公开(公告)号：US20210154952A1

公开(公告)日：2021-05-27

申请号：US16965382

申请日：2019-03-25

Applicant: Toray Industries, Inc.

Inventor： Yoshiki Takebe ,  Kotaro Shinohara ,  Masato Honma

IPC: B29C70/34 ,  B29C70/54

Abstract: Provided is a molded article that has both a low specific gravity and high rigidity and further has suppressed wrinkles and scrapes, and a manufacturing method for the same. Hence, provided is a press-molded article manufacturing method for press-molding a sheet-shaped molding substrate that is disposed in a cavity of a molding die and contains reinforcing fibers randomly dispersed in a matrix resin using a press molding machine provided with a molding die that is a convex molding die provided with a cavity formed between a concave mold for forming an opening of a molded article and a convex mold that matches with the concave, and has at least one surface (B) on which a pressure is loaded in a range of 0% to 70% of a pressure loaded on a surface (A) when the pressure loaded on the surface (A) from the press molding machine is 100% with respect to the surface (A) orthogonal to a direction of pressure applied to the molding die from the press molding machine, the press-molded article manufacturing method comprising: a shaping step (III) of loading a surface pressure of 1 MPa or more as an external pressure from the press molding machine to the surface (A); and a pressure holding step (IV) of setting a pressure loaded as an external pressure from the press molding machine on the molding substrate to 0.1 MPa or less without releasing the molding die after the shaping step (III).

公开(公告)号：US10994510B2

公开(公告)日：2021-05-04

申请号：US16471242

申请日：2017-12-20

Applicant: TORAY INDUSTRIES, INC.

Inventor： Yoshiki Takebe ,  Masato Honma

IPC: B32B5/12 ,  B32B7/03 ,  B29C43/20 ,  B29C70/14 ,  B29C70/34 ,  B29C70/46 ,  B32B3/26 ,  B32B5/26 ,  B32B7/02 ,  B32B27/08 ,  B32B38/00

Abstract: A composite structure includes a structure that contains first reinforced fibers and first resin and a laminate that is disposed on at least one surface of the structure and has a plurality of layers containing second reinforced fibers and second resin, with the structure and the laminate integrated, the first reinforced fibers being discontinuous fibers and having a thickness-wise average fiber orientation angle in a range of 5 to 60°, the second reinforced fibers being discontinuous fibers and having a thickness-wise average fiber orientation angle in a range of 0 to 5°, the structure having a density in a range of 0.01 to 1 g/cm3, the laminate having a variation in volume content of the second reinforced fibers in a range of 0 to 10%, and the composite structure having a protruding portion on a laminate's surface opposite from a laminate's surface in contact with the structure.

公开(公告)号：US10882224B2

公开(公告)日：2021-01-05

申请号：US16065621

申请日：2016-12-09

Applicant: TORAY INDUSTRIES, INC.

Inventor： Takashi Fujioka ,  Yoshiki Takebe ,  Masato Honma

IPC: B29C39/38 ,  B29C39/18 ,  B29C43/18 ,  B29C43/52 ,  B29C70/28 ,  B32B27/12 ,  C08J5/04 ,  B29C70/46 ,  B29K101/10 ,  B29K101/12 ,  B29K105/06 ,  B29K105/04

Abstract: A method for manufacturing a structure material is a method for manufacturing a structure material that includes a thermoplastic resin, reinforced fibers, and voids. The method includes: a first process for arranging a structure precursor comprising the thermoplastic resin and the reinforced fibers in a mold with a surface temperature of 80° C. or less; a second process for raising the surface temperature of the mold up to a temperature at which a storage elastic modulus (G′) of the structure precursor is less than 1.2×108 Pa; a third process for lowering the surface temperature of the mold down to a temperature at which the storage elastic modulus (G′) of the structure precursor is 1.2×108 Pa or more; and a fourth process for removing a structure material obtained after end of the third process from the mold.

公开(公告)号：US12269225B2

公开(公告)日：2025-04-08

申请号：US17604489

申请日：2020-05-15

Applicant: Toray Industries, Inc.

