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公开(公告)号：US11746200B2
公开(公告)日：2023-09-05
申请号：US17280564
申请日：2019-09-24
Applicant: Toray Industries, Inc.
Inventor： Yasukazu Ono , Takafumi Hashimoto , Akira Shimoyama , Tetsuya Motohashi
CPC classification number: C08J5/243 , B29C70/502 , C08K7/06 , B29C2793/0027 , C08J2333/04 , C08J2363/00 , C08J2367/00 , C08K2201/004
Abstract: A fiber-reinforced resin molding material is obtained by impregnating a chopped fiber bundle with a matrix resin, has a layered structure including three or more layers in a thickness direction thereof, and satisfies the relationships Lao>Lam and Wao>Wam, where Lao and Wao represent the number average fiber length and the number average fiber bundle width, respectively, of the chopped fiber bundle in the outermost layer thereof, and Lam and Wam represent the number average fiber length and the number average fiber bundle width, respectively, of the chopped fiber bundle in a middle layer thereof.
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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
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%.
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公开(公告)号：US10066084B2
公开(公告)日：2018-09-04
申请号：US14763188
申请日：2014-02-19
Applicant: Toray Industries, Inc.
Inventor： Katsuhiro Miyoshi , Takashi Shimada , Takafumi Hashimoto , Tetsuya Ohara , Yoshihiro Naruse
Abstract: A stampable sheet includes a resin and carbon fiber sheet including fiber bundles of discontinuous carbon fibers, wherein the carbon fiber sheet includes fiber bundles having a bundle width of 50 μm or greater and opened fibers ranging from fiber bundles having a bundle width less than 50 μm to fibers obtained by opening to the single-fiber level. When the direction along which the opened fibers have been oriented most is a 0° direction and the range of from the 0° to 90° direction is divided into angular zones, the distribution curve showing the proportion of the number of fiber bundles in each angular zone to that in all angular zones and the distribution curve showing the proportion of the number of opened fibers in each angular zone to that in all angular zones are reverse to each other in terms of gradient of the 0° to 90° direction.
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公开(公告)号：US09481770B2
公开(公告)日：2016-11-01
申请号：US14403677
申请日：2013-05-15
Applicant: Toray Industries, Inc.
Inventor： Yoshihiro Naruse , Katsuhiro Miyoshi , Takashi Shimada , Takafumi Hashimoto , Tetsuya Ohara
CPC classification number: C08J5/06 , B32B2250/05 , B32B2260/046 , B32B2262/106 , B32B2305/076 , B32B2305/28 , B32B2307/54 , C08J5/042 , C08J2377/02
Abstract: A carbon fiber composite material which includes a carbon fiber sheet as a reinforcing material and a thermoplastic resin as a matrix resin, the carbon fiber sheet exhibiting a work per areal weight of 1×10−3 to 30×10−3 [(N·mm)/(g/m2)] in a tensile test using a specimen having a width of 25 mm. The carbon fiber composite material exhibits excellent flowability in molding and ensures excellent moldability even when molded into a complicated shape. Further, the composite material can yield a molded product which has high mechanical properties with minimized dispersion, thus being suitable for press molding.
Abstract translation: 作为增强材料的碳纤维片和作为基质树脂的热塑性树脂的碳纤维复合材料，所述碳纤维片的每面重为1×10-3〜30×10-3 [（N· mm）/（g / m 2）]在使用宽度为25mm的试样的拉伸试验中。 碳纤维复合材料在成型时表现出优异的流动性，并且即使在模制成复杂形状时也确保优异的成型性。 此外，复合材料可以产生具有高机械性能并且最小化分散体的模制产品，因此适合于压制成型。
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公开(公告)号：US20150183941A1
公开(公告)日：2015-07-02
申请号：US14403677
申请日：2013-05-15
Applicant: Toray Industries, Inc.
