公开(公告)号：US11168190B2

公开(公告)日：2021-11-09

申请号：US16341054

申请日：2017-09-28

Applicant: Toray Industries, Inc.

Inventor： Tetsuya Motohashi ,  Takafumi Hashimoto

IPC: C08J5/24 ,  B29B15/08 ,  D04H1/72 ,  D04H1/732 ,  C08J5/04 ,  B29K307/04 ,  B29K105/12

Abstract: A random mat includes a chopped fiber bundle [A] obtained by obliquely cutting a partially separated fiber bundle [B] prepared by alternately forming separation-processed sections, each of which is separated into a plurality of bundles, and not-separation-processed sections, along the lengthwise direction of a fiber bundle, wherein the total cross-sectional area of reinforcing fibers exhibits a specific change amount between both tips of the chopped fiber bundle [A]; a production method produces the random mat; and a fiber-reinforced resin molding material uses the random mat.

公开(公告)号：US11097448B2

公开(公告)日：2021-08-24

申请号：US16084373

申请日：2017-02-23

Applicant: Toray Industries, Inc.

Inventor： Tetsuya Motohashi ,  Takafumi Hashimoto ,  Katsuhiro Miyoshi ,  Tamotsu Suzuki ,  Yasumoto Noguchi

IPC: B29B11/16 ,  B29C70/12 ,  B29K307/04

Abstract: A fiber-reinforced resin molding material containing at least bundled aggregates [A] of discontinuous reinforcing fibers and a matrix resin [M], wherein each of the bundled aggregates [A] is obtained by cutting a partially-separated fiber bundle, prepared by forming separation treatment sections separated into a plurality of bundles and non-separation treatment sections alternately along a lengthwise direction of a fiber bundle including a plurality of single fibers, at an angle θ (0°

公开(公告)号：US20190263625A1

公开(公告)日：2019-08-29

申请号：US16307678

申请日：2017-06-01

Applicant: Toray Industries, Inc.

Inventor： Tetsuya Motohashi ,  Takafumi Hashimoto ,  Yasumoto Noguchi ,  Yoshihiro Kawahara ,  Tamotsu Suzuki ,  Chiasa Sato

IPC: B65H51/005 ,  B29B15/10 ,  D02J1/18 ,  D02J1/06 ,  D06H3/02 ,  D06H7/02 ,  D04H1/64 ,  D04H1/732 ,  C08J5/04 ,  C08J5/18 ,  C08J5/24

Abstract: A partially separated fiber bundle includes separation-processed sections, each divided into a plurality of bundles of at least three bundles, and not-separation-processed sections, that are alternately formed along the lengthwise direction of a fiber bundle that comprises a plurality of single fibers. The partially separated fiber bundle is characterized in that, at any width-direction cross-section taken along the lengthwise direction thereof, a rate of single fibers contained in a region at which adjacent divided fiber bundles are joined by a not-separation-processed part is 67% or less relative to the total single fibers in the width-direction cross-section.

公开(公告)号：US20190091944A1

公开(公告)日：2019-03-28

申请号：US16085018

申请日：2017-02-23

Applicant: Toray Industries, Inc.

Inventor： Tetsuya Motohashi ,  Takafumi Hashimoto ,  Chiasa Sato ,  Ichiro Taketa

IPC: B29C70/14 ,  B29C70/54 ,  B29C70/46 ,  B29B11/02

Abstract: A molded article of a fiber-reinforced resin contains at least a bundled aggregate [A] of discontinuous reinforcing fibers and a matrix resin [M], wherein the average layer thickness h in the molded article of the fiber-reinforced resin is 100 μm or less and the CV value of the average layer thickness h is 40% or less; and a compression molding method therefor. It is possible to reliably and greatly reduce the occurrence of stress concentration in the molded article and to thereby achieve higher mechanical properties and further reduce variation in the mechanical properties.

公开(公告)号：US20180094368A1

公开(公告)日：2018-04-05

申请号：US15562510

申请日：2016-03-17

Applicant: Toray Industries, Inc.

Inventor： Kenta Bamba ,  Tetsuya Motohashi ,  Katsuhiro Miyoshi ,  Takafumi Hashimoto

IPC: D04H1/4242 ,  C08J5/04 ,  C08K3/04 ,  C08K3/013

CPC classification number: D04H1/4242 ,  C08J5/042 ,  C08J5/06 ,  C08J2300/22 ,  C08J2300/24 ,  C08J2363/10 ,  C08K3/013 ,  C08K3/046

Abstract: A fiber-reinforced resin forming material contains at least a matrix resin and bundled aggregates of discontinuous reinforcing fibers, wherein: the bundled aggregates include both reinforcing fiber aggregates A having a shape formed by cutting after having performed a splitting treatment to completely split the strands of continuous reinforcing fibers into a plurality of bundles of strands, and reinforcing fiber aggregates B1 having a shape that includes unsplit parts where splitting treatment was inadequate and/or reinforcing fiber aggregates B2 having a shape not subjected to splitting treatment; and both the ratio of the weight of the reinforcing fiber aggregates B1 with respect to the total weight of reinforcing fibers in the fiber-reinforced resin forming material, and the ratio of the total weight of the reinforcing fiber aggregates B1 and the reinforcing fiber aggregates B2 with respect to the total weight of reinforcing fibers in the fiber-reinforced resin forming material, are 50-95%.

