JP2023069599A - molding material - Google Patents

Abstract

To provide a molding material for obtaining a member with an exposed clean surface of thermoplastic prepreg in obtaining a member having a site made of thermoplastic prepreg on the surface of parent material made of thermosetting prepreg.SOLUTION: In a molding material, the following elements are laminated in the order of an element [1] cloth, an element [2] thermoplastic prepreg, and an element [3] thermosetting prepreg.SELECTED DRAWING: Figure 1

Description

TECHNICAL FIELD The present invention relates to a molding material for obtaining a member in which a thermosetting prepreg and a thermoplastic prepreg are combined and integrated.

Resin materials reinforced with reinforcing fibers are being applied to aircraft due to their excellent specific strength and specific rigidity. In general, members made of this material are rarely used as a single member when used as part of the structure of an aircraft fuselage, for example, and are used as a composite member combined with separate members of different shapes. is common.

Patent Literature 1 discloses a composite member in which a stringer-like reinforcing member is fastened to a panel-like member with a fastener and integrated. Each of the separate members to be fastened is perforated, and the members are positioned with respect to each other and then fastened with fasteners. At that time, the series of steps requires time due to the procedure of repeatedly fastening a large number of fasteners at intervals, and there is a limit to how much time can be shortened. Furthermore, the weight of the fastener itself, which is made of metal, impairs the lightness of the composite member.

Patent Literature 2 discloses an example in which a component made of a thermoplastic prepreg made of reinforcing fibers and a thermoplastic resin is joined to another member by means of heat welding. Thermoplastic resin melts or softens when heated to exhibit stickiness. In this state, when the members to be joined are cooled to normal temperature while being pressure-bonded, the thermoplastic resin is solidified and the members are bonded together. This mode of joining ameliorate the problems found in the metal fasteners described above.

In Patent Document 3, as a configuration of a part that can be thermally welded, a layer made of reinforcing fibers and a thermosetting resin is used as a base material, and a layer made of reinforcing fibers and a thermoplastic resin is provided on the surface of the base material. There is a disclosure of the parts and their conjugates. A similar idea is also disclosed in Non-Patent Document 1. In these aspects, while maintaining the advantage of being able to join to other separate parts by heat welding, the parts that need to be joined to other members are made of a thermoplastic material, which makes them less expensive than thermoplastic materials. Since the majority of the member can be formed of a thermosetting material, the cost of the member can be reduced.

: International Publication No. 2010/046684 : JP 2015-120359 : U.S. Patent No. 5,304,269

: Ageorges C, Ye L, Hou M.; Composites: Part A 32 (2001) p839-857

As disclosed in Patent Documents 2 and 3, the means of joining members by thermal welding using a thermoplastic material placed on the surfaces of the members provides an improvement to the problems found in fastening fasteners. However, in forming a member by integrating a thermoplastic material and an uncured thermosetting material by molding in order to obtain a member that can be welded and joined, the thermosetting resin may flow out and adhere to the surface of thermoplastic materials. The problem is that if the surface of the thermoplastic material to be used as the joint surface is contaminated, the quality of the joint is lowered.

The present invention is a molding material in which the following elements are laminated in the order of element [1]/element [2]/element [3].
Element [1] Fabric element [2] Thermoplastic prepreg element [3] Thermosetting prepreg According to a preferred embodiment of the molding material of the present invention, the air permeability of the fabric is 0.01 cm ³ /(cm ² ·s) or more 2000 less than 0.00 cm ³ /(cm ² ·s).

According to a preferred embodiment of the molding material of the present invention, the entire surface of the fabric is in contact only with the thermoplastic prepreg.

According to a preferred embodiment of the molding material of the present invention, the minimum distance between S1 and S2 of the outer peripheral line S1 of the fabric and the outer peripheral line S2 of the thermoplastic prepreg is 1 mm or more and less than 100 mm.

According to a preferred embodiment of the molding material of the present invention, the fabric and the thermoplastic prepreg are bound together.

According to a preferred aspect of the molding material of the present invention, the thermoplastic prepreg and the thermosetting prepreg are fixed.

The molded article of the present invention is a molded article obtained by molding the molding material by means of heating and/or pressing.

