Patent ID: 8771452
Filing Date: 2014-07-08
Classification: B29C,B29K,B32B,Y10T

Abstract:
1. A process for producing a fiber-reinforced resin material comprising reinforcement fibers and a thermoplastic resin, the process comprising at least: a step of producing fiber-reinforced resin sheets, each fiber-reinforced resin sheet produced from a reinforcement fiber sheet in which the reinforcement fibers are drawn and aligned in the same direction and a resin sheet comprising the thermoplastic resin; a step of molding each of the fiber-reinforced resin sheets by heating and pressurizing at least parts of the fiber-reinforced resin sheet corresponding to a protruding part and a recessed part so as to form the protruding part on one face of the fiber-reinforced resin sheet along one direction and to form the recessed part along the one direction in another face located on the opposite side to the protruding part; a step of laminating the fiber-reinforced resin sheets while causing at least the protruding part of one of the molded fiber-reinforced resin sheets to engage with a fiber-reinforced resin sheet that is to be laminated therewith; and a step of molding the laminated fiber-reinforced resin sheets into the fiber-reinforced resin material while pressurizing and heating them so as to impregnate the reinforcement fibers with the thermoplastic resin; wherein, in the step of laminating the fiber-reinforced resin sheets, the fiber-reinforced resin sheets are laminated in such a manner that the protruding parts of the respective fiber-reinforced resin sheets overlap with one another and the recessed parts of the respective fiber-reinforced resin sheets to be laminated with one another overlap with one another; wherein, in the step of molding the fiber-reinforced resin sheets, the protruding parts protrude in a direction that differs from a direction in which the reinforcement fibers are drawn and aligned; the step of molding the fiber-reinforced resin sheet comprises: in the step of laminating the fiber-reinforced resin sheet, the first and second fiberreinforced resin sheets are alternately laminated.