a compound (C) having one or more groups selected from the group consisting of isocyanate groups, in an amount of 0.1 to 10 parts by weight with respect to 100 parts by weight of the total amount of said polyphenylene sulfide resin (A) and said thermoplastic resin (B) having a glass-transition temperature of 100° C. or higher.