US20040170554A1
Expired / Lapsed
US
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Carbon fiber reinforced base material, preform and composite material comprising the same
Assignee: Toray Industries Inc
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Filing: 2002-07-02
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Granted: —
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Expires: 2022-07-02
Abstract
Abstract A carbon fiber reinforced substrate comprising a fabric composed of carbon fiber bundles and a first resin adhering to the fabric. Each of the carbon fiber bundles comprises numerous continuous carbon filaments, has the tensile modulus of 210 GPa or more, and has the fracture strain energy of 40 MJ/m 3 or more. The amount of the first resin adhering to the fabric is in a range from 1 to 20 parts by weight per 100 parts by weight of said fabric. A preform comprising a laminate composed of plural layers of the carbon fiber reinforced substrate, wherein the layers are integrated by means of the first resin. A composite comprising the preform impregnated with a matrix resin.
Inventors
- 👤 Eisuke Wadahara
- 👤 Akira Nishimura
- 👤 Ikuo Horibe
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-02 03:14
CPC Classifications
B; B32; B32B; B32B5/00; B32B5/22; B32B5/24; B32B5/26; B29; B29B; B29B11/00; B29B11/14; B29B11/16; B29B15/00; B29B15/08; B29B15/10; B29B15/105; B29C; B29C70/00; B29C70/003; B29C70/0035; B29C70/04; B29C70/06; B29C70/10; B29C70/16; B29C70/22; B29C70/226; B32B27/00; B32B27/12; B32B27/28; B32B27/281; B32B27/32; B32B27/34; B32B27/38; B32B27/42; B32B5/02; B32B5/024; B32B9/00; B32B9/005; B32B9/007; B32B9/04; B32B9/047; B29L; B29L2031/00; B29L2031/30; B29L2031/3055; B29L2031/3067; B29L2031/3076; B32B2262/00; B32B2262/10; B32B2262/106; B32B2363/00; B32B2377/00; B32B2605/00; B32B2605/08; B32B2605/12; B32B2605/18; D; D10; D10B; D10B2101/00; D10B2101/10; D10B2101/12; D10B2331/00; D10B2331/02; D10B2331/021; Y; Y10; Y10T; Y10T428/00; Y10T428/24; Y10T428/24802; Y10T442/00; Y10T442/20; Y10T442/2041; Y10T442/2098; Y10T442/2107; Y10T442/2115; Y10T442/2123; Y10T442/2131; Y10T442/2139; Y10T442/2926; Y10T442/2984
Claims Analysis
Total Claims: 24
Claim 1
Independent Claim
92 words
1 . A carbon fiber reinforced substrate comprises a fabric composed of carbon fiber bundles and a first resin adhering to said fabric, wherein said carbon fiber bundles respectively comprises numerous continuous carbon filaments, the tensile modulus of said carbon fiber bundles is 210 GPa or more, the fracture strain energy of said carbon fiber bundles is 40 MJ/m 3 or more, and the amount of said first resin adhering to said fabric is in a range from 1 to 20 parts by weight per 100 parts by weight of said fabric.
Claim 2
Dependent Claim
92 words
1 . A carbon fiber reinforced substrate comprises a fabric composed of carbon fiber bundles and a first resin adhering to said fabric, wherein said carbon fiber bundles respectively comprises numerous continuous carbon filaments, the tensile modulus of said carbon fiber bundles is 210 GPa or more, the fracture strain energy of said carbon fiber bundles is 40 MJ/m 3 or more, and the amount of said first resin adhering to said fabric is in a range from 1 to 20 parts by weight per 100 parts by weight of said fabric.
Claim 3
Dependent Claim
38 words
2 . A carbon fiber reinforced substrate according to claim 1 , wherein the amount of said first resin is in a range from 1 to 10 parts by weight per 100 parts by weight of said fabric.
Claim 4
Dependent Claim
39 words
3 . A carbon fiber reinforced substrate according to claim 1 , wherein the first resin adhering to said fabric adheres relatively more densely on a surface of said fabric than in the inside of said carbon fiber bundles.
Claim 5
Dependent Claim
50 words
4 . A carbon fiber reinforced substrate according to claim 1 , wherein said tensile modulus of said carbon fiber bundles is in a range from more than 280 to less than 500 GPa, and the fracture strain energy of said carbon fiber bundles is 53 MJ/m 3 or more.
