Reinforced fiber/resin fiber composite, and method for manufacturing same

Abstract

A reinforced fiber / resin fiber composite is provided in which the ratio and arrangement of a long fiber and a thermoplastic resin fiber included in an intermediate material are accurately controlled to simultaneously provide good impregnation characteristics of the long fiber and good interfacial characteristics between the long fiber and the thermoplastic resin. A reinforced fiber / resin fiber composite (50) is provided which is an intermediate material for a long-fiber reinforced thermoplastic resin structure. The reinforced fiber (15) is a long fiber extending in a longitudinal direction. The resin fiber (25) includes at least two thermoplastic resin fibers. The at least two thermoplastic resin fibers are arranged around the reinforced fiber (15) to surround the reinforced fiber (15).

Description

TECHNICAL FIELD[0001]The present invention relates to reinforced fiber / resin fiber composites which are an intermediate material for a long-fiber reinforced thermoplastic resin structure, and methods for manufacturing the same.BACKGROUND ART[0002]Fiber reinforced thermoplastic resins, which are a combination of a thermoplastic resin and a fiber, have good properties, i.e., light weight and high strength, and therefore, are used in a variety of fields. For example, in transport machines, such as automobiles, ships, aircrafts, etc., molded products of fiber reinforced thermoplastic resins are used as a portion of parts to improve fuel efficiency and safety.[0003]As a type of fiber reinforced thermoplastic resin, fiber reinforced plastics (FRPs), which are a molded product of a thermoplastic resin to which a short fiber is added, have been well known. In recent years, a long-fiber reinforced thermoplastic resin, which is a combination of a thermoplastic resin and a long fiber (e.g., a ...

AI Technical Summary

Benefits of technology

The present invention aims to provide a reinforced fiber / resin fiber composite that can simultaneously achieve different physical properties of reinforced fiber and resin fiber. The ratio and arrangement of long fiber and thermoplastic resin fiber are accurately controlled. This composite can be efficiently and reliably manufactured at low cost. The braiding technique allows for control of arrangement and tension on a strand-by-strand basis, resulting in accurate control of long-fiber reinforced thermoplastic resin structure. Physical properties of each resin fiber can be imparted to the final product in the desired form.

Problems solved by technology

On the other hand, in the long-fiber reinforced thermoplastic resin, the thermoplastic resin has a very high melt viscosity, and therefore, it is disadvantageously difficult to impregnate the long fiber with the thermoplastic resin.

As the impregnation characteristics of the resin decrease, the molded product cannot exhibit sufficient strength.

If the interfacial characteristics are insufficient, the long fiber and the thermoplastic resin are likely to come off the adhesion surface therebetween, so that the molded product is likely to be damaged.

Here, generally, as the impregnation characteristics of the thermoplastic resin with respect to the long fiber become better, the interfacial characteristics between the long fiber and the thermoplastic resin become worse.

For example, when the surface of the long fiber is modified by acid modification etc. in order to improve the interfacial characteristics, the contact angle of the thermoplastic resin with respect to the long fiber increases (i.e., the wettability of the long fiber surface deteriorates), and as a result, the impregnation characteristics become worse.

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