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：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.

公开(公告)号：US20190084186A1

公开(公告)日：2019-03-21

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

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：US20180001580A1

公开(公告)日：2018-01-04

申请号：US15545076

申请日：2015-11-12

Applicant: Toray Industries, Inc.

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

IPC: B29C70/50 ,  B29C70/14 ,  B29B11/16

CPC classification number: B29C70/508 ,  B29B11/16 ,  B29C70/12 ,  B29C70/14 ,  B29C70/506

Abstract: A reinforcing fiber composite material includes at least a matrix resin and discontinuous reinforcing fibers which include discontinuous reinforcing fiber aggregates, wherein the discontinuous reinforcing fibers include at least 5 wt % of discontinuous reinforcing fiber aggregates (A) in each of which a most widened section, where the width of the discontinuous reinforcing fiber aggregate in a direction intersecting the alignment direction of the discontinuous reinforcing fibers is made greatest when the discontinuous reinforcing fiber aggregate is two-dimensionally projected, is present at a position excluding both ends of the discontinuous reinforcing fiber aggregate, and the aspect ratio (width of the discontinuous reinforcing fiber aggregate/thickness of the discontinuous reinforcing fiber aggregate) of the most widened section is 1.3 times or more the aspect ratio of at least one of the ends of the discontinuous reinforcing fiber aggregate.

公开(公告)号：US20170305074A1

公开(公告)日：2017-10-26

申请号：US15513720

申请日：2015-09-03

Applicant: Toray Industries, Inc.

Inventor： Katsuhiro Miyoshi ,  Yukitane Kimoto ,  Takafumi Hashimoto

IPC: B29C70/12 ,  B29K307/04 ,  B29K105/12

CPC classification number: B29C70/12 ,  B29K2105/12 ,  B29K2307/04

Abstract: A reinforcing fiber composite material characterized by comprising discontinuous reinforcing fibers containing discontinuous reinforcing fiber aggregates and a matrix resin, wherein a fan-shaped discontinuous reinforcing fiber aggregate (A) is contained at an amount of 5% by weight or more in the discontinuous reinforcing fibers, and wherein the fan-shaped discontinuous reinforcing fiber aggregate (A) has a fan-like section in which an aspect ratio at least at one end part of a discontinuous reinforcing fiber aggregate (the width of the discontinuous reinforcing fiber aggregate/the thickness of the discontinuous reinforcing fiber aggregate) is 1.5 times or more relative to an aspect ratio at a narrowest part at which the width of the discontinuous reinforcing fiber aggregate is smallest when the discontinuous reinforcing fiber aggregate is projected two-dimensionally.

公开(公告)号：US20170260345A1

公开(公告)日：2017-09-14

申请号：US15512333

申请日：2015-08-31

Applicant: Toray Industries, Inc.

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

IPC: C08J5/04 ,  C08J5/24

CPC classification number: C08J5/042 ,  C08J5/04 ,  C08J5/24 ,  C08J2335/02

Abstract: A fiber-reinforced resin molding material includes at least bundled discontinuous reinforcing fiber aggregates and matrix resin, wherein said bundled reinforcing fiber aggregates include both reinforcing fiber aggregates (A) which are formed by cutting continuous reinforcing fiber strands after fiber splitting, in which said strands are completely split into multiple bundles, and reinforcing fiber aggregates (B) having at least unsplit strand sections in which fiber splitting is incomplete, an incision substantially originating from fiber splitting is present at least at one of both end portions of said reinforcing fiber aggregates (B), and a ratio of the weight of said reinforcing fiber aggregates (B) to the total weight of reinforcing fibers in said material is 5-50%.