Inventor： Yoshihiro Naruse , Katsuhiro Miyoshi , Takashi Shimada , Takafumi Hashimoto , Tetsuya Ohara
IPC: C08J5/06
CPC classification number: C08J5/06 , B32B2250/05 , B32B2260/046 , B32B2262/106 , B32B2305/076 , B32B2305/28 , B32B2307/54 , C08J5/042 , C08J2377/02
Abstract: A carbon fiber composite material which includes a carbon fiber sheet as a reinforcing material and a thermoplastic resin as a matrix resin, the carbon fiber sheet exhibiting a work per areal weight of 1×10−3 to 30×10−3 [(N·mm)/(g/m2)] in a tensile test using a specimen having a width of 25 mm. The carbon fiber composite material exhibits excellent flowability in molding and ensures excellent moldability even when molded into a complicated shape. Further, the composite material can yield a molded product which has high mechanical properties with minimized dispersion, thus being suitable for press molding.
Abstract translation: 作为增强材料的碳纤维片和作为基质树脂的热塑性树脂的碳纤维复合材料，所述碳纤维片的每面重为1×10-3〜30×10-3 [（N· mm）/（g / m 2）]在使用宽度为25mm的试样的拉伸试验中。 碳纤维复合材料在成型时表现出优异的流动性，并且即使在模制成复杂形状时也确保优异的成型性。 此外，复合材料可以产生具有高机械性能并且最小化分散体的模制产品，因此适合于压制成型。
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Patent Agency Ranking
公开(公告)号：US11492731B2
公开(公告)日：2022-11-08
申请号：US17130976
申请日：2020-12-22
Applicant: Toray Industries, Inc.
Inventor： Tetsuya Motohashi , Takafumi Hashimoto , Katsuhiro Miyoshi , Yoshihiro Kawahara , Tamotsu Suzuki , Chiasa Sato
IPC: D02J1/18 , B65H51/005 , D01D11/02 , B29B15/12 , D04H1/732 , B29C70/18 , B29K307/04
Abstract: A method of producing a partially separated fiber bundle wherein, while a fiber bundle includes a plurality of single fibers travels along a lengthwise direction of the fiber bundle, a separator provided with a plurality of projected parts is penetrated into the fiber bundle to create a separation-processed part, and entangled parts, where the single fibers are interlaced, are formed at contact parts with the projected parts in at least one separation-processed part, thereafter the separator is removed from the fiber bundle, and after passing through an entanglement accumulation part including the entangled parts, the separator is penetrated again into the fiber bundle, characterized in that a separation processing time t1 during being penetrated with the separator and a time t2 from being removed with the separator to being penetrated again into the fiber bundle satisfy Equation (1): 0.03≤t2/(t1+t2)≤0.5.
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公开(公告)号：US20210108342A1
公开(公告)日：2021-04-15
申请号：US17130976
申请日：2020-12-22
Applicant: Toray Industries, Inc.
Inventor： Tetsuya Motohashi , Takafumi Hashimoto , Katsuhiro Miyoshi , Yoshihiro Kawahara , Tamotsu Suzuki , Chiasa Sato
IPC: D02J1/18 , B65H51/005 , B29B15/12 , B29C70/18
Abstract: A method of producing a partially separated fiber bundle wherein, while a fiber bundle includes a plurality of single fibers travels along a lengthwise direction of the fiber bundle, a separator provided with a plurality of projected parts is penetrated into the fiber bundle to create a separation-processed part, and entangled parts, where the single fibers are interlaced, are formed at contact parts with the projected parts in at least one separation-processed part, thereafter the separator is removed from the fiber bundle, and after passing through an entanglement accumulation part including the entangled parts, the separator is penetrated again into the fiber bundle, characterized in that a separation processing time t1 during being penetrated with the separator and a time t2 from being removed with the separator to being penetrated again into the fiber bundle satisfy Equation (1): 0.03≤t2/(t1+t2)≤0.5.
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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%.
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公开(公告)号：US20190153632A1
公开(公告)日：2019-05-23
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 , B65H51/005 , B29B15/12
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.
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公开(公告)号：US20190077050A1
公开(公告)日：2019-03-14
申请号：US16078716
申请日：2017-02-15
Applicant: Toray Industries, Inc.
Inventor： Katsuhiro Miyoshi , Takafumi Hashimoto , Tetsuya Motohashi
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.
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