JP-2026075472-A - Fiber-reinforced resin laminated chopped sheet

Abstract

[Problem] The present invention provides a fiber-reinforced resin laminated chopped sheet that can achieve both excellent flame resistance and moldability. [Solution] The fiber-reinforced resin laminated chopped sheet is formed by laminating and integrating multiple chopped materials, which are cut pieces of a fiber-reinforced resin sheet, in the thickness direction in a state where the fiber directions are random in two dimensions. The fiber-reinforced resin sheet comprises a resin film made of a thermoplastic resin composition containing one or more selected from the group consisting of polyetheretherketone resin, polyetherimide resin, and polyphenyl sulfide resin, and a plurality of reinforcing fibers integrated into the resin film in a state where the fiber directions are oriented in the same direction. It satisfies the criteria for non-combustibility in the railway vehicle material flammability test in accordance with Article 83 of Chapter 8, Section 5 "Fire countermeasures for vehicles, etc." of Ministry of Land, Infrastructure, Transport and Tourism Ordinance No. 151, and is a railway vehicle material. [Selection Diagram] Figure 1

Inventors

• 金森 尚哲
• 畠山 広大

Assignees

• フクビ化学工業株式会社

Dates

Publication Date

20260508

Application Date

20241022

Claims (2)

1. Multiple chopped materials, which are cut pieces of fiber-reinforced resin sheet, are laminated and integrated in the thickness direction in a state where the fiber direction is random in two dimensions. The fiber-reinforced resin sheet comprises a resin film made of a thermoplastic resin composition containing one or more selected from the group consisting of polyetheretherketone resin, polyetherimide resin, and polyphenyl sulfide resin, and a plurality of reinforcing fibers integrated into the resin film in a state in which the fiber directions are oriented in the same direction. In a flammability test for railway vehicle materials conducted in accordance with Article 83 of Chapter 8, Section 5, "Fire Prevention Measures for Vehicles, etc." of Ministry of Land, Infrastructure, Transport and Tourism Ordinance No. 151, the material satisfies the criteria for non-combustibility. A fiber-reinforced resin laminated chopped sheet, a material used in railway vehicles.
2. A fiber-reinforced resin laminated chopped sheet according to claim 1, wherein the thickness is 0.5 mm or more.

Description

Application for application of Article 30, Paragraph 2 of the Patent Law. Test date: August 6, 2024. Test location: Combustion Test Room, Japan Railway Rolling Stock and Machinery Technology Association. This invention relates to a fiber-reinforced resin laminated chopped sheet, which is suitably used as a material for railway vehicles. Fiber-reinforced plastics (FRP) are lightweight and possess excellent mechanical properties. Therefore, fiber-reinforced plastics are widely used in electrical and electronic components, electronic equipment housings, medical devices, building materials, furniture, home appliances, sporting goods, and more. Fiber-reinforced plastics are manufactured using an intermediate material, or prepreg (hereinafter also referred to as "fiber-reinforced resin sheet"), which is made by impregnating a matrix resin with reinforcing materials consisting of long fibers (continuous fibers), such as reinforcing fibers. Specifically, fiber-reinforced plastics or molded products containing them can be obtained by laminating multiple fiber-reinforced resin sheets and then heating and curing them, or by heating and cooling them to solidify them. Traditionally, when fiber-reinforced composite materials were applied to molded products requiring flame retardancy and heat resistance, thermosetting resins, which offer superior flame retardancy compared to thermoplastic resins, were more commonly used as the resin for the fiber-reinforced composite. However, in recent years, fiber-reinforced composite materials using thermoplastic resins with excellent flame retardancy have been reported, enabling the manufacture of molded products in a variety of shapes. For example, Patent Document 1 describes a fiber-reinforced resin composite sheet comprising a flame-retardant resin film made of a thermoplastic resin composition and multiple reinforcing fibers, wherein the flammability classification of the fiber-reinforced resin composite sheet determined in the UL94-5V combustion test compliant with the ASTM D5048 standard is 5V-A or 5V-B. Patent Document 1 also describes a fiber-reinforced composite material in the form of a laminated chopped sheet composed of multiple chopped materials cut from a fiber-reinforced resin composite sheet. On the other hand, materials used in railway vehicle interiors and other applications also require flame retardancy. However, railway vehicle materials are often required to meet higher standards specifically for railway vehicle materials, rather than the UL94 combustion test standards described in Patent Document 1. International Publication No. 2021/215162 Figure 1 is a schematic cross-sectional view showing an example of the structure of a fiber-reinforced resin laminated chopped sheet according to this embodiment.Figure 2 is an enlarged schematic diagram showing a fiber-reinforced resin laminated chopped sheet viewed from the direction of the arrow shown in Figure 1.Figure 3 is a schematic diagram showing an example of a cross-section of a fiber-reinforced resin sheet, which is an intermediate material of the fiber-reinforced resin laminated chopped sheet according to this embodiment.Figure 4 is a schematic diagram showing another example of a cross-section of a fiber-reinforced resin sheet, which is an intermediate material of the fiber-reinforced resin laminated chopped sheet according to this embodiment.Figure 5 is a schematic diagram illustrating an example of a method for manufacturing a fiber-reinforced resin laminated chopped sheet according to this embodiment.Figure 6 is a diagram illustrating the flammability test of railway vehicle materials in this embodiment. The inventors of this invention have diligently studied fiber-reinforced resin laminated chopped sheets (hereinafter also simply referred to as "laminated chopped sheets") that can achieve both excellent flame resistance and moldability. As a result, it was found that by using one or more resins from a specific type as the resin in the intermediate fiber-reinforced resin sheet, it is possible to manufacture laminated chopped sheets that achieve both excellent flame resistance and moldability. In this specification, "(The laminated chopped sheet) has excellent non-combustibility" means that it meets the criteria for non-combustibility in the railway vehicle material flammability test in accordance with Article 83 of Chapter 8, Section 5, "Fire Prevention Measures for Vehicles, etc." of Ministry of Land, Infrastructure, Transport and Tourism Ordinance No. 151, and possesses non-combustibility suitable for use as a railway vehicle material. The specific criteria for the railway vehicle material flammability test will be described in detail later. Throughout this specification, "lamination and integration" or "integration" means a state in which the target chopped material (cut pieces of fiber-reinforced resin sheet), thin layer laminated chopped sheet, laminated chopped sheet, resin film, reinforcing fiber, etc.,