公开(公告)号：US10723088B2

公开(公告)日：2020-07-28

申请号：US16335782

申请日：2017-08-31

Applicant: Toray Industries, Inc.

Inventor： Masayuki Koshi ,  Hiroyuki Ome ,  Eita Konno ,  Shoma Ishida

IPC: B29C70/20 ,  B29C70/52 ,  B29K77/00 ,  B29K307/04

Abstract: A fiber-reinforced thermoplastic-resin base includes continuous reinforcing fibers aligned in parallel to each other and a thermoplastic resin is impregnated thereinto, wherein the base has a fiber volume content of 40-65 vol % and a dispersion parameter D of the fibers, determined by (i)-(iv), of 90% or more: (i) a cross-section of the fiber-reinforced thermoplastic-resin base that is perpendicular to the alignment direction of the reinforcing fibers is divided into a plurality of sections, and one of the sections is photographed, (ii) the photograph image of the section is divided into a plurality of square units each having a one-side length t, (iii) a dispersion parameter d is calculated, (iv) with respect to other sections, (i) to (iii) are repeatedly performed, and an average value of dispersion parameters d of the plurality of sections is dispersion parameter D.

公开(公告)号：US12104044B2

公开(公告)日：2024-10-01

申请号：US17433647

申请日：2020-04-03

Applicant: Toray Industries, Inc.

Inventor： Shoma Ishida ,  Koji Suzuki ,  Yoshihiro Naruse

IPC: C08K7/14 ,  B33Y70/10 ,  C08L35/02 ,  C08L61/02 ,  C08L81/04 ,  B33Y10/00 ,  B33Y80/00 ,  C08K3/04 ,  C08K3/40

CPC classification number: C08K7/14 ,  B33Y70/10 ,  C08L35/02 ,  C08L61/02 ,  C08L81/04 ,  B33Y10/00 ,  B33Y80/00 ,  C08K3/04 ,  C08K3/40 ,  C08L2205/16 ,  C08L2207/04

Abstract: A fiber-reinforced thermoplastic resin filament for a 3D printer is formed by impregnating a thermoplastic resin into a plurality of continuous reinforcing fibers, wherein: an average value S of a roundness parameter s of a cross section is 60% to 100%, the average value S being evaluated by (i) taking a photograph of the cross section perpendicular to the axial direction of the filament, (ii) drawing an inscribed circle and a circumscribed circle of the filament in a cross-sectional image and determining the diameter length of each, (iii) calculating the roundness parameter s defined by equation (1), and (iv) repeating (i)-(iii) at a plurality of locations on the filament and calculating the average value S of the roundness parameter s; and the coefficient of variation of the diameter length of the circumscribed circle is 0% to 10%.

公开(公告)号：US20220145047A1

公开(公告)日：2022-05-12

申请号：US17433647

申请日：2020-04-03

Applicant: Toray Industries, Inc.

Inventor： Shoma Ishida ,  Koji Suzuki ,  Yoshihiro Naruse

IPC: C08K7/14 ,  C08L61/02 ,  C08L81/04 ,  C08L35/02 ,  B33Y70/10

Abstract: A fiber-reinforced thermoplastic resin filament for a 3D printer is formed by impregnating a thermoplastic resin into a plurality of continuous reinforcing fibers, wherein: an average value S of a roundness parameter s of a cross section is 60% to 100%, the average value S being evaluated by (i) taking a photograph of the cross section perpendicular to the axial direction of the filament, (ii) drawing an inscribed circle and a circumscribed circle of the filament in a cross-sectional image and determining the diameter length of each, (iii) calculating the roundness parameter s defined by equation (1), and (iv) repeating (i)-(iii) at a plurality of locations on the filament and calculating the average value S of the roundness parameter s; and the coefficient of variation of the diameter length of the circumscribed circle is 0% to 10%.

公开(公告)号：US20250154326A1

公开(公告)日：2025-05-15

申请号：US18838536

申请日：2023-02-15

Applicant: Toray Industries, Inc.

Inventor： Koji Suzuki ,  Shoma Ishida ,  Yoshihiro Naruse

IPC: C08J5/04 ,  B29C64/118 ,  B29K69/00 ,  B29K77/00 ,  B29K81/00 ,  B29K307/04 ,  B33Y70/10 ,  C08J5/24

Abstract: A fiber-reinforced thermoplastic resin filament includes at least one substance selected from the group consisting of polyphenylene sulfide resins, polyarylene ether ketone resins, polyamides, polycarbonates, polyether imide resins, polyethersulfone resins, and liquid crystal polymer resins impregnated in a plurality of continuous reinforcing fibers; in a cross-section perpendicular to the axial direction of the fiber-reinforced thermoplastic resin filament, the OUT/IN ratio of the reinforcing fibers is 0 to 90%, the OUT/IN ratio being defined as the ratio of the reinforcing fiber volume content in an outer periphery that spans 15% of the thickness of the filament inward from the outer edge, to the reinforcing fiber volume content in an inner portion that excludes the outer periphery; and the coefficient of static friction of the surface is 0.20 to 0.80.

公开(公告)号：US12172341B2

公开(公告)日：2024-12-24

申请号：US17267975

申请日：2019-08-20

Applicant: Toray Industries, Inc.

