Stock material or miscellaneous articles – Self-sustaining carbon mass or layer with impregnant or...
Patent
1998-08-11
2000-09-12
Speer, Timothy M.
Stock material or miscellaneous articles
Self-sustaining carbon mass or layer with impregnant or...
428327, 428413, 4284231, 4282974, 156230, 156238, 1563073, 1563077, B32B 516, B32B 906, B32B 3120
Patent
active
06117551&
DESCRIPTION:
BRIEF SUMMARY
TECHNICAL FIELD
The present invention relates to a carbon fiber prepreg and a production process thereof. In more detail, it relates to a carbon fiber prepreg obtained by impregnating a carbon fiber bundle comprising a plurality of continuous filaments and with a specific degree of fiber entanglement, with a base resin mainly composed of a thermosetting resin, characterized in that the thermoplastic resin exists as particles with a specific particle size by a specific quantity in a specific positional distribution, and also to a production process thereof.
A fabricated product (fiber reinforced composite) (hereinafter simply called a composite) obtained by laminating, heating and pressing a plurality of sheets of the carbon fiber prepreg of the present invention is excellent in impact resistance and has an especially high compressive strength as a cross laminated panel.
BACKGROUND ARTS
Composites with a thermosetting resin as the matrix are widely used in various areas such as aerospace area, sporting area, civil engineering and architecture area since they are light in weight and excellent in mechanical properties, corrosion resistance, etc. So far, various prepregs as combinations of a thermosetting resin and reinforcing fibers, and composites made from them are known. Above all, prepregs made from an epoxy resin and carbon fibers are excellent in specific strength and specific elastic modulus, and the composites fabricated from them are excellent in such properties as heat resistance and compressive strength.
A prepreg is obtained by impregnating reinforcing fibers such as carbon fibers with a matrix resin such as an epoxy resin, and can be produced by any of various methods. A prepreg is typically produced by preparing a resin coated film with a matrix resin laminated on a releasable film such as paper and a reinforcing fiber sheet with reinforcing fibers such as carbon fibers arranged like a sheet, and overlaying the resin coated film on one or both sides of the reinforcing fiber sheet, with the resin side kept inside, and heating and pressing them, to impregnate the reinforcing fibers with the resin.
In general, a composite with a thermosetting resin as the matrix resin is brittle and weak in impact.
Depending on applications, a prepreg with higher impact resistance is necessary. For example, Japanese Patent Laid-Open (Kokai) No. 1-104624 discloses an interlaminar particle reinforced prepreg with thermoplastic resin particles as a surface layer, to ensure that when a plurality of layers of the prepreg are laminated, particles made of a highly tough thermoplastic resin are localized between laminate layers.
However, the prepreg produced according to this technique is limited in applicability to an area requiring a compression interlaminar shear strength, since it declines in compression interlaminar shear strength (CILS), though highly improved in impact resistance. Furthermore, an interlaminar particle reinforced prepreg has a disadvantage that the tackiness described later is generally low, compared to a prepreg without containing particles.
DISCLOSURE OF THE INVENTION
An object of the present invention is to solve the problem of the above prior arts by providing a prepreg good in tackiness and less changing in trackiness with the lapse of time.
Another object of the present invention is to provide a prepreg which allows the formation of a composite excellent in CILS at high temperature after moisture absorption while keeping good impact resistance.
A further other object of the present invention is to provide a prepreg which allows the production of a composite very higher than the conventional composite in the laminate compressive strength (LCS) of a cross laminated panel produced as a composite by laminating, heating and pressing a plurality of layers of the prepreg.
A still further other object of the present invention is to provide a process for producing the prepreg.
The present invention is as described below.
(A1) A carbon fiber prepreg, characterized in that a carbon fiber bundle com
REFERENCES:
patent: 5061533 (1991-10-01), Gomi et al.
patent: 5236018 (1993-08-01), Kobayashi et al.
patent: 5902755 (1999-05-01), Driggett et al.
patent: 5910456 (1999-06-01), Matsuhisa et al.
patent: 5985431 (1999-11-01), Oosedo et al.
Kishi Hajime
Nagata Hideo
Odagiri Nobuyuki
Terashita Takeshi
Yamane Shoji
Miller Austin R.
Speer Timothy M.
Toray Industries Inc.
Young Bryant
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