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Method for laminating fiber-reinforced thermoplastic resin prepreg UPDATE 新技術説明会

外国特許コード F190009882
整理番号 2117
掲載日 2019年8月20日
出願国 欧州特許庁(EPO)
出願番号 11765496
公報番号 2554348
公報番号 2554348
出願日 平成23年3月28日(2011.3.28)
公報発行日 平成25年2月6日(2013.2.6)
公報発行日 平成29年12月20日(2017.12.20)
国際出願番号 JP2011057579
国際公開番号 WO2011125596
国際出願日 平成23年3月28日(2011.3.28)
国際公開日 平成23年10月13日(2011.10.13)
優先権データ
  • 特願2010-080046 (2010.3.31) JP
  • 2011JP57579 (2011.3.28) WO
発明の名称 (英語) Method for laminating fiber-reinforced thermoplastic resin prepreg UPDATE 新技術説明会
発明の概要(英語) To provide a method for manufacturing a multi-layered near net shape for a mold product with improved yields of material, strength and rigidity. Prepreg tapes 1 of composite material comprised of thermoplastic resin and reinforced fibers are used to manufacture the near net shape, wherein the prepreg tapes 1 in a same layer are disposed in different directions based on the directions of fibers contained the prepreg tapes 1 and an outer force to be applied to the mold product, and wherein each prepreg tape 1 is placed and stitched by a suitable stitching method.
特許請求の範囲(英語) [claim1]
1. A method for laminating fiber-reinforced thermoplastic resin prepreg comprising: forming a flat layer made of a plurality of fiber-reinforced thermoplastic resin prepreg tapes (1) by means of a stitching process in which each fiber-reinforced thermoplastic resin prepreg tape (1) is placed on a sheet-shaped base material (3) at a desired position and direction, stitched thereto, and cut in a desired length;
forming at least another flat layer made of a plurality of fiber-reinforced thermoplastic resin prepreg tapes (1) by means of a subsequent stitching process in which each fiber-reinforced thermoplastic resin prepreg tape (1) is placed on the preceding flat layer made of the plurality of fiber-reinforced thermoplastic resin prepreg tapes (1) at a desired position and direction to thereby form a near net shape of plural layers having a predetermined shape.

[claim2]
2. The method of claim 1, wherein at least one of the following arrangements is used in forming a single layer or plural layers of fiber-reinforced thermoplastic resin prepreg tapes to provide required strength and rigidity to a mold product (2), the arrangements including:
arranging a longitudinal direction of fibers contained in the fiber-reinforced thermoplastic resin prepreg tapes (1) to be aligned with a direction of tensile strength to be applied to a mold product (2);
arranging the longitudinal direction of fibers (7) contained in the fiber-reinforced thermoplastic resin prepreg tapes (1) not to be perpendicular to the direction of tensile strength to be applied to the mold product (2);
arranging to provide fiber-reinforced thermoplastic resin prepreg tapes (1) to a portion or narrow portion nearby a section where a group of fiber-reinforced thermoplastic resin prepreg tapes (1) meets another group of fiber-reinforced thermoplastic resin prepreg tapes (1) whose fibers' longitudinal direction differs from fibers of the former prepreg tapes; and
arranging to provide fiber-reinforced thermoplastic resin prepreg tapes to a portion extending above or below a section where a group of fiber-reinforced thermoplastic resin prepreg tapes (1) meets another group of fiber-reinforced thermoplastic resin prepreg tapes (1) whose fibers' longitudinal direction differs from fibers of the former prepreg tapes.

[claim3]
3. The method of claim 1 or 2, wherein stitching is thoroughly applied by providing sewing threads with a small distance therebetween to the laminated fiber-reinforced thermoplastic resin prepreg tapes (1) on an area where detachment or deformation of layers is liable to be generated, in order to provide a mold product (2) having required strength and rigidity.

[claim4]
4. The method of claims 1, 2 or 3, wherein the sheet-shaped base material (3) is composed of the same thermoplastic resin as the resin included in the fiber-reinforced thermoplastic resin prepreg tapes (1), and is configured in a form of a plastic sheet, a plastic film, a cloth, a knit, a mat, a stitching sheet, or a desired combination thereof.

[claim5]
5. The method of claim 1, 2, 3 or 4, wherein the stitching process for the near net shape of a mold product (2) is performed by a embroidery sawing machine including a moving device for moving an object to be straightly stitched in the X- and Y-axis directions in accordance with a programmed control data including stitching sawing data, disposition data of prepreg tapes, and cutting position data.
  • 出願人(英語)
  • HIROSHIMA PREFECTURE
  • TOKAI INDUSTRIAL SEWING MACHINE CO., LTD.
  • 発明者(英語)
  • SHIMOHARA Ichiro
  • IKEDA Shin-ya
  • MATSUBA Akira
  • KONO Yosuke
  • NISHIDA Hironori
  • KONDOU Tetsuro
国際特許分類(IPC)
参考情報 (研究プロジェクト等) Hiroshima Prefectural Technology Research Institute

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