Claim 6
Dependent Claim
64 words
5 . A carbon fiber reinforced substrate according to claim 1 , wherein said fabric is a uni-directional woven fabric, bi-directional woven fabric or uni-directional sheet, the carbon fiber unit weight of the carbon fiber substrate is in a range from 50 to 500 g/m 2 , and the thickness of the carbon fiber substrate is in a range from 0.1 to 0.8 mm.
Claim 7
Dependent Claim
45 words
6 . A carbon fiber reinforced substrate according to claim 1 , wherein said fabric is a uni-directional woven fabric or uni-directional sheet, and the air permeability of the carbon fiber substrate is in a range from 10 to 200 cm 3 /cm 2 ·sec.
Claim 8
Dependent Claim
36 words
7 . A carbon fiber reinforced substrate according to claim 1 , wherein said first resin is studded on a surface of said fabric, and the diameters of the studded pieces are 1 mm or less.
Claim 9
Dependent Claim
24 words
8 . A carbon fiber reinforced substrate according to claim 1 , wherein said first resin discontinuously adheres on a surface of said fabric.
Claim 10
Dependent Claim
44 words
9 . A carbon fiber reinforced substrate according to claim 1 , wherein said first resin adheres on a surface of said fabric, and the average thickness of the first resin adhering on the surface is in a range from 5 to 250 μm.
Claim 11
Dependent Claim
33 words
10 . A carbon fiber reinforced substrate according to claim 1 , wherein the melting point or flow initiation temperature of said first resin is in a range from 50 to 150° C.
Claim 12
Dependent Claim
24 words
11 . A carbon fiber reinforced substrate according to claim 1 , wherein the main component of said first resin is a thermosetting resin.
Claim 13
Dependent Claim
24 words
12 . A carbon fiber reinforced substrate according to claim 1 , wherein the main component of said first resin is a thermoplastic resin.
Claim 14
Dependent Claim
37 words
13 . A carbon fiber reinforced substrate according to claim 12 , wherein the amount of said thermoplastic resin is in a range from 70 to 100 wt % based on the weight of said first resin.
Claim 15
Dependent Claim
45 words
14 . A carbon fiber reinforced substrate according to claim 1 , wherein the main component of said first resin is at least one selected from the group consisting of epoxy resins, polyamide resins, polyetherimide resins, polyphenylene ether resins, polyether sulfone resins and phenoxy resins.
Claim 16
Dependent Claim
55 words
15 . A carbon fiber reinforced substrate according to claim 1 , wherein the amount of a second resin higher in melting point or flow initiation temperature than said first resin and adhering to said fabric is in a range from 1 to 10 parts by weight per 100 parts by weight of said fabric.
Claim 17
Dependent Claim
61 words
16 . A carbon fiber reinforced substrate according to claim 1 , wherein the amount of a second resin neither molten nor caused to flow at the melting point or flow initiation temperature of said first resin and adhering to said fabric is in a range from 1 to 10 parts by weight per 100 parts by weight of said fabric.
Claim 18
Dependent Claim
31 words
17 . A carbon fiber reinforced substrate according to claim 15 or 16 , wherein said second resin adheres on a surface of said fabric by means of said first resin.
Claim 19
Dependent Claim
33 words
18 . A carbon fiber reinforced substrate according to any one of claims 15 through 17 , wherein said second resin is particles with an average particle diameter of 1 to 500 μm.
Claim 20
Dependent Claim
29 words
19 . A carbon fiber reinforced substrate according to any one of claims 15 through 18 , wherein the main component of said second resin is a thermoplastic resin.
Claim 21
Dependent Claim
57 words
20 . A carbon fiber reinforced substrate according to any one of claims 15 through 19 , wherein the main component of said second resin is at least one thermoplastic resin having a glass transition temperature of 30 to 280° C. selected from the group consisting of polyamide resins, polyamideimide resins, polyetherimide resins and polyether sulfone resins.
Claim 22
Dependent Claim
56 words
21 . A perform comprises a laminate comprising at least two or more layers of the carbon fiber reinforced substrate as set forth in any one of claims 1 through 20 , wherein the layers of the carbon fiber reinforced substrate are integrally bonded to each other by means of said first resin or second resin.
Claim 23
Dependent Claim
33 words
22 . A composite comprises at least the preform as set forth in claim 21 and a third resin, wherein said preform is impregnated with a third resin different from said first resin.
Claim 24
Dependent Claim
41 words
23 . A composite according to claim 22 , which is used as any one of a primary structure element, secondary structure element, exterior element, interior element and parts forming those elements in an aircraft, a motor vehicle or a ship.
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