Fiber-reinforced composite material and method for producing the same

Abstract

System and method of producing a fiber-reinforced composite material for preventing void formation and improving mechanical properties such as strength and modulus of elasticity are described. The fiber-reinforced composite material contains a thermoplastic resin as a matrix resin and is formed using reinforcing fibers, in particular, a sheet of fiber substrate such as a woven fabric of reinforcing fibers, or a yarn bundle of a fiber substrate of reinforcing fibers. The fiber-reinforced composite material is composed of a resin-laminated substrate which includes a resin-filled substrate formed by filling spaces between fibers in a sheet or a strand of a fiber substrate with thermoplastic polyurethane filler, and a matrix resin layer composed of a thermoplastic resin disposed on the surface of the resin-filled substrate. The added amount of the thermoplastic polyurethane filler to the fiber substrate is from 10 to 30 vol % with respect to the volume of the fiber substrate.

1 . A resin-laminated substrate, comprising:
 a resin-filled substrate formed by filling spaces between fibers in a fiber substrate with a thermoplastic polyurethane filler; and   a matrix resin layer composed of a thermoplastic resin, which is disposed on the surface of the resin-filled substrate;   wherein the added amount of the thermoplastic polyurethane filler to the fiber substrate is from 10 to 30 vol % with respect to the volume of the fiber substrate.   
     
     
         2 . (canceled) 
     
     
         3 . (canceled) 
     
     
         4 . A fiber-reinforced composite material formed by using the resin-laminated substrate according to  claim 1 . 
     
     
         5 . A method for producing a resin-laminated substrate, comprising:
 applying an aqueous resin dispersion to a fiber substrate, the aqueous resin dispersion being obtained by dispersing thermoplastic polyurethane filler particles in an aqueous medium;   removing the aqueous medium by drying process to form a resin-filled substrate, the fiber substrate being filled with the thermoplastic polyurethane filler by filling spaces between fibers in the fiber substrate with the thermoplastic polyurethane filler particles in an amount of 10 to 30 vol % with respect to the volume of the fiber substrate; and   stacking a matrix resin layer on the surface of the resin-filled substrate to form an integrated article of the resin-filled substrate and the matrix resin.   
     
     
         6 . (canceled) 
     
     
         7 . (canceled) 
     
     
         8 . A method for producing a fiber-reinforced composite material, comprising:
 laminating or aligning the resin-laminated substrate formed by the method for producing a resin-laminated substrate according to  claim 5 ; and   heating it under pressure to concurrently form it into any shape.   
     
     
         9 . The resin-laminated substrate according to  claim 1 , wherein the fiber substrate is a sheet, wherein the resin-filled substrate is a sheet, and wherein the matrix resin is laminated on the sheet of the resin-filled substrate. 
     
     
         10 . The resin-laminated substrate according to  claim 1 , wherein the fiber substrate is a yarn bundle, and wherein the resin-filled substrate is a strand. 
     
     
         11 . The fiber-reinforced composite material according to  claim 4 , wherein the fiber substrate is a sheet, wherein the resin-filled substrate is a sheet, and wherein the matrix resin layer is laminated on the sheet of the resin-filled substrate. 
     
     
         12 . The fiber-reinforced composite material according to  claim 4 , wherein the fiber substrate is a yarn bundle, and wherein the resin-filled substrate is a strand. 
     
     
         13 . The method for producing a resin-laminated substrate according to  claim 5 , wherein the fiber substrate is a sheet, and wherein the resin-filled substrate and a matrix resin are laminated and are heated under pressure to form an integrated article of the resin-filled substrate and the matrix resin. 
     
     
         14 . The method for producing a resin-laminated substrate according to  claim 5 , wherein the fiber substrate is a yarn bundle, wherein the resin-filled substrate is a strand, and wherein the surface of the strand of the resin-filled substrate is coated with a matrix resin to form an integrated article of the resin-filled substrate and the matrix resin. 
     
     
         15 . The method for producing a fiber-reinforced composite material according to  claim 8 , wherein the fiber substrate is a sheet, and wherein the resin-filled substrate and a matrix resin are laminated and are heated under pressure to form an integrated article of the resin-filled substrate and the matrix resin. 
     
     
         16 . The method for producing a fiber-reinforced composite material according to  claim 8 , wherein the fiber substrate is a yarn bundle, wherein the resin-filled substrate is a strand, and wherein the surface of the strand of the resin-filled substrate is coated with a matrix resin to form an integrated article of the resin-filled substrate and the matrix resin.