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    Composite prepreg, preform using the same, fiber-reinforced composite material assembly, and method for producing the same
    11.
    发明授权
    Composite prepreg, preform using the same, fiber-reinforced composite material assembly, and method for producing the same 有权

    公开(公告)号：US12024606B2

    公开(公告)日：2024-07-02

    申请号：US17789839

    申请日：2020-11-12

    Applicant: Toray Industries, Inc.

    Inventor： Naokichi Imai ,  Masato Honma

    IPC: B29C70/54 ,  C08J5/24

    CPC classification number: C08J5/243 ,  B29C70/54

    Abstract: Provided is a composite prepreg including a region (A) containing a thermosetting resin (a) and a reinforcing fiber and a region (B) containing a thermosetting resin (b) and a reinforcing fiber, the composite prepreg satisfying conditions (i) and (ii) or satisfying conditions (ii) and (iii):



    (i) The thermosetting resin (b) is a resin having a gel time Tb longer than a gel time Ta of the thermosetting resin (a), and in at least a part of a temperature range of 40° C. or more and 180° C. or less, satisfy Ta/Tb≤0.8;
    (ii) A ratio of the region (A) on a surface of the composite prepreg is 20 to 80%; and
    (iii) The thermosetting resin (b) is a resin having a higher heat generation starting temperature Eb than a heat generation starting temperature Ea of the thermosetting resin (a), and in a differential scanning calorimetry chart obtained by measuring at 5° C./min with 40° C. as a starting temperature, satisfy Eb−Ea≥30.

    FIBER-REINFORCED COMPOSITE MATERIAL AND SANDWICH STRUCTURE
    12.
    发明申请
    FIBER-REINFORCED COMPOSITE MATERIAL AND SANDWICH STRUCTURE 有权

    公开(公告)号：US20230040874A1

    公开(公告)日：2023-02-09

    申请号：US17777691

    申请日：2020-11-16

    Applicant: Toray Industries, Inc.

    Inventor： Naokichi Imai ,  Kotaro Shinohara ,  Masato Honma

    IPC: B32B5/02 ,  B32B3/28 ,  B32B5/26 ,  B32B5/12

    Abstract: An object of the present invention is to obtain a fiber-reinforced composite material achieving both lightweight properties and mechanical properties at a high level. The present invention provides a fiber-reinforced composite material including a resin (A) and a reinforcing fiber (B), and having: a porous structure portion having micropores with an average pore diameter of 500 μm or less as measured by a mercury intrusion method; and a coarse cavity portion defined by the porous structure portion and having a maximum length of more than 500 μm as a cross-sectional opening portion.

    Method for manufacturing fiber-reinforced composite material
    13.
    发明授权
    Method for manufacturing fiber-reinforced composite material 有权

    公开(公告)号：US10583640B2

    公开(公告)日：2020-03-10

    申请号：US15739364

    申请日：2016-06-30

    Applicant: TORAY INDUSTRIES, INC.

    Inventor： Naokichi Imai ,  Masato Honma

    IPC: B29C33/68 ,  B32B27/32 ,  B29C43/18 ,  C08J5/04 ,  B32B5/28 ,  B29C70/46 ,  B29C43/58 ,  B32B1/04 ,  B32B27/20 ,  B32B27/38 ,  C08J5/24

    Abstract: A method for producing a fiber-reinforced composite material is provided. By satisfying particular conditions, this method is capable of suppressing the problem of poor appearance caused by the release film in the production of the fiber-reinforced composite material having a three-dimensional shape by heat-press molding to enable production of the fiber-reinforced composite material having a high quality appearance in high cycle.A method for manufacturing a fiber-reinforced composite material wherein a fiber-reinforced substrate containing a reinforcing fiber (A) and a thermosetting resin (B) is sandwiched between release films (C) to constitute a layered material, and the layered material is pressed in a mold heated to molding temperature to thereby cure the thermosetting resin (B), wherein the method satisfies the following (i), (ii), and (iii) or (i), (ii), and (iv): (i) the fiber-reinforced composite material has at least 1 bent part, (ii) the molding temperature is 130 to 180° C., and pressure application time is 0.5 to 20 minutes, (iii) the release film (C) has a thermal contraction rate satisfying the following expressions (1) and (2): 0

    Integrally molded body and method for producing the same
    17.
    发明授权
    Integrally molded body and method for producing the same 有权

    公开(公告)号：US11141893B2

    公开(公告)日：2021-10-12

    申请号：US16641436

    申请日：2018-08-24

    Applicant: Toray Industries, Inc.

    Inventor： Takafumi Suzuki ,  Yuichiro Sento ,  Naokichi Imai ,  Mitsushige Hamaguchi ,  Masato Honma

    IPC: B29C45/14 ,  B32B5/28 ,  B29K705/02 ,  B32B27/08

    Abstract: In order to solve reduction in strength and rigidity at a weldline which is a problem of an injection molding body, and enable free design such as thin wall molding or complex shape molding of the injection molding body, there is provided an integrally molded body in which a substrate for reinforcement (a) having a discontinuous fiber (a1) and a resin (a2) and an injection molding body (b) having a discontinuous fiber (b1) and a resin (b2) are integrated, in which the substrate for reinforcement (a) has a difference in an orientation angle of the discontinuous fiber (a1) in each of regions obtained by dividing a major axis direction of the substrate for reinforcement (a) into 10 equal parts of within 10°, and the substrate for reinforcement (a) covers a part or all of a weldline of the injection molding body (b) to be integrated with the injection molding body (b).

    Electronic device housing
    18.
    发明授权
    Electronic device housing 有权

    公开(公告)号：US10908651B2

    公开(公告)日：2021-02-02

    申请号：US15760735

    申请日：2016-09-06

    Applicant: TORAY INDUSTRIES, INC.

    Inventor： Masato Honma ,  Yoshiki Takebe ,  Naokichi Imai ,  Takashi Fujioka

    IPC: G06F1/16 ,  G06F1/20

    Abstract: An electronic device housing includes: a bottom cover; a top cover; a partition structure that is disposed in a space divided by the bottom cover and the top cover and has an opening; and a heat generation member. The partition structure is joined to the bottom cover or the top cover to form a hollow structure, and the heat generation member is disposed on a surface of the partition structure on the hollow structure side.

    Molded article and molding material
    19.
    发明授权
    Molded article and molding material 有权

    公开(公告)号：US10472498B2

    公开(公告)日：2019-11-12

    申请号：US15873031

    申请日：2018-01-17

    Applicant: Toray Industries, Inc.

    Inventor： Naokichi Imai ,  Kentaro Sano ,  Keisuke Inose

    IPC: C08K9/04 ,  C08K7/06 ,  C08L81/00 ,  B29C70/14 ,  B29C45/00

    Abstract: A molded article includes 10 to 40% by mass of reinforcing fibers (A); and 60 to 90% by mass of a matrix resin (B) mainly including a polyarylene sulfide, the molded article satisfying conditions (I) to (IV) and having a tensile strength of 240 MPa or more in a main orientation direction of the reinforcing fibers (A) in the molded article: (I) strand tensile strength of the reinforcing fibers (A) is 1.5 to 5.5 OPa; (II) number average fiber length of the reinforcing fibers (A) in the molded article is 0.4 mm or more and less than 0.6 mm; (III) tensile elongation of the matrix resin (B) is 1.5 to 10%; and (IV) interfacial shear strength between the reinforcing fibers (A) and the matrix resin (B) is 20 MPa or more.

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