Inventor： Masayuki Koshi ,  Shoma Ishida ,  Yoshihiro Naruse

IPC: B29B15/12 ,  B29B15/14 ,  B29C70/20 ,  B29C70/50 ,  B29C70/68 ,  C08J5/24 ,  B29K101/12 ,  B29K105/08 ,  C08J5/04

Abstract: A method produces thermoplastic resin-impregnated sheet-shaped reinforcing fiber bundle obtained by impregnating reinforcing fibers made from continuous fibers with a thermoplastic resin, said method including: an application step in which a sheet-shaped reinforcing fiber bundle obtained by arranging reinforcing fibers made from continuous fibers in one direction is passed through an application section which retains thermoplastic resin, and the thermoplastic resin is applied to the sheet-shaped reinforcing fiber bundle to constitute a thermoplastic resin-impregnated sheet-shaped reinforcing fiber bundle; a further impregnation step in which the applied thermoplastic resin is further impregnated into the inside of the thermoplastic resin-impregnated sheet-shaped reinforcing fiber bundle; and a shaping step in which the thermoplastic resin-impregnated sheet-shaped reinforcing fiber bundle is shaped and solidified by cooling.

公开(公告)号：US20200369838A1

公开(公告)日：2020-11-26

申请号：US16759252

申请日：2018-11-05

Applicant: Toray Industries, Inc.

Inventor： Masayuki Koshi ,  Yoshihiro Naruse ,  Shoma Ishida

IPC: C08J5/04 ,  D06M15/63 ,  D06M15/647

Abstract: A fiber-reinforced thermoplastic resin filament is obtained by impregnating a continuous reinforcing fiber with a thermoplastic resin, and satisfies all of conditions (a) to (c). (a) The volume ratio of a reinforcing fiber in a fiber-reinforced thermoplastic resin filament is 30 to 80%; and the volume ratio of a thermoplastic resin in a fiber-reinforced thermoplastic resin filament is 70 to 20%. (b) The thickness of a fiber-reinforced thermoplastic resin filament is 0.01 to 3 mm. (c) The length of a filament contained in a fiber-reinforced thermoplastic resin filament is 1 m or more.

公开(公告)号：US11566114B2

公开(公告)日：2023-01-31

申请号：US16759252

申请日：2018-11-05

Applicant: Toray Industries, Inc.

Inventor： Masayuki Koshi ,  Yoshihiro Naruse ,  Shoma Ishida

IPC: C08J5/04 ,  D06M15/63 ,  D06M15/647 ,  D06M101/30

Abstract: A fiber-reinforced thermoplastic resin filament is obtained by impregnating a continuous reinforcing fiber with a thermoplastic resin, and satisfies all of conditions (a) to (c). (a) The volume ratio of a reinforcing fiber in a fiber-reinforced thermoplastic resin filament is 30 to 80%; and the volume ratio of a thermoplastic resin in a fiber-reinforced thermoplastic resin filament is 70 to 20%. (b) The thickness of a fiber-reinforced thermoplastic resin filament is 0.01 to 3 mm. (c) The length of a filament contained in a fiber-reinforced thermoplastic resin filament is 1 m or more.

公开(公告)号：US20210253813A1

公开(公告)日：2021-08-19

申请号：US17269870

申请日：2019-08-20

Applicant: Toray Industries, Inc.

Inventor： Masayuki Koshi ,  Shoma Ishida ,  Hiroyuki Ome

IPC: C08J5/24 ,  B32B5/06 ,  B32B5/26 ,  B32B5/28 ,  B32B7/08 ,  B29C70/16

Abstract: A fiber-reinforced thermoplastic resin includes a continuous fiber base material made from continuous reinforcing fibers, and a thermoplastic resin applied to the surface thereof. The thermoplastic resin coats the entire surface of the continuous fiber base material in a solidified state, and impregnates the continuous fiber base material while leaving voids therein, with these voids being formed intermittently in the direction in which the fibers are arranged. A laminate uses the fiber-reinforced thermoplastic resin base material.

公开(公告)号：US20210213690A1

公开(公告)日：2021-07-15

申请号：US17267975

申请日：2019-08-20

Applicant: Toray Industries, Inc.

Inventor： Masayuki Koshi ,  Shoma Ishida ,  Yoshihiro Naruse

IPC: B29C70/50 ,  B29B15/14 ,  B29B15/12 ,  B29C70/68 ,  B29C70/20 ,  C08J5/24

Abstract: A method produces thermoplastic resin-impregnated sheet-shaped reinforcing fiber bundle obtained by impregnating reinforcing fibers made from continuous fibers with a thermoplastic resin, said method including: an application step in which a sheet-shaped reinforcing fiber bundle obtained by arranging reinforcing fibers made from continuous fibers in one direction is passed through an application section which retains thermoplastic resin, and the thermoplastic resin is applied to the sheet-shaped reinforcing fiber bundle to constitute a thermoplastic resin-impregnated sheet-shaped reinforcing fiber bundle; a further impregnation step in which the applied thermoplastic resin is further impregnated into the inside of the thermoplastic resin-impregnated sheet-shaped reinforcing fiber bundle; and a shaping step in which the thermoplastic resin-impregnated sheet-shaped reinforcing fiber bundle is shaped and solidified by cooling.