US4356228A
Expired / Lapsed
US
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Fiber-reinforced moldable sheet and process for preparation thereof
Assignee: Toray Industries Inc
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Filing: 1981-05-18
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Granted: 1982-10-26
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Expires: 2001-05-18
Abstract
Abstract A carbon fiber-reinforced moldable sheet is provided. The moldable sheet comprises a thermoplastic resin and at least two reinforcing agents differing in the length/diameter ratio, which are incorporated with the thermoplastic resin. One reinforcing agent (A) contained in the composite sheet is a carbon fiber having a length/diameter ratio of 200 to 30,000 and the other reinforcing agent (B) is a fibrous and/or powdery reinforcer having a length/diameter ratio of less than 50, and the contents of the reinforcers (A) and (B) in the moldable sheet are 5 to 30% by volume and at least 5% by volume, respectively, the sum of the contents of the reinforcing agents (A) and (B) being in the range of from 20 to 50% by volume. The reinforcing effect of the carbon reinforcing fiber (A) is enhanced by the fibrous and/or powdery reinforcing agent (B) filled among spaces of reinforcing fibers (A). Therefore, molded articles made therefrom are excellent in mechanical properties and appearance and light in weight.
Inventors
- 👤 Hirokazu Kobayashi
- 👤 Minoru Kitanaka
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-24 22:23
CPC Classifications
B; B29; B29C; B29C70/00; B29C70/04; B29C70/28; B29C70/40; B29C70/42; B29C70/46; B29C70/467; B29C70/02; B29C70/021; B29C70/025; C; C08; C08J; C08J5/00; C08J5/04; C08J5/0405; C08J5/042; B29K; B29K2101/00; B29K2101/12; B29K2105/00; B29K2105/06; B29K2105/12; B29K2307/00; B29K2707/00; B29K2707/04; Y; Y10; Y10S; Y10S428/00; Y10S428/902; Y10T; Y10T428/00; Y10T428/25; Y10T428/254; Y10T428/29; Y10T428/2913; Y10T428/2918; Y10T428/30
Claims Analysis
Total Claims: 15
Claim 1
Independent Claim
121 words
A fiber-reinforced moldable sheet comprising a thermoplastic resin and at least two reinforcing agents differing in the length/diameter ratio, which are incorporated with said thermoplastic resin in a mixed state, wherein one reinforcing agent (A) contained in said composite sheet is a carbon fiber having a length/diameter ratio of 200 to 30,000 and the other reinforcing agent (B) is a fibrous reinforcing agent having a length/diameter ratio of less than 50, and the contents of the reinforcing agents (A) and (B) in said moldable sheet are 5 to 30% by volume and at least 5% by volume, respectively, the sum of the contents of the reinforcing agent (A) and (B) being in the range of from 20 to 50% by volume.
Claim 2
Dependent Claim
121 words
A fiber-reinforced moldable sheet comprising a thermoplastic resin and at least two reinforcing agents differing in the length/diameter ratio, which are incorporated with said thermoplastic resin in a mixed state, wherein one reinforcing agent (A) contained in said composite sheet is a carbon fiber having a length/diameter ratio of 200 to 30,000 and the other reinforcing agent (B) is a fibrous reinforcing agent having a length/diameter ratio of less than 50, and the contents of the reinforcing agents (A) and (B) in said moldable sheet are 5 to 30% by volume and at least 5% by volume, respectively, the sum of the contents of the reinforcing agent (A) and (B) being in the range of from 20 to 50% by volume.
Claim 3
Dependent Claim
33 words
A fiber-reinforced moldable sheet as set forth in claim 1, wherein the reinforcing agent (A) is a mat comprising isotropically dispersed carbon fiber chopped strands having a length/diameter ratio of 500 to 10,000.
Claim 4
Dependent Claim
31 words
A fiber-reinforced moldable sheet as set forth in claim 1 or 2, wherein the reinforcing agent (B) comprises finely cut carbon fibers having a length/diameter ratio of not larger than 40.
Claim 5
Dependent Claim
66 words
A fiber-reinforced moldable sheet as set forth in any one of claims 1 through 3, wherein the contents of the reinforcing agents (A) and (B) in said moldable sheet are 20 to 30% by volume and at least 10% by volume, respectively, and the sum of the contents of the reinforcing agent (A) and (B) are in the range of from 30 to 50% by volume.
Claim 6
Dependent Claim
22 words
A fiber-reinforced moldable sheet as set forth in any one of claims 1 through 4, wherein the thermoplastic resin is a polyamide.
Claim 7
Dependent Claim
22 words
A fiber-reinforced moldable sheet as set forth in any one of claims 1 through 4, wherein the thermoplastic resin is a polyester.
Claim 8
Dependent Claim
22 words
A fiber-reinforced moldable sheet as set forth in any one of claims 1 through 4, wherein the thermoplastic resin is a polycarbonate.
Claim 9
Dependent Claim
22 words
A fiber-reinforced moldable sheet as set forth in any one of claims 1 through 4, wherein the thermoplastic resin is a polyamideimide.
Claim 10
Dependent Claim
23 words
A fiber-reinforced moldable sheet as set forth in any one of claims 1 through 4, wherein the thermoplastic resin is a polyphenylene sulfide.
Claim 11
Dependent Claim
22 words
A fiber-reinforced moldable sheet as set forth in any one of claims 1 through 4, wherein the thermoplastic resin is a polysulfone.
Claim 12
Dependent Claim
62 words
A process for the preparation of a fiber-reinforced moldable sheet of a sheet form as set forth in any one of claims 1 through 10, which comprises alternately laminating the reinforcing agent (A) and a sheet formed by mixing the thermoplastic resin with the reinforcing agent (B) in a molten state and heating and pressing the laminate to form an impregnated product.
Claim 13
Dependent Claim
64 words
A process for the preparation of a fiber-reinforced moldable sheet as set forth in any one of claims 1 through 10, which comprises alternately laminating a mixture of the reinforcing agents (A) and (B) and a sheet of the thermoplastic resin, heating the laminate at a temperature higher than the melting point of the resin and pressing the laminate to obtain an impregnated product.
Claim 14
Dependent Claim
79 words
A process for the preparation of a fiber-reinforced moldable sheet as set forth in any one of claims 1 through 10, which comprises dispersing and mixing a powder of the thermoplastic resin and the reinforcing agents (A) and (B) in a liquid medium, collecting said dispersed components in the form of a mat, drying the mat, heating the mat at a temperature higher than the melting point of the resin and pressing the mat to obtain an impregnated product.
Claim 15
Dependent Claim
38 words
A process for the preparation of a fiber-reinforced moldable sheet according to any one of claims 11 through 13, wherein the thermoplastic resin is incorporated with the reinforcing agents at the pressing step by using a heating press.
References Cited (Backward Citations)
US4269884A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1985-10-25 | 1986-04-26 | 1986-10-26 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1989-10-25 | 1990-04-26 | 1990-10-26 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1993-10-25 | 1994-04-26 | 1994-10-26 | $7700.00 | Window Closed / Lapsed |