According to a preferred aspect of the molded article of the present invention, the molding material is molded in a temperature range equal to or higher than the melting point of the thermoplastic resin contained in the thermoplastic prepreg.

According to a preferred aspect of the molded article of the present invention, the molding material is molded in a temperature range below the melting point of the thermoplastic resin contained in the thermoplastic prepreg.

The member of the present invention is obtained by removing the fabric portion from the molded article.

According to the molding material of the present invention, it is possible to obtain a member having an exposed thermoplastic prepreg surface that is used as a joint surface with another member without requiring an additional step such as sandblasting.

It is a figure which shows an example of the molding material of this invention. It is a figure which shows an example of the molding material of this invention.

An object of the present invention is to solve the above problems, and is a molding material in which the following elements are laminated in the order of element [1]/element [2]/element [3].
Element [1] Fabric element [2] Thermoplastic prepreg element [3] Thermosetting prepreg Next, details of an embodiment of the molded article of the present invention will be described.

The thermosetting prepreg of the present invention is composed of a sheet-like thermosetting prepreg in which reinforcing fibers are impregnated with a thermosetting resin. It constitutes a base in a molded body formed from a molding material.

When continuous fibers are used as the reinforcing fibers, a prepreg that efficiently exhibits the strength characteristics of the fibers can be obtained. In particular, a unidirectional prepreg in which fibers are arranged in a specific direction is suitable for structural members such as aircraft because of its high strength. Alternatively, if a fiber base material made of a woven or knitted fabric of fibers is used, the slackness of the reinforcing fibers can impart flexibility to the prepreg. Furthermore, by using discontinuous fibers, the prepreg itself may have a configuration in which the shape moldability is further enhanced.

As the thermosetting prepreg, a laminated prepreg may be used in order to give the molded body desired thickness, rigidity and strength. The form of a laminated composite plate obtained by baking unidirectional prepregs laminated while changing the fiber angle for the purpose of imparting isotropic properties is suitable when the molded body is used as a structural member.

The type of reinforcing fiber is not particularly limited, and carbon fiber, glass fiber, aramid fiber, or the like can be used, and a hybrid structure combining these is also possible. A form containing carbon fibers is particularly preferable from the viewpoint of strength design for production of molded articles and ease of production of members.

Various thermosetting resins can be used as the thermosetting resin contained in the thermosetting prepreg of the present invention. Although the type thereof is not particularly limited, it is preferably at least one selected from epoxy resins, benzoxazine resins, cyanate ester resins, bismaleimide resins, phenolic resins and modified resins thereof. Epoxy resins are particularly preferred because of their excellent mechanical properties. For applications requiring heat resistance, cyanate ester resins or bismaleimide resins may be used.

The thermoplastic prepreg of the present invention is a sheet-like thermoplastic prepreg in which reinforcing fibers are impregnated with a thermoplastic resin. In a molded body formed from a molding material, it becomes a portion covering part or all of the base portion of the molded body made of thermosetting prepreg.

When continuous fibers are used as the reinforcing fibers, a prepreg that efficiently exhibits the strength characteristics of the fibers can be obtained. In particular, a unidirectional prepreg in which fibers are arranged in a specific direction can be exemplified as a structure with high strength.

Alternatively, if a fiber base material made of a woven or knitted fabric is used, the slack given to the reinforcing fibers allows the thermoplastic resin contained in the prepreg to become flexible in a molten state. suitable for

A laminate of prepregs can be used for the purpose of imparting desired thickness and rigidity to the molded body. The prepreg fibers may be oriented more in the direction in which the molded body is desired to have rigidity.

The type of reinforcing fiber is not particularly limited. The same types of reinforcing fibers as listed in the section on thermosetting prepreg may be used.