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

IPC: B29C70/88 ,  B29C70/20 ,  B29K77/00 ,  B29K81/00 ,  B29K105/08 ,  B29K105/10 ,  B29K307/04

Abstract: A fiber-reinforced plastic substrate is described in which a plurality of resins having different properties are firmly compounded and that includes components [A], [B], and [C]: [A] reinforcing fibers; [B] thermoplastic resin (b); and [C] thermoplastic resin (c), wherein the component [A] is arranged in one direction, in the fiber-reinforced plastic substrate, a resin area including the component [B] and a resin area including the component [C] are present, the resin area including the component [B] is present on a surface of one side of the fiber-reinforced plastic substrate, and a distance Ra(bc) between Hansen solubility parameters of the component [B] and the component [C] satisfies formula (1): Ra(bc)={4(δDB−δDC)2+(δPB−δPC)2+(δHB−δHC)2}1/2≥8 wherein Ra(bc), δDB, δDC, δPB, δPC, δHB and δHC are as defined.

公开(公告)号：US11697274B2

公开(公告)日：2023-07-11

申请号：US16977862

申请日：2019-03-28

Applicant: Toray Industries, Inc.

Inventor： Yoshiki Takebe ,  Masato Honma

IPC: B32B27/08 ,  B29C45/14 ,  C08J5/04 ,  C08J9/00 ,  C08J9/42 ,  B29K101/12

CPC classification number: B32B27/08 ,  B29C45/14008 ,  C08J5/042 ,  C08J9/0085 ,  C08J9/42 ,  B29K2101/12 ,  B29K2715/003 ,  C08J2323/12 ,  C08J2333/26 ,  C08J2377/02 ,  C08J2381/02 ,  C08J2423/12 ,  C08J2469/00 ,  C08J2477/02 ,  C08J2481/02

Abstract: A molded product having both small specific gravity and high stiffness and also suffering few sink marks is described along with a method for the production thereof, where the molded product includes a porous body (A) integrated with an injection molded body (B), the porous body (A) having an apparent density of 0.05 to 0.8 g/cm3, the average thickness (tA) of the porous body (A) and the average thickness (tB) of the injection molded body (B) satisfying the relation tA≥3×tB, and the injection molded body (B) covering at least one face of the porous body (A).

公开(公告)号：US20230036115A1

公开(公告)日：2023-02-02

申请号：US17786615

申请日：2020-11-06

Applicant: Toray Industries, Inc.

Inventor： Miho Onodera ,  Yoshiki Takebe ,  Daisuke Konishi ,  Yuta Naito ,  Yoshifumi Nakayama ,  Masato Honma

IPC: C08J5/24

Abstract: A prepreg and an integrally molded article are described, the prepreg including a thermoplastic resin existing on one face of a layer in which reinforcing fibers are impregnated with a thermosetting resin, wherein the prepreg exhibits, in injection molding or press molding, thermal weldability with a member containing a thermoplastic resin, and wherein the thermosetting resin has a specific peak on a loss tangent (tan δ) curve obtained by dynamic mechanical analysis (DMA), so that the prepreg exhibits suitable flexibility and adhesiveness, excellent formability on a complicated mold face, and adhesion to a mold face, causes no positional shift, and can be efficiently reinforced and stiffened at an intended position.

公开(公告)号：US10093777B2

公开(公告)日：2018-10-09

申请号：US14442764

申请日：2013-12-06

Applicant: TORAY Industries, Inc.

Inventor： Yoshiki Takebe ,  Hiroki Kihara ,  Noriyuki Hirano

IPC: C08J5/04 ,  C08K7/06 ,  B29C70/02 ,  B29C45/00 ,  B29C45/14 ,  C08J5/24 ,  B29C43/30 ,  B32B5/02 ,  B32B27/12 ,  B32B27/34 ,  B32B27/36 ,  B29C43/18 ,  B29C70/34 ,  B29L31/34 ,  B29K105/12 ,  B29K101/12 ,  B29K307/04

Abstract: A fiber-reinforced resin sheet and an integrally molded article are provided. The fiber-reinforced resin sheet comprises a nonwoven fabric made of reinforcing fibers having a thermoplastic resin (A) impregnated on one side of the nonwoven fabric. The fiber-reinforced resin sheet satisfies any one of the following conditions (I) and (II): (I) the nonwoven fabric has an area wherein the reinforcing fibers constituting the nonwoven fabric are exposed on the other side in the thickness direction of the nonwoven fabric, and (II) the nonwoven fabric has a thermoplastic resin (B) impregnated on the other side in thickness direction of the nonwoven fabric, and the nonwoven fabric has a reinforcing fiber volume ratio Vfm of up to 20% by volume, and wherein the thermoplastic resin (A) and the thermoplastic resin (B) form an interface layer in the sheet, and the interface layer has a concave-convex shape with a maximum height Ry of at least 50 μm and an average roughness Rz of at least 30 μm.

