US6995099B1
Expired / Lapsed
US
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Composite reinforcing fiber base material, preform and production method for fiber reinforced plastic
Assignee: Toray Industries Inc
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Filing: 2000-02-22
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Granted: 2006-02-07
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Expires: 2020-02-22
Abstract
Abstract The present invention is aimed at providing FRP formed by integrating a fiber reinforcing material and a non-woven fabric, and having excellent shaping ability, impact resistance after molding, and excellent reliability and low cost. The aim of the present invention is achieved by a complex fiber reinforcing material including a sheet-shaped fiber reinforcing material composed of reinforcing fibers, and a non-woven fabric laminated on at least one side of the fiber reinforcing material, wherein the fibers constituting the non-woven fabric pass through the fiber reinforcing material to integrate the non-woven fabric with the fiber reinforcing material.
Inventors
- 👤 Akira Nishimura
- 👤 Kiyoshi Homma
- 👤 Ikuo Horibe
- 👤 Takehiko Hirabara
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-29 07:36
CPC Classifications
B; B32; B32B; B32B5/00; B32B5/22; B32B5/24; B32B5/26; B29; B29B; B29B11/00; B29B11/14; B29B11/16; B29C; B29C70/00; B29C70/04; B29C70/06; B29C70/08; B29C70/083; B29C70/10; B29C70/16; B29C70/22; B29C70/226; B29C70/28; B29C70/40; B29C70/42; B29C70/44; B29C70/443; B32B5/02; B32B5/022; B32B5/024; B32B5/06; B32B5/08; B32B5/10; B32B7/00; B32B7/04; B32B7/12; D; D04; D04H; D04H1/00; D04H1/40; D04H1/44; D04H1/46; D04H1/498; D04H1/54; D04H1/559; D04H1/58; D04H1/593; D04H3/00; D04H3/002; D04H3/02; D04H3/04; D04H3/08; D04H3/10; D04H3/115; B32B2262/00; B32B2262/02; B32B2262/0261; B32B2262/0269; B32B2262/10; B32B2262/106; B32B2262/12; B32B2307/00; B32B2307/50; B32B2307/558; B32B2605/00; B32B2605/18; Y; Y10; Y10T; Y10T428/00; Y10T428/24; Y10T428/24058; Y10T428/24124; Y10T428/29; Y10T428/2913; Y10T428/2929; Y10T442/00; Y10T442/20; Y10T442/2008; Y10T442/2016; Y10T442/2926; Y10T442/2984; Y10T442/30; Y10T442/60; Y10T442/637; Y10T442/641; Y10T442/681; Y10T442/69
Claims Analysis
Total Claims: 24
Claim 1
Independent Claim
105 words
A complex fiber reinforcing material comprising a sheet-formed carbon fiber reinforcing material comprising a woven fabric or a stitch cloth of carbon fibers, and a non woven fabric comprising short fibers including organic fibers, wherein the non-woven fabric is laminated onto at least one side of the carbon fiber reinforcing material, the short fibers pass through the fiber reinforcing material to integrate the carbon fiber reinforcing material with the non-woven fabric, the weight per unit area of the carbon fiber reinforcing material is 100 to 2000 g/m 2 and the weight per unit area of the non-woven fabric is 5 to 30 g/m 2 .
Claim 2
Dependent Claim
105 words
A complex fiber reinforcing material comprising a sheet-formed carbon fiber reinforcing material comprising a woven fabric or a stitch cloth of carbon fibers, and a non woven fabric comprising short fibers including organic fibers, wherein the non-woven fabric is laminated onto at least one side of the carbon fiber reinforcing material, the short fibers pass through the fiber reinforcing material to integrate the carbon fiber reinforcing material with the non-woven fabric, the weight per unit area of the carbon fiber reinforcing material is 100 to 2000 g/m 2 and the weight per unit area of the non-woven fabric is 5 to 30 g/m 2 .
Claim 3
Dependent Claim
92 words
A complex fiber reinforcing material comprising a sheet-formed carbon fiber reinforcing material comprising a woven fabric or a stitch cloth of carbon fibers, and a nonwoven fabric including organic fibers laminated on at least one side of the carbon fiber reinforcing material, wherein the non-woven fabric is integrated with the fiber reinforcing material by a pressure sensitive adhesive, the weight per unit area of the carbon fiber reinforcing material is 100 to 2000 g/m 2 and the weight per unit area of the non-woven fabric is 5 to 30 g/m 2 .
Claim 4
Dependent Claim
92 words
A complex fiber reinforcing material comprising a sheet-formed carbon fiber reinforcing material comprising a woven fabric or a stitch cloth of carbon fibers, and a nonwoven fabric including organic fibers laminated on at least one side of the carbon fiber reinforcing material, wherein the non-woven fabric is integrated with the fiber reinforcing material by a pressure sensitive adhesive, the weight per unit area of the carbon fiber reinforcing material is 100 to 2000 g/m 2 and the weight per unit area of the non-woven fabric is 5 to 30 g/m 2 .
Claim 5
Dependent Claim
106 words
A complex fiber reinforcing material comprising a sheet-formed carbon fiber reinforcing material comprising a woven fabric or a stitch cloth of carbon fibers, and a non woven fabric including organic fibers laminated on at least one side of the carbon fiber reinforcing material, wherein the non-woven fabric contains 5 to 50% by weight of low-melting point fibers, and the carbon fiber reinforcing material is integrated with the non-woven fabric by heat bonding, the weight per unit area of the carbon fiber reinforcing material is 100 to 2000 μm 2 and the weight per unit area of the non-woven fabric is 5 to 30 g/m 2 .