The types of thermoplastic resins are not particularly limited, but polyamide resins, polyester resins, polyphenylene sulfide resins, polyacetal resins, polyphenylene oxide resins, polycarbonate resins, polylactic acid resins, polypropylene resins, polyimide resins (PI resins) and polyamideimide resins. (PAI resin) containing thermoplastic polyimide resin, polyether ether ketone resin (PEEK resin) and polyether ketone ketone resin (PEKK resin) containing polyaryl ether ketone resin, polysulfone resin (PSU resin), polyether sulfone At least one selected from aromatic polyethersulfone-based resins including sulfone resins (PES resins) and polyphenylenesulfone resins (PPSU resins), and modified resins thereof can be used. At least one selected from aromatic polyamide resins, polyphenylene sulfide resins, polyether ketone ketone resins, and polyether ether ketone resins can be preferably used from the viewpoint of achieving both moldability and heat resistance of the molded article.

The fabric of the present invention is constructed from fibrous materials. The form is not particularly limited as long as it is a structure made of fibers, and woven fabrics, non-woven fabrics, knitted fabrics, felts, and the like can be used.

The fibers constituting the fabric are not particularly limited, but polyester fibers typified by, for example, polyethylene terephthalate, polybutylene terephthalate, and those obtained by copolymerizing these with a third component such as sulfoisophthalate and isophthalic acid. , nylon 6, nylon 66, nylon 46, vinylon fiber, polyethylene fiber, polypropylene fiber, acrylic fiber, aramid fiber, glass fiber, carbon fiber, metal fiber, etc. can be used. Among them, inexpensive and relatively high-strength fibers, polyester fibers, and polyamide fibers are preferable.

The fiber can be used as it is, or it can be used as a yarn. For example, a nonwoven fabric can be obtained by using the fibers as they are. Woven fabrics and knitted fabrics can be obtained from yarns. When yarns are used, yarns processed by additional twisting, pliing twisting, false twisting, air mixed yarn, etc. may be used.

In addition, it is preferable that the oil agent and sizing agent used when producing the fabric are removed by scouring treatment prior to producing the fabric. By doing so, the surface of the thermoplastic prepreg is not contaminated with the components of the fabric when a molded article is obtained from the molding material.

The molding material of the present invention can be molded with a molding machine having a heating and pressing mechanism. For molding, an autoclave method, a vacuum pressure molding method (Vaccum Bag Only: VBO method), or a hot press molding method can be preferably used. In particular, the autoclave method is preferable for obtaining a high-quality molded article.

The thermosetting prepreg constituting the molding material of the present invention contains an uncured thermosetting resin. In the molding method using heat, the uncured thermosetting resin may become less viscous as the environmental temperature rises and flow out of the thermosetting prepreg. Some of the flowed out thermosetting resin flows into and adheres to the surface of the thermoplastic prepreg that is in contact with the thermosetting prepreg. This phenomenon tends to occur in the autoclave molding method and the VBO method in which a vacuum pressure is applied to the molding material.

Furthermore, the thermoplastic prepreg that constitutes the molding material of the present invention has the characteristics of a thermoplastic resin that is solidified at room temperature and is solid. In particular, when single-layer prepregs are handled, they are fragile and may crack in the direction parallel to the fibers due to handling during lamination or molding. When the cracked prepreg is used as a molding material, the uncured thermosetting resin derived from the thermosetting prepreg permeates the cracked portion of the thermoplastic prepreg and contacts the thermosetting prepreg of the thermoplastic prepreg. There are some that seep out and adhere to the surface that is paired with the surface.

Due to the phenomenon during molding such as the above, the thermosetting resin adheres to the surface of the thermoplastic prepreg that is in contact with the thermosetting prepreg, and the part to be used as the bonding surface of the member is contaminated. This may lead to deterioration in quality when the member is joined to another member.

The fabric of the present invention preferably has air permeability. By having air permeability, the effect of adsorbing the thermosetting resin that flows into or exudes to the surface of the thermoplastic prepreg as described above is enhanced.

Furthermore, the air permeability of the fabric is preferably 0.01 cm ³ /(cm ² s) or more and less than 2000.00 cm ³ /(cm ² s), more preferably 5.00 cm ³ /(cm ² s) or more. It is less than 300.00 cm ³ /(cm ² ·s), more preferably 10.00 cm ³ /(cm ² ·s) or more and less than 150.00 cm ³ /(cm ² ·s). If the air permeability is greater than 0.01 cm ³ /(cm ² ·s), the effect of the thermosetting resin incorporated in the fabric to remain in the fabric even after being hardened by receiving heat from molding is enhanced. In general, the higher the air permeability, the better the thermosetting resin can be adsorbed. Since the effect of adsorbing the thermosetting resin is weakened at the portion of the fabric where the tear occurs, the air permeability of the fabric should be less than 2000.00 cm ³ /(cm ² ·s). The air permeability of fabric can be measured according to JIS L 1096 (2010).

