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1. 发明申请

US20210154952A1 PRESS-MOLDED ARTICLE MANUFACTURING METHOD 有权
公开(公告)号：US20210154952A1
公开(公告)日：2021-05-27
申请号：US16965382
申请日：2019-03-25
申请人： Toray Industries, Inc.
发明人： Yoshiki Takebe , Kotaro Shinohara , Masato Honma
IPC分类号： B29C70/34 , B29C70/54
摘要： 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).

2. 发明授权

US10994510B2 Composite structure and method for manufacturing same 有权
公开(公告)号：US10994510B2
公开(公告)日：2021-05-04
申请号：US16471242
申请日：2017-12-20
申请人： TORAY INDUSTRIES, INC.
发明人： Yoshiki Takebe , Masato Honma
IPC分类号： B32B5/12 , B32B7/03 , B29C43/20 , B29C70/14 , B29C70/34 , B29C70/46 , B32B3/26 , B32B5/26 , B32B7/02 , B32B27/08 , B32B38/00
摘要： 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.

3. 发明授权

US10882224B2 Method for manufacturing structure material 有权
公开(公告)号：US10882224B2
公开(公告)日：2021-01-05
申请号：US16065621
申请日：2016-12-09
申请人： TORAY INDUSTRIES, INC.
发明人： Takashi Fujioka , Yoshiki Takebe , Masato Honma
IPC分类号： B29C39/38 , B29C39/18 , B29C43/18 , B29C43/52 , B29C70/28 , B32B27/12 , C08J5/04 , B29C70/46 , B29K101/10 , B29K101/12 , B29K105/06 , B29K105/04
摘要： 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.

4. 发明授权

US11697274B2 Molded article and production method therefor 有权
公开(公告)号：US11697274B2
公开(公告)日：2023-07-11
申请号：US16977862
申请日：2019-03-28
申请人： Toray Industries, Inc.
发明人： Yoshiki Takebe , Masato Honma
IPC分类号： B32B27/08 , B29C45/14 , C08J5/04 , C08J9/00 , C08J9/42 , B29K101/12
CPC分类号： 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
摘要： 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).

5. 发明申请

US20230036115A1 PREPREG, MOLDED ARTICLE, AND INTEGRALLY MOLDED ARTICLE 有权
公开(公告)号：US20230036115A1
公开(公告)日：2023-02-02
申请号：US17786615
申请日：2020-11-06
申请人： Toray Industries, Inc.
发明人： Miho Onodera , Yoshiki Takebe , Daisuke Konishi , Yuta Naito , Yoshifumi Nakayama , Masato Honma
IPC分类号： C08J5/24
摘要： 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.

6. 发明授权

US10093777B2 Fiber-reinforced resin sheet, integrated molded product and process for producing same 有权
公开(公告)号：US10093777B2
公开(公告)日：2018-10-09
申请号：US14442764
申请日：2013-12-06
申请人： TORAY Industries, Inc.
发明人： Yoshiki Takebe , Hiroki Kihara , Noriyuki Hirano
IPC分类号： 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
摘要： 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.

7. 发明申请

US20220227024A1 METHOD FOR PRODUCING FIBER-REINFORCED PLASTIC SUBSTRATE, AND FIBER-REINFORCED PLASTIC SUBSTRATE AND INTEGRATED MOLDING THEREOF 有权
公开(公告)号：US20220227024A1
公开(公告)日：2022-07-21
申请号：US17607106
申请日：2020-05-15
申请人： Toray Industries, Inc.
发明人： Kotaro Shinohara , Yoshiki Takebe , Yoshihumi Nakayama , Masato Honma
IPC分类号： B29B15/12 , C08J5/04
摘要： 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.

8. 发明申请

US20210291487A1 SANDWICH LAMINATE, SANDWICH STRUCTURE AND UNIFIED MOLDED PRODUCT USING SAME AND PROCESSES FOR PRODUCING BOTH 有权
公开(公告)号：US20210291487A1
公开(公告)日：2021-09-23
申请号：US17340183
申请日：2021-06-07
申请人： Toray Industries, Inc.
发明人： Yoshiki Takebe , Hiroki Kihara , Noriyuki Hirano
IPC分类号： B32B5/26 , B32B27/32 , B32B37/06 , B32B37/10
摘要： A laminate includes a core obtained by impregnating a mat of fibers with a thermoplastic resin (B); and a skin obtained by impregnating continuous fiber(s) with a thermoplastic resin (A), wherein sheet-form intermediate substrates in the laminate have a thermal expansibility, the usable temperature region of said thermoplastic resin (A) and that of said thermoplastic resin (B) overlap over a temperature range of at least 5° C., said thermoplastic resin (A) has a temperature region that does not melt at a lower limit of said usable temperature region, said fibers contained in said mat penetrate through interface layers formed by said thermoplastic resin (A) and said thermoplastic resin (B), and said thermoplastic resin (A) and said thermoplastic resin (B) form interface layers each with a concave-convex shape having a maximum height Ry of not less than 50 μm and an average roughness Rz of not less than 30 μm.

9. 发明授权

US10947352B2 Structure material and manufacturing method therefor 有权
公开(公告)号：US10947352B2
公开(公告)日：2021-03-16
申请号：US16471949
申请日：2017-12-20
申请人： TORAY INDUSTRIES, INC.
发明人： Takashi Fujioka , Yoshiki Takebe , Masato Honma
IPC分类号： C08J5/04 , B29C70/06 , B29K305/00 , B29K307/04 , B29L31/00
摘要： Provided is a mountain-shaped structure material being excellent in stiffness and lightness. The present invention is a structure material including a resin, reinforced fibers and voids. The structure material has a specific bending stiffness represented as Ec1/3·ρ−1 being 2.5 or more where a bending modulus is Ec and a density is ρ. The structure material has a mountain shape.

10. 发明申请

US20210039291A1 MOLDED ARTICLE AND PRODUCTION METHOD THEREFOR 有权
公开(公告)号：US20210039291A1
公开(公告)日：2021-02-11
申请号：US16977862
申请日：2019-03-28
申请人： Toray Industries, Inc.
发明人： Yoshiki Takebe , Masato Honma
IPC分类号： B29C45/14 , C08J9/00 , C08J5/04 , C08J9/42
摘要： 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).

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