Claim 6
Dependent Claim
106 words
A complex fiber reinforcing material comprising a sheet-formed carbon fiber reinforcing material comprising a woven fabric or a stitch cloth of carbon fibers, and a non woven fabric including organic fibers laminated on at least one side of the carbon fiber reinforcing material, wherein the non-woven fabric contains 5 to 50% by weight of low-melting point fibers, and the carbon fiber reinforcing material is integrated with the non-woven fabric by heat bonding, the weight per unit area of the carbon fiber reinforcing material is 100 to 2000 μm 2 and the weight per unit area of the non-woven fabric is 5 to 30 g/m 2 .
Claim 7
Dependent Claim
46 words
A complex fiber reinforcing material according to any one of claims 1 to 3 , wherein the size of the carbon fiber yarns of the carbon fiber reinforcing material is 550 to 270000 decitex, and the number of filaments per carbon fiber is 1000 to 400000.
Claim 8
Dependent Claim
33 words
A complex fiber reinforcing material according to any one of claims 1 to 3 , wherein the carbon fiber reinforcing material comprises a woven fabric having a cover factor of 95% or more.
Claim 9
Dependent Claim
31 words
A complex fiber reinforcing material according to any one of claims 1 to 3 , wherein the non-woven fabric contains low-melting-point fibers comprising a thermoplastic polymer having a low melting point.
Claim 10
Dependent Claim
41 words
A complex fiber reinforcing material according to any one of claims 1 to 3 , wherein the non-woven fabric comprises conjugate fibers comprising a core having a sectional area of 30 to 70% of the sectional area of the conjugate fiber.
Claim 11
Dependent Claim
31 words
A complex fiber reinforcing material according to claim 7 , wherein the cores of each of the conjugate fibers comprise nylon 6 or nylon 66, and the sheath comprises nylon copolymer.
Claim 12
Dependent Claim
61 words
A complex fiber reinforcing material according to any one of claims 1 to 3 , wherein the carbon fiber reinforcing material comprises a uni-directional woven fabric comprising carbon fibers yarns oriented in a length direction of the material, and auxiliary yarns thinner than the carbon fiber yarns and oriented in a width direction of the material, to form a woven structure.
Claim 13
Dependent Claim
32 words
A complex fiber reinforcing material according to claim 9 , wherein the carbon fiber yarns are oriented in the length direction at intervals of 0.1 to 5 mm in uni-directional woven fabric.
Claim 14
Dependent Claim
47 words
A complex fiber reinforcing material according to any one of claims 1 to 3 , wherein the carbon fiber reinforcing material comprises a bi-directional woven fabric comprising carbon fiber yarns oriented in a length direction and a width direction of the material to form a woven structure.
Claim 15
Dependent Claim
62 words
A complex fiber reinforcing material according to claim 11 , wherein the carbon fiber yarns of the bi-directional woven fabric, which are oriented in at least one of the length direction and the width direction, are flat carbon fiber yarns having a width in the range of 4 to 30 mm, and a thickness in the range of 0.1 to 1.0 mm.
Claim 16
Dependent Claim
46 words
A complex fiber reinforcing material according to any one of claims 1 to 3 , wherein the fiber reinforcing material comprises a stitch cloth comprising at least two groups of reinforcing yarns which are crossed with each other and which are stitched with a stitch yarn.
Claim 17
Dependent Claim
37 words
A complex fiber reinforcing material according to any one of claims 1 to 3 , wherein the carbon fibers have a tensile modulus of 200 Gpa or more, and a tensile strength of 4.5 Gpa or more.
Claim 18
Dependent Claim
35 words
A complex fiber reinforcing material according to any one of claims 1 to 3 , wherein the non-woven fabric has a void ratio of 30 to 95% of the total area of the non-woven fabric.
Claim 19
Dependent Claim
25 words
A complex fiber reinforcing material according to claim 2 , wherein the amount of pressure sensitive adhesive used is 1 to 10 g/m 2 .
Claim 20
Dependent Claim
51 words
A preform comprising a laminate of a plurality of layers of the complex fiber reinforcing material according to any one of claims 1 to 3 , wherein the plurality of the complex fiber reinforcing material are laminated such that the carbon fiber reinforcing material and the nonwoven fabric are located alternately.
Claim 21
Dependent Claim
28 words
A preform according to claim 17 , wherein the fiber reinforcing material layers are integrated with each other by heat bonding low-melting-point fibers contained in the non-woven fabric.
Claim 22
Dependent Claim
23 words
A preform according to claim 17 , wherein the fiber reinforcing material layers are integrated with each other by a pressure sensitive adhesive.
Claim 23
Independent Claim
50 words
A method of producing a fiber reinforced plastic comprising covering a preform according to any one of claims 1 to 3 with a bag film, injecting a resin into the bag film in a vacuum state to impregnate the complex fiber reinforcing material with the resin, and curing the resin.
Claim 24
Independent Claim
57 words
A method of producing a fiber reinforced plastic comprising setting a preform according to any one of claims 1 to 3 in a cavity formed by a male mold and a female mold, injecting a resin into the cavity in a vacuum state to impregnate the complex fiber reinforcing material with the resin, and curing the resin.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2009-02-06 | 2009-08-08 | 2010-02-07 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2013-02-06 | 2013-08-08 | 2014-02-07 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2017-02-06 | 2017-08-08 | 2018-02-07 | $7700.00 | Window Closed / Lapsed |