公开(公告)号：US12030218B2

公开(公告)日：2024-07-09

申请号：US17287801

申请日：2019-10-30

Applicant: Toray Industries, Inc.

Inventor： Yasukazu Ono ,  Takafumi Hashimoto ,  Tetsuya Motohashi ,  Tadashi Watanabe

IPC: B29B11/16 ,  B29K105/12 ,  B29K101/10

CPC classification number: B29B11/16 ,  B29K2101/10 ,  B29K2105/12

Abstract: A fiber-reinforced resin molding material [C] includes a chopped fiber bundle [A] and a matrix resin [B], the material being characterized in that, when divided into n layers along the thickness direction of the fiber-reinforced resin molding material [C], the number-average fiber length [Lk] of the chopped fiber bundle [Ak] constituting each layer Fk (1≤k≤n) gradually increases from one outermost layer F1 of the fiber-reinforced resin molding material [C] toward the other outermost layer Fn. Also provided is a molded article obtained by molding the fiber-reinforced resin molding material. This fiber-reinforced resin molding material exhibits excellent flowability, and can exhibit excellent mechanical properties when made into a molded article.

公开(公告)号：US20220176647A1

公开(公告)日：2022-06-09

申请号：US17598504

申请日：2020-03-09

Applicant: Toray Industries, Inc.

Inventor： Yusuke Yamanaka ,  Takafumi Hashimoto ,  Tetsuya Motohashi ,  Yasukazu Ono

IPC: B29C70/12 ,  B29B15/10 ,  B29C70/42 ,  C08J5/04

Abstract: A fiber-reinforced resin molding material molded product includes a fiber-reinforced resin molding material prepared by impregnating chopped fiber bundles obtained by cutting a reinforcing fiber bundle with a matrix resin, wherein in a region excluding 30 mm from an edge of the molded product, when an arbitrary rectangular region having an area of 40 mm2 or more and defined by a thickness of the molded product and a width in a direction perpendicular to a thickness direction of the molded product is set in a cross section in an arbitrary thickness direction of the molded product, with respect to a bundle thickness of the chopped fiber bundles present in the set rectangular region.

公开(公告)号：US11162196B2

公开(公告)日：2021-11-02

申请号：US16310694

申请日：2017-06-01

Applicant: Toray Industries, Inc.

Inventor： Tetsuya Motohashi ,  Takafumi Hashimoto ,  Katsuhiro Miyoshi ,  Chiasa Sato

IPC: D02J1/18 ,  B29B15/12 ,  B65H51/005 ,  C08J5/24 ,  C08J5/06

Abstract: A partially separated fiber bundle includes separation-processed sections and not-separation-processed sections that are alternately formed along the lengthwise direction of a fiber bundle that includes a plurality of single fibers, wherein the separation-processed sections include a plurality of divided fiber bundles that have been divided by separation processing. The partially separated fiber bundle is characterized in that the numbers of single fibers of the divided fiber bundles in the separation-processed section are nonuniform.

公开(公告)号：US11001012B2

公开(公告)日：2021-05-11

申请号：US16085018

申请日：2017-02-23

Applicant: Toray Industries, Inc.

Inventor： Tetsuya Motohashi ,  Takafumi Hashimoto ,  Chiasa Sato ,  Ichiro Taketa

IPC: B29C70/14 ,  C08J5/04 ,  B29C43/34 ,  B29B15/08 ,  B29B11/02 ,  B29C70/46 ,  B29C70/54 ,  B29K307/04

Abstract: A molded article of a fiber-reinforced resin contains at least a bundled aggregate [A] of discontinuous reinforcing fibers and a matrix resin [M], wherein the average layer thickness h in the molded article of the fiber-reinforced resin is 100 μm or less and the CV value of the average layer thickness h is 40% or less; and a compression molding method therefor. It is possible to reliably and greatly reduce the occurrence of stress concentration in the molded article and to thereby achieve higher mechanical properties and further reduce variation in the mechanical properties.

公开(公告)号：US10688734B2

公开(公告)日：2020-06-23

申请号：US16079606

申请日：2017-02-15

Applicant: Toray Industries, Inc.

Inventor： Katsuhiro Miyoshi ,  Takafumi Hashimoto ,  Tetsuya Motohashi

IPC: B29C70/14 ,  B29B15/08 ,  B29C70/12

Abstract: A fiber-reinforced material includes a discontinuous reinforcing fiber aggregate of a discontinuous reinforcing fiber having a number average fiber length of 3 to 100 mm and a matrix resin, the discontinuous reinforcing fiber aggregate including a plurality of discontinuous reinforcing fiber bundles having a predetermined number of unidirectionally-bundled single yarns of the discontinuous reinforcing fiber, wherein the discontinuous reinforcing fiber bundle has a cut surface inclined at a predetermined angle with respect to an orientation direction of the single yarn of the discontinuous reinforcing fiber bundle and has different fiber bundle lengths defined as a distance between both ends along the orientation direction of the single yarn of the discontinuous reinforcing fiber bundle, the shorter the fiber bundle length of the discontinuous reinforcing fiber bundle, the smaller a tip angle defined as an acute angle at an end of a two-dimensional plane projection of the discontinuous reinforcing fiber bundle.