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

IPC: C08J5/24 ,  B29C70/50 ,  C08K7/06

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.

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：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.

公开(公告)号：US11230630B2

公开(公告)日：2022-01-25

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

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：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.

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：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.

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

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

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：US11794419B2

公开(公告)日：2023-10-24

申请号：US17598504

申请日：2020-03-09

Applicant: Toray Industries, Inc.

Inventor： Yusuke Yamanaka ,  Takafumi Hashimoto ,  Tetsuya Motohashi ,  Yasukazu Ono

IPC: B29C70/12 ,  B29B15/10 ,  B29C70/42 ,  C08J5/04 ,  B29K101/10 ,  B29K105/12 ,  B29K307/04

CPC classification number: B29C70/12 ,  B29B15/105 ,  B29C70/42 ,  C08J5/042 ,  B29K2101/10 ,  B29K2105/12 ,  B29K2307/04

Abstract: A fiber-reinforced resin molding material molded product includes a fiber-reinforced resin molding material prepared by impregnating chopped fiber bundles obtained by cutting a reinforcing fiber bundle with a matrix resin, wherein in a region excluding 30 mm from an edge of the molded product, when an arbitrary rectangular region having an area of 40 mm2 or more and defined by a thickness of the molded product and a width in a direction perpendicular to a thickness direction of the molded product is set in a cross section in an arbitrary thickness direction of the molded product, with respect to a bundle thickness of the chopped fiber bundles present in the set rectangular region.

公开(公告)号：US11371171B2

公开(公告)日：2022-06-28

申请号：US16310165

申请日：2017-06-06

Applicant: Toray Industries, Inc.

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

IPC: B29C70/54 ,  D02J1/18 ,  C08J5/06 ,  C08J5/24 ,  B29C70/02 ,  B29B11/00 ,  B29B15/12 ,  B65H51/005 ,  B65H54/02 ,  B65H73/00

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.