US 11,794,419 B2
Fiber-reinforced resin molding material molded product and method of producing same
Yusuke Yamanaka, Nagoya (JP); Takafumi Hashimoto, Nagoya (JP); Tetsuya Motohashi, Nagoya (JP); and Yasukazu Ono, Nagoya (JP)
Assigned to Toray Industries, Inc., Tokyo (JP)
Appl. No. 17/598,504
Filed by Toray Industries, Inc., Tokyo (JP)
PCT Filed Mar. 9, 2020, PCT No. PCT/JP2020/010098
§ 371(c)(1), (2) Date Sep. 27, 2021,
PCT Pub. No. WO2020/195756, PCT Pub. Date Oct. 1, 2020.
Claims priority of application No. 2019-060666 (JP), filed on Mar. 27, 2019.
Prior Publication US 2022/0176647 A1, Jun. 9, 2022
Int. Cl. B29C 70/12 (2006.01); B29B 15/10 (2006.01); B29C 70/42 (2006.01); C08J 5/04 (2006.01); B29K 101/10 (2006.01); B29K 105/12 (2006.01); B29K 307/04 (2006.01)
CPC B29C 70/12 (2013.01) [B29B 15/105 (2013.01); B29C 70/42 (2013.01); C08J 5/042 (2013.01); B29K 2101/10 (2013.01); B29K 2105/12 (2013.01); B29K 2307/04 (2013.01)] 11 Claims
OG exemplary drawing
 
1. A fiber-reinforced resin molding material molded product which is a molded product [D] comprising a fiber-reinforced resin molding material [C] prepared by impregnating chopped fiber bundles [A] obtained by cutting a reinforcing fiber bundle with a matrix resin [B], wherein in a region excluding 30 mm from an edge of the molded product [D], when an arbitrary rectangular region having an area of 40 mm2 or more and defined by a thickness of the molded product and a width in a direction perpendicular to a thickness direction of the molded product is set in a cross section in an arbitrary thickness direction of the molded product [D], with respect to a bundle thickness [E] of the chopped fiber bundles [A] present in the set rectangular region, requirements [1]-[3] are satisfied:
[1] when a frequency distribution in which values of the bundle thickness [E] are distributed in sections set from 0 μm at intervals of every 10 μm is created, the most frequent value of the bundle thickness [E] in a section representing the highest value is 30-100 μm;
[2] a ratio of a number of the chopped fiber bundles [A] having a bundle thickness [E] of 200 μm or more to a total number of the chopped fiber bundles [A] is 5% or less; and
[3] a CV value of the bundle thickness [E] is in a range of 10-60%.