Toray Industries, Inc.

Yoshihiro Naruse

Masayuki Koshi

Takafumi Hashimoto

Katsuhiro Miyoshi

Takashi Shimada

Shuichi Nonaka

Shoma Ishida

Takashi Ochi

Naoya Ouchiyama

Takeo Matsunase

Tetsuya Ohara

Kazuhiro Tanahashi

Koji Suzuki

Tomoyuki Horiguchi

Kosaku Takeuchi

Makito Yokoe

Kohei Yamashita

Keishi Miwa

Kakuji Murakami

Toshihiro Sasaki

Yoshitaka Matsumura

Masahiro Hashimoto

Hirohito Minowa

KaKuji Murakami

Satoshi Kondo

A fiber-reinforced resin base material includes continuous reinforcing fibers or a reinforcing fiber base material in which discontinuous fibers are dispersed, the continuous reinforcing fibers or a reinforcing fiber base material being impregnated with a polyphenylene sulfide resin composition, wherein the fiber-reinforced resin base material has a glass-transition temperature, as measured by the DMA method (bending mode), of 115° C. or higher.

Fiber-reinforced resin base material

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.

Method of producing thermoplastic resin-impregnated sheet-shaped reinforcing fiber bundle

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%.

Fiber-reinforced thermoplastic resin filament for 3D printer, and molded article thereof

A fiber-reinforced polymer alloy substrate, in which continuous reinforcing fibers are arranged in parallel and are impregnated with a polymer alloy, is characterized in that: a polymer alloy obtained by combining thermoplastic resins of at least two types is used as the polymer alloy; the fiber volume content is in the range of 40 to 70% by volume; and the dispersion parameter D of the fibers is 90% or more. In the obtained fiber-reinforced polymer alloy substrate, the reinforcing fibers are dispersed with high uniformity, and high mechanical properties and heat resistance are stably exhibited with low variation.

Fiber-reinforced polymer alloy substrate and molded article using same

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).

Fiber-reinforced thermoplastic resin filament and shaped product of same

A stampable sheet includes a resin and carbon fiber sheet including fiber bundles of discontinuous carbon fibers, wherein the carbon fiber sheet includes fiber bundles having a bundle width of 50 &#x3bc;m or greater and opened fibers ranging from fiber bundles having a bundle width less than 50 &#x3bc;m to fibers obtained by opening to the single-fiber level. When the direction along which the opened fibers have been oriented most is a 0&#xb0; direction and the range of from the 0&#xb0; to 90&#xb0; direction is divided into angular zones, the distribution curve showing the proportion of the number of fiber bundles in each angular zone to that in all angular zones and the distribution curve showing the proportion of the number of opened fibers in each angular zone to that in all angular zones are reverse to each other in terms of gradient of the 0&#xb0; to 90&#xb0; direction.

Stampable sheet

A spongelike structure or a powder having fibers three-dimensionally arranged therein with high dispersibility, whose apparent density can be designed depending on the purpose or utility, as well as a process producing it. A fiber dispersion in which fibers having a number mean diameter in a predetermined range are dispersed in a dispersion medium, and this fiber dispersion is dried to remove the dispersion medium, thereby, a spongelike structure and a powder are produced.

Process for producing spongelike structure

A stimuli-responsive material includes a stimuli-responsive polymer, fibers and water, wherein the fibers have a number average diameter of 1 to 900 nm and are present in the stimuli-responsive material in a dispersed state; and a medical material and an anti-adhesive material, each of which includes a stimuli-responsive material including a stimuli-responsive polymer, fibers and water, wherein the fibers have a number average diameter of 1 to 900 nm and are present in the stimuli-responsive material in a dispersed state.

Stimuli-responsive material and medical material

A carbon fiber composite material which includes a carbon fiber sheet as a reinforcing material and a thermoplastic resin as a matrix resin, the carbon fiber sheet exhibiting a work per areal weight of 1&#xd7;10to 30&#xd7;10[(N&#xb7;mm)/(g/m)] in a tensile test using a specimen having a width of 25 mm. The carbon fiber composite material exhibits excellent flowability in molding and ensures excellent moldability even when molded into a complicated shape. Further, the composite material can yield a molded product which has high mechanical properties with minimized dispersion, thus being suitable for press molding.

Carbon fiber composite material

A carbon-fiber-reinforced plastic prepared by impregnating a matrix resin into a sheet-like base material includes discontinuous carbon fibers, wherein a content ratio of carbon fibers having lengths of 10 mm or longer in the base material is 60 wt % or more relative to a total amount of the carbon fibers, and an average value of orientation degrees of carbon fibers contained in the base material is 2-10.

Carbon-fiber-reinforced plastic and process for producing same

An abrasive cloth which comprises an article in a sheet form having, in at least a part thereof, nanofibers comprising a thermoplastic polymer and having a number average single fiber fineness of 1&#xd7;10to 2&#xd7;10dtex wherein the sum of single fiber fineness percentages (which is defined in the specification) of a single fiber fineness of 1&#xd7;10to 2&#xd7;10dtex is the range of 60% or more, and exhibits a stress at 10% elongation in a longitudinal direction of 5 to 200 N/cm-width; and a method for preparing a nanofiber structure, which comprises providing a nanofiber dispersion having a dispersant and, dispersed therein, nanofibers comprising a thermoplastic polymer and having a number average diameter of 1 to 500 nm, attaching the dispersion to a support, and then removing said dispersant. The above abrasive cloth is excellent in texturing characteristics, and the above method allows the preparation of a nanofiber structure wherein nanofibers form a composite with the support.

Abrasive cloth and method for producing nanofiber structure

This invention provides compound solutions, emulsions and gels excellent in homogeneous dispersibility and long-term dispersion stability and also excellent in the properties as cosmetics, using disarranged nanofibers not limited in either form or polymer, widely applicable and small in the irregularity of single fiber diameter. This invention also provides a method for producing them. Furthermore, this invention provides synthetic papers composed of fibers, small in pore area and uniform in pore size, using disarranged nanofibers, and also provides a method for producing them. This invention provides compound solutions, emulsions, gels and synthetic papers containing disarranged nanofibers of 1 to 500 nm in number average diameter and 60% or more in the sum Pa of single fiber ratios.

Nano-fiber compound solutions, emulsions and gels, production method thereof, Nano-fiber synthetic papers, and production method thereof

A polyester fiber comprises a hygroscopic polyester composition which contains 1 to 20 percent by weight of hygroscopic silica-based inorganic particles in which the average diameter, the specific surface area, the micropore volume, and the hygroscopic parameter &#x394;MR are within specified ranges. This hygroscopic fiber is suitable for clothes which require comfortableness.

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Nagoya, Japan

Yoshihiro Naruse