Patent ID: 11926111
Assignee: TORAY INDUSTRIES, INC.
Field: Other special machines (Mechanical engineering)
Classification: CPC B  C | IPC B  C

Claim 0:
1. A method for manufacturing a fiber-reinforced plastic composite containing a fiber-reinforced plastic part having a plate-like portion and a rib protruding from one surface of the plate-like portion, and a metal part laminated on part of or all of the plate-like portion of the fiber-reinforced plastic part, comprising:
a lamination step for stacking a plurality of sheets of base material to form a base laminate,
a base material heating step for heating the base laminate, and
a molding step for integrating the base laminate and the metal part by pressing them between a rib molding member having a recessed portion for forming a rib and a skin molding member free of such a recessed portion in a pressing device,
the recessed portion having a width, measured in a direction perpendicular to a length direction of the recessed portion of the rib molding member, of 0.1 to 1.5 mm,
the metal part having an average thickness of 0.5 to 3 mm,
the base laminate including, as sheets of base material, a plurality of incised prepreg layers, each prepreg layer containing unidirectionally oriented fibers and a resin, and a plurality of incisions crossing the fibers to provide discontinuous fibers in the incised prepreg layers,
wherein in the molding step, the discontinuous fibers in the incised prepreg layers contained in the base laminate flow together with the resin, thereby shaping the plate-like portion while forming the rib at the same time, and
in the molding step, an absolute value of an acute angle between an orientation direction of the unidirectionally oriented fibers included in the incised prepreg layer that is closest to the rib molding member and the length direction of the recessed portion of the rib molding member, which is represented as θs, being less than 60°,
wherein the metal part has a product of its elastic modulus (GPa) multiplied by its thickness (mm) in the range of 50 to 300.