1. Woven fabrics, which reinforced continuous fiber yarns and thermoplastic matrix resin fiber yarns are integrated (hybrid co-woven fabrics).
2. The reinforced fibers are continuous fiber yarns but flexible and suitable for difficult-to-process shapes and deep-drawing forms.
3. They are roll-shaped materials and can be easily cut.
4. Total cost reduction can be expected at the time of mass production.
(Original yarns are woven and processed as they are. In the weaving process, conventional equipment can be used. Forming can be made in one process from dry fabrics.)
1. Various reinforced continuous fibers can be used (carbon, glass, aramid, basalt, and flax etc.).
2. Various matrices can be used (PEEK, PEI, PPS, PA12, PA6, PA9T, PC, PP, PE, PLA, Thermoplastic Epoxy, etc.).
3. Easy to make the Vf design (low to high).
4. Storage for a long time at normal temperature is possible.
5. Recycling is possible.
As the methods of resin impregnation in woven fabrics for FRTP application, conventionally known are a resin melting method, a solvent method, a comingled yarn method, a film resin impregnation method, and a powder method.
1. Matrix resin is evenly dispersed by weaving reinforcement yarn and matrix resin yarn integratedly. In addition low viscosity grade of resin is commonly used for filament yarn of matrix, and it can be easily impregnated in the reinforcement yarns.
2. Strength of woven fabric is kept by designing woven structure with crimps of reinforcement yarn as possibly low level. And woven texture of reinforcement yarn, like carbon fiber, can clearly remain after molding.
3. When matrix resin is melt, one sheet of ”hybrid double layer woven fabric” becomes one ply of prepreg, and therefore thickness design can be controlled easily. Also Vf can be easily controlled by designing yarns and fabric structure.
4. This ”hybrid double layer woven fabric” is suitable for the process; heat&cool compression and autoclave.