The air permeability of the fabric can be changed by changing the thickness of the fiber or filament, the pitch of the weave or knitting of the filament, or the basis weight of the fabric. In particular, woven fabrics can be preferably used as the fabric of the present invention because these can be changed relatively easily.

The fabric may not be able to take in any more thermosetting resin when the interstices of the fibers that make up the fabric are filled with the thermosetting resin derived from the prepreg. This phenomenon is likely to occur in a situation where the fabric is placed in contact with the thermosetting prepreg and the fabric can directly take in the thermosetting resin from the thermosetting prepreg. Therefore, from the viewpoint of utilizing the effect of the fabric to improve the cleanliness of the thermoplastic prepreg, it is preferable that the entire surface of the fabric is in contact only with the thermoplastic prepreg.

As a configuration that further enhances the above effects, the minimum distance between the outer peripheral line S1 of the fabric and the outer peripheral line S2 of the thermoplastic prepreg is preferably 0.1 mm or more and less than 100.0 mm, and more preferably. is preferably 2.0 mm or more and less than 50.0 mm.

The distance between S1 and S2 can be appropriately changed depending on the shape of the fabric and the positional relationship between the fabric and the thermoplastic prepreg. FIG. 2 shows an example of a molding material using a rectangular fabric and a rectangular thermoplastic prepreg. At this time, reference numeral 6 indicates the minimum value of the distance between S1 and S2, and reference numeral 7 indicates the maximum value of the distance between S1 and S2. As described above, for a molding material in which the distance between S1 and S2 is not uniform depending on the part, it is preferable to set the minimum value (minimum distance) of the distance between S1 and S2 within the above range.

With the minimum distance between S1 and S2 being 0.1 mm or more, the thermosetting resin deposited on the thermoplastic prepreg is effectively adsorbed by the fabric. As the distance increases, the effect of improving the cleanliness of the thermoplastic prepreg by the fabric increases, but on the other hand, after forming a molded body from the molding material, the fabric is removed and the area that can be used as a joint surface becomes smaller. The minimum distance between S1 and S2 is preferably less than 100.0 mm from the viewpoint of reducing the use of expensive thermoplastic prepreg and increasing the economic efficiency of molding materials.

In the molding material, it is preferable that the fabric and the thermoplastic prepreg are bound together. The position of the fabric on the thermoplastic prepreg is not displaced, and the handleability during molding is improved. In addition, when the member obtained from the molding material is joined to another member, the fact that the position is not deviated also has the effect of facilitating the alignment of the joining portion.

Examples of binding means include a method of melting the fibers constituting the fabric and welding them to the thermoplastic prepreg, or a method of melting the thermoplastic resin contained in the thermoplastic prepreg and welding it to the fabric. This means may be carried out by heating and/or pressure.

In the bound portion of the fabric, the gaps between the fibers may be reduced due to the fibers forming the fabric melting or the thermoplastic resin entering between the fibers of the fabric. At this portion, the fabric may be less effective in absorbing the thermosetting resin.

That is, the area of the bound portion is preferably 0.001×S or more and less than 0.50×S with respect to the contact area S (mm ² ) between the fabric and the thermoplastic prepreg, more preferably 0.50×S. 005×S or more and less than 0.10×S. When it is 0.005×S or more, the position of the fabric is well fixed on the thermoplastic prepreg, and the fabric is less likely to loosen and wrinkle on the thermoplastic prepreg. If it is less than 0.50×S, the effect of the fabric adsorbing the thermosetting resin, which is provided by the molding material of the present invention, can be maintained.

The binding portion may be provided on the entire surface where the fabric and the thermoplastic prepreg are in contact, or may be provided on a portion of the surface. The binding portion may be planar, linear, or point-like. The arrangement of the binding portions may be regular according to a pattern or may be irregular.

