公开(公告)号：US10569986B2

公开(公告)日：2020-02-25

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 ,  C08J5/04 ,  C08J5/18 ,  C08J5/24 ,  D02J1/06 ,  D02J1/18 ,  D04H1/64 ,  D04H1/732 ,  D06H3/02 ,  D06H7/02 ,  B29K101/10

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：US20190054707A1

公开(公告)日：2019-02-21

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

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.

公开(公告)号：US20210323196A1

公开(公告)日：2021-10-21

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

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：US11007675B2

公开(公告)日：2021-05-18

申请号：US16078716

申请日：2017-02-15

Applicant: Toray Industries, Inc.

Inventor： Katsuhiro Miyoshi ,  Takafumi Hashimoto ,  Tetsuya Motohashi

IPC: B29B15/12 ,  B29C70/10 ,  B29B11/16 ,  B29C45/00 ,  B29C65/00 ,  B29C70/14 ,  B29C70/20 ,  B29K101/10 ,  B29K101/12 ,  B29K105/12 ,  B29C70/54

Abstract: A discontinuous fiber-reinforced composite material including 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, and the longer the fiber bundle length of the discontinuous reinforcing fiber bundle is, 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 is.

公开(公告)号：US10907280B2

公开(公告)日：2021-02-02

申请号：US16308593

申请日：2017-06-01

Applicant: Toray Industries, Inc.

Inventor： Tetsuya Motohashi ,  Takafumi Hashimoto ,  Masaru Tateyama ,  Mitsuki Fuse ,  Akihiko Matsui ,  Chiasa Sato

IPC: D02J1/18 ,  D02J1/08 ,  B65H51/005 ,  B29B15/12 ,  B29C70/18

Abstract: A method of producing a partially separated fiber bundle includes a partial separation processing step for alternately forming separation-processed sections, each divided into a plurality of bundles, and not-separation-processed sections along the lengthwise direction of a fiber bundle, wherein a separation means provided with a plurality of projected parts is penetrated into the fiber bundle to create separation-processed parts, the separation means is removed from the fiber bundle, and the separation means is penetrated into the fiber bundle again, characterized in that a sizing agent is applied at an arbitrary timing during the production process of the partially separated fiber bundle. A partially separated fiber bundle is obtained by the production method, a fiber-reinforced resin molding material uses the partially separated fiber bundle, and a production method makes the fiber-reinforced resin molding material.

公开(公告)号：US20190352474A1

公开(公告)日：2019-11-21

申请号：US16482743

申请日：2018-01-26

Applicant: Toray Industries, Inc.

Inventor： Mitsuki Fuse ,  Masaru Tateyama ,  Hiroshi Hirano ,  Satoshi Seike ,  Akihiko Matsui ,  Kazuma Ura ,  Tetsuya Motohashi

IPC: C08J5/06 ,  D02J1/18 ,  D06M15/59 ,  C08J3/21 ,  C08L77/06 ,  B65H51/005

Abstract: A partially separated fiber bundle having a surface of a reinforcing fiber coated with a sizing agent containing a water-soluble polyamide-based resin, in which a separated fiber section consisting of a plurality of separated fiber bundles and an unseparated fiber section are provided alternately along a longitudinal direction of the reinforcing fiber bundle consisting of a plurality of single yarns, wherein the reinforcing fiber bundle contains 600 fibers/mm or more and less than 1,600 fibers/mm of fibers per unit width while the reinforcing fiber has a drape level of 120 mm or more and 240 mm or less.

公开(公告)号：US20190233604A1

公开(公告)日：2019-08-01

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

CPC classification number: C08J5/24 ,  B29B15/08 ,  B29K2105/128 ,  B29K2307/04 ,  C08J5/04 ,  C08J2331/02 ,  D04H1/72 ,  D04H1/732

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：US20190177888A1

公开(公告)日：2019-06-13

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：US20190177887A1

公开(公告)日：2019-06-13

申请号：US16310165

申请日：2017-06-06

Applicant: Toray Industries Inc.

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

IPC: D02J1/18 ,  B29B15/12 ,  C08J5/24 ,  C08J5/06 ,  B65H51/005 ,  B65H73/00 ,  B65H54/02

Abstract: A production method for a separated fiber bundle includes at least: [A] a partial separation step for obtaining a partially separated fiber bundle in which separation-processed parts, each separated into a plurality of bundles, and not-separation-processed parts are alternately formed along the lengthwise direction of a fiber bundle comprising a plurality of single fibers; and [B] a cutting step for cutting the not-separation-processed parts of the partially separated fiber bundle formed in the step [A] along the lengthwise direction of the fiber bundle. A separated fiber bundle produced by the method, a fiber-reinforced resin molding material that uses the separated fiber bundle, and a production method for the fiber-reinforced resin molding material.

公开(公告)号：US20190161890A1

公开(公告)日：2019-05-30

申请号：US16309391

申请日：2017-06-01

Applicant: Toray Industries, Inc.

Inventor： Tetsuya Motohashi ,  Takafumi Hashimoto ,  Katsuhiro Miyoshi ,  Yoshihiro Kawahara ,  Tamotsu Suzuki ,  Chiasa Sato

IPC: D02J1/18 ,  B29B15/12 ,  B65H51/005 ,  B29C70/18

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 separated bundles. The content of the not-separation-processed sections is 3% or more and 50% or less of the partially separated fiber bundle.