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：US10309045B2

公开(公告)日：2019-06-04

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 ,  C08J5/06 ,  C08K3/04 ,  C08K3/013 ,  C08J5/04

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：US10392482B2

公开(公告)日：2019-08-27

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

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%.

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：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%.

公开(公告)号：US20160339669A1

公开(公告)日：2016-11-24

申请号：US15111871

申请日：2015-01-13

Applicant: TORAY INDUSTRIES, INC.

Inventor： Katsuhiro Miyoshi ,  Takafumi Hashimoto ,  Kenta Bamba ,  Yoshihiro Naruse ,  Takuro Tokunaga

IPC: B32B5/02 ,  B32B27/20 ,  D04H1/4242 ,  B32B27/12

CPC classification number: B32B5/022 ,  B32B5/26 ,  B32B7/04 ,  B32B27/08 ,  B32B27/12 ,  B32B27/20 ,  B32B2250/02 ,  B32B2250/20 ,  B32B2260/023 ,  B32B2260/046 ,  B32B2262/02 ,  B32B2262/0253 ,  B32B2262/0261 ,  B32B2262/0269 ,  B32B2262/10 ,  B32B2262/101 ,  B32B2262/103 ,  B32B2262/105 ,  B32B2262/106 ,  B32B2262/14 ,  B32B2264/0214 ,  B32B2264/10 ,  B32B2264/101 ,  B32B2264/102 ,  B32B2264/104 ,  B32B2264/108 ,  B32B2307/302 ,  B32B2307/546 ,  B32B2451/00 ,  B32B2457/00 ,  B32B2605/00 ,  B32B2605/003 ,  B32B2605/18 ,  C08J5/042 ,  C08J5/043 ,  C08J5/048 ,  C08J2323/12 ,  C08J2377/00 ,  D04H1/4242

Abstract: A stampable sheet includes a skin layer and a core layer characterized in that the core layer comprises a thermoplastic resin and a carbon fiber nonwoven sheet having fiber bundles of discontinuous carbon fibers, the carbon fiber nonwoven sheet contains at least five fiber bundles (A) having a bundle width of at least 150 μm in 100 mm×100 mm of stampable sheet, and the skin layer comprises a thermoplastic resin and a strengthened fiber nonwoven sheet having opened discontinuous strengthened fibers.

Abstract translation: 冲压片包括表皮层和芯层，其特征在于，芯层包括热塑性树脂和具有不连续碳纤维的纤维束的碳纤维非织造片，所述碳纤维非织造片包含至少五根纤维束（A），其具有 在100mm×100mm的冲压片中的束宽度为至少150μm，并且表层包括热塑性树脂和具有断开的不连续强化纤维的强化纤维非织造片材。