The configuration of dispersed dot-like binding portions has the effect of improving the surface quality of the molded article obtained from the molding material because wrinkles occurring in the fabric are reduced. A linear bond has the advantage of being easy to implement.

The molding material of the present invention is preferably formed by fixing a thermoplastic prepreg and a thermosetting prepreg. When both prepregs are fixed, it is easy to obtain a member in which the thermoplastic resin is arranged at a desired position without shifting the positional relationship between the thermoplastic prepreg and the thermosetting prepreg in handling the molding material. Become.

A method for fixing the thermoplastic prepreg and the thermosetting prepreg is not particularly limited, but a method using the adhesive force of the thermosetting resin contained in the thermosetting resin can be exemplified. The thermoplastic prepreg and the thermosetting prepreg may be layered, pressed and/or heated.

The fixing portion may be provided on the entire surface where the thermoplastic prepreg and the thermosetting prepreg are in contact with each other, or may be provided on a part of the surface. The fixing portion may be planar, linear, or point-like. The arrangement of the fixed parts may have regularity according to a pattern or may be irregular.

The molded article of the present invention is obtained by molding the molding material of the present invention.

The molded article of the present invention is preferably molded in a temperature range equal to or higher than the melting point of the thermoplastic resin contained in the thermoplastic prepreg. By setting the molding temperature to a temperature equal to or higher than the melting point of the thermoplastic resin, the thermoplastic resin is melted during molding, thereby increasing the smoothness of the surface of the member. When the smoothness of the part to be joined is increased, the strength at the time of joining is stably developed. The upper limit of the molding temperature is not particularly limited, but the thermal decomposition temperature of the thermosetting resin contained in the thermosetting prepreg constituting the molding material can be exemplified.

It is also preferable that the molded article of the present invention is molded in a temperature range below the melting point of the thermoplastic resin contained in the thermoplastic prepreg. By setting the molding temperature lower than the melting point of the thermoplastic resin, the thermoplastic resin does not melt during molding. Therefore, the thermoplastic resin does not adhere to the fabric made of the fibers, and the fabric can be easily removed from the molded product, resulting in excellent member productivity. The lower limit of the molding temperature is not particularly limited, but from the viewpoint of inducing curing of the thermosetting resin contained in the thermosetting prepreg constituting the molding material, 80° C. is generally exemplified.

The member of the present invention is a member obtained by removing the fabric portion from the molded article. By removing the cloth contaminated with the cured resin derived from the thermosetting resin constituting the thermosetting prepreg from the surface of the molded article, a clean thermoplastic prepreg portion can be exposed on the surface of the member. This member can be welded and joined to other members by means of heat and/or pressure.

EXAMPLES The present invention will be specifically described below with reference to Examples, but the present invention is not limited to the description of these Examples.

[material]
Reinforcing fiber: Carbon fiber “Torayca” (registered trademark) T800S
Thermosetting resin: 3900 resin (manufactured by Toray Industries, Inc.)
Thermoplastic resin [1]: Polyamide 6 resin (melting point 240°C, weight average molecular weight 30,000)
Thermoplastic resin [2]: PPS resin (melting point 235°C, weight average molecular weight 40,000)

[Molding material]
Thermosetting prepreg: Carbon fiber T800S aligned in one direction was impregnated with epoxy resin 3900 resin to produce a unidirectional prepreg. The volume content of carbon fibers in the prepreg was 53%.

Thermoplastic prepreg [1]: A unidirectional prepreg was produced by impregnating carbon fibers T800S aligned in one direction with a polyamide 6 resin by a melt impregnation method. The volume content of carbon fibers in the prepreg was 48%.

Thermoplastic prepreg [2]: A unidirectional prepreg was produced by impregnating carbon fibers T800S aligned in one direction with a PPS resin by a melt impregnation method. The volume content of carbon fibers in the prepreg was 51%.

Cloth [1]: A plain weave fabric was produced from polyester filaments using a loom to obtain a fabric. The air permeability based on JIS L 1096 (2010) was 15 cm ³ /cm ² ·s.