公开(公告)号：US20250050547A1

公开(公告)日：2025-02-13

申请号：US18928800

申请日：2024-10-28

Applicant: Toray Industries, Inc.

Inventor： Kotaro Shinohara ,  Yoshiki Takebe ,  Yoshihumi Nakayama ,  Masato Honma

IPC: B29B15/12 ,  B29K101/10 ,  B29K101/12 ,  B29K105/08 ,  C08J5/04

Abstract: A method is described for producing a fiber-reinforced plastic substrate that simultaneously satisfies three points of joinability, mechanical characteristics, and productivity, the method including the following components [A], [B], and [C], wherein at least the following drawing step, first impregnating step, second impregnating step, and take-up step are continuously and sequentially performed while the component [A] is caused to run: [A] a reinforcing fiber [B] a thermoplastic resin [C] a thermosetting resin 2 step of drawing a continuous reinforcing fiber sheet containing the component [A]; step of impregnating either the component [B] or the component [C] from one surface of the continuous reinforcing fiber sheet to obtain a fiber-reinforced plastic intermediate in which either the component [B] or the component [C] is disposed on a first surface; step of impregnating the other of the component [B] or the component [C] from a second surface opposite to the first surface to obtain a fiber-reinforced plastic substrate; and step of taking up the fiber-reinforced plastic substrate.

公开(公告)号：US12162186B2

公开(公告)日：2024-12-10

申请号：US17607106

申请日：2020-05-15

Applicant: Toray Industries, Inc.

Inventor： Kotaro Shinohara ,  Yoshiki Takebe ,  Yoshihumi Nakayama ,  Masato Honma

IPC: B29B15/12 ,  C08J5/04 ,  B29K101/10 ,  B29K101/12 ,  B29K105/08

Abstract: A method is described for producing a fiber-reinforced plastic substrate that simultaneously satisfies three points of joinability, mechanical characteristics, and productivity, the method including the following components [A], [B], and [C], wherein at least the following drawing step, first impregnating step, second impregnating step, and take-up step are continuously and sequentially performed while the component [A] is caused to run: [A] a reinforcing fiber [B] a thermoplastic resin [C] a thermosetting resin step of drawing a continuous reinforcing fiber sheet containing the component [A]; step of impregnating either the component [B] or the component [C] from one surface of the continuous reinforcing fiber sheet to obtain a fiber-reinforced plastic intermediate in which either the component [B] or the component [C] is disposed on a first surface; step of impregnating the other of the component [B] or the component [C] from a second surface opposite to the first surface to obtain a fiber-reinforced plastic substrate; and step of taking up the fiber-reinforced plastic substrate.

公开(公告)号：US20220227024A1

公开(公告)日：2022-07-21

申请号：US17607106

申请日：2020-05-15

Applicant: Toray Industries, Inc.

Inventor： Kotaro Shinohara ,  Yoshiki Takebe ,  Yoshihumi Nakayama ,  Masato Honma

IPC: B29B15/12 ,  C08J5/04

Abstract: A method is described for producing a fiber-reinforced plastic substrate that simultaneously satisfies three points of joinability, mechanical characteristics, and productivity, the method including the following components [A], [B], and [C], wherein at least the following drawing step, first impregnating step, second impregnating step, and take-up step are continuously and sequentially performed while the component [A] is caused to run:
[A] a reinforcing fiber [B] a thermoplastic resin [C] a thermosetting resin step of drawing a continuous reinforcing fiber sheet containing the component [A]; step of impregnating either the component [B] or the component [C] from one surface of the continuous reinforcing fiber sheet to obtain a fiber-reinforced plastic intermediate in which either the component [B] or the component [C] is disposed on a first surface; step of impregnating the other of the component [B] or the component [C] from a second surface opposite to the first surface to obtain a fiber-reinforced plastic substrate; and step of taking up the fiber-reinforced plastic substrate.