Cloth [2]: A plain weave fabric was produced from the E-glass roving using a loom. The air permeability based on JIS L 1096 (2010) was 46 cm ³ /cm ² ·s.

[Example 1]
Fabric, thermosetting prepreg, and thermoplastic prepreg [1], all of which are 30 cm square, are aligned in the order of thermosetting prepreg/thermoplastic prepreg [1]/fabric [1] from the bottom. A molding material [1] was obtained by laminating them in the following manner.

Molding material [1] was molded in an autoclave to obtain molding [1]. In the molding, an aluminum tool plate, a fluororesin release film, a molding material, a fluororesin release film, and a bagging film were stacked in this order from the bottom. The bagging film was sealed against the tool plate. While evacuating the space formed by the tool plate and the bagging film, molding was performed in an autoclave under the conditions of a pressure of 0.3 MPa, an environmental temperature of 180° C., and a standing time of 120 minutes. After cooling the set of tool plates to room temperature in an autoclave, the compact was removed from the tool plate.

The fabric portion on the surface of molded body [1] was peeled off to obtain member [1].

Five members [1] were produced, and the portion of the surface of each member made of the thermoplastic prepreg was visually inspected. The thermosetting resin adhered to 0.0% to 2.0% of the surface of the portion made of the thermoplastic prepreg.

[Example 2]
A molding material [2], a compact [2] and a member [2] were obtained in the same manner as in Example 1, except that the thermoplastic prepreg [2] was used instead of the thermoplastic prepreg [1]. .

Five members [2] were produced, and the portion of the surface of each member made of the thermoplastic prepreg was visually inspected. The thermosetting resin adhered to 0.0% to 4.0% of the surface of the portion made of the thermoplastic prepreg.

[Example 3]
The fabric [1] was cut into 25 cm squares, the thermoplastic prepreg [1] into 27 cm squares, and the thermosetting prepreg into 30 cm squares. From the bottom, the layers were laminated in the order of thermosetting prepreg/thermoplastic prepreg [1]/fabric. At this time, the lamination was performed so that the centers of the respective elements coincided and the linear sides of the respective elements were parallel. The minimum distance between the outer circumference S1 of the fabric and the outer circumference S2 of the thermoplastic prepreg was 10 mm. This laminate was used as a molding material [3].

Molding material [3], molding [3] and member [3] were obtained in the same manner as in Example 1 from molding material [3].

Five members [3] were produced, and the portion of the surface of each member made of the thermoplastic prepreg was visually inspected. The thermosetting resin adhered to 0.0% to 1.0% of the surface of the portion made of the thermoplastic prepreg.

[Example 4]
The fabric [1] was cut into 25 cm squares, the thermoplastic prepreg [1] into 27 cm squares, and the thermosetting prepreg into 30 cm squares. After placing the thermoplastic prepreg on the fabric [1], a soldering iron is applied from above the thermoplastic prepreg, the thermoplastic resin contained in the thermoplastic prepreg is heated and melted, and a part of it is applied to the fabric [1]. ] to bind the fabric [1] and the thermoplastic prepreg. The binding portions were in the shape of dots with a size of about 1 mm, and the intervals between them were in the shape of lattice points with a size of about 10 mm.

Using the laminate of the fabric [1] subjected to this treatment and the thermoplastic prepreg [1], it was laminated in the order of thermosetting prepreg / thermoplastic prepreg [1] / fabric [1] from the bottom. . At this time, the lamination was performed so that the centers of the respective elements coincided and the linear sides of the respective elements were parallel. The minimum distance between the outer circumference S1 of the fabric and the outer circumference S2 of the thermoplastic prepreg was 10 mm.

Next, pressure was applied from above the laminate by hand to remove air between the thermoplastic prepreg [1] and the thermosetting prepreg, and the two were brought into close contact with each other and fixed. This laminate was used as a molding material [4].

A compact [4] was obtained in the same manner as in Example 1 using the molding material [4].

The fabric portion on the surface of the molded body [4] was peeled off to obtain a member [4].

Five members [4] were produced, and the portion of the surface of each member made of the thermoplastic prepreg was visually inspected. The thermosetting resin adhered to 0.0% to less than 1.0% of the surface of the portion made of the thermoplastic prepreg.

In addition, since the molding material of this embodiment is fixed between the elements of the molding material, the molding material does not come apart and is excellent in handleability during molding, and the positional relationship of the elements is shifted before and after molding. There was nothing.

[Example 5]
A molding material [5] was obtained in the same manner as in Example 1, except that the fabric [2] was used instead of the fabric [1].

A molded article [5] was obtained in the same manner as in Example [1], except that the molding material [5] was used and the ambient temperature for autoclave molding was 260°C.

The fabric portion on the surface of the molded product [5] was peeled off to obtain a member [5].

Five members [5] were produced, and the portion of the surface of each member made of the thermoplastic prepreg was visually inspected. The thermosetting resin adhered to 1.0% to 2.0% of the surface of the portion made of the thermoplastic prepreg.

[Comparative Example 1]
A molding material [6], a molded article [6] and a member [6] were obtained in the same manner as in Example 1, except that the fabric was not used.

Five members [6] were produced, and the portion of the surface of each member made of the thermoplastic prepreg was visually inspected. 18% to 24% of the surface of the portion made of the thermoplastic prepreg was covered with the thermosetting resin. Contamination with the thermosetting resin was conspicuous on the surface of the portion made of the thermoplastic prepreg.

[Comparative Example 2]
A polyimide film (Upilex-75S (registered trademark), manufactured by Ube Industries, Ltd.) was used instead of the cloth. The air permeability of the polyimide film measured according to JIS L 1096 (2010) was 0.00 cm ³ /(cm ² ·s).

A molding material [7], a molding [7] and a member [7] were obtained in the same manner as in Example 1, except that a polyimide film was used instead of the cloth [1].

Five members [7] were produced, and the portion of the surface of each member made of the thermoplastic prepreg was visually inspected. 15% to 28% of the surface of the portion made of the thermoplastic prepreg was covered with the thermosetting resin. Contamination with the thermosetting resin was conspicuous on the surface of the portion made of the thermoplastic prepreg.

Applications of the molding material, molded article and member of the present invention include, for example, electrical and electronic device parts, civil engineering and construction parts, structural parts for automobiles and motorcycles, and aircraft parts.

1: Fabric 2: Thermoplastic prepreg 3: Thermosetting prepreg 4: Outer peripheral line S1 of fabric
5: Peripheral line S2 of thermoplastic prepreg
6: Minimum value of the distance between the outer peripheral line S1 of the fabric and the outer peripheral line S2 of the thermoplastic prepreg 7: Maximum value of the distance between the outer peripheral line S1 of the fabric and the outer peripheral line S2 of the thermoplastic prepreg

Claims (10)

A molding material in which the following elements are laminated in the order of element [1]/element [2]/element [3].
Element [1] Fabric element [2] Thermoplastic prepreg Element [3] Thermoset prepreg The molding material according to claim 1, wherein the fabric has an air permeability of 0.01 cm ³ /(cm ² ·s) or more and less than 2000.00 cm ³ /(cm ² ·s). 3. The molding material according to claim 1, wherein the entire surface of the fabric is in contact only with the thermoplastic prepreg. The molding material according to claim 3, wherein the minimum distance between S1 and S2 of the outer peripheral line S1 of the fabric and the outer peripheral line S2 of the thermoplastic prepreg is 0.1 mm or more and less than 100.0 mm. 5. The molding material according to any one of claims 1 to 4, wherein the fabric and the thermoplastic prepreg are bound together. The molding material according to any one of claims 1 to 5, wherein the thermoplastic prepreg and the thermosetting prepreg are fixed. A molded article obtained by molding the molding material according to any one of claims 1 to 6 by means of heating and/or pressing. The molded article according to claim 7, which is obtained by molding in a temperature range equal to or higher than the melting point of the thermoplastic resin contained in the thermoplastic prepreg. The molded article according to claim 7, which is obtained by molding in a temperature range below the melting point of the thermoplastic resin contained in the thermoplastic prepreg. A member obtained by removing a fabric portion from the molded article according to any one of claims 7 to 9.

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