公开(公告)号：US20210079563A1

公开(公告)日：2021-03-18

申请号：US16975435

申请日：2019-03-05

Applicant: TORAY INDUSTRIES, INC.

Inventor： Haruki OKUDA ,  Fumihiko TANAKA

IPC: D01F9/22

Abstract: A carbon fiber includes single fibers having lengths of 10 cm or less, a fiber axis of each single fiber having an undulation width of 2.5 μm or more when a part thereof between two points with a straight-line distance of 1 mm is observed from a lateral direction, and a coefficient of variation in the undulation width being 100% or less. A method of producing carbon fiber production includes performing stabilization treatment of a precursor fiber bundle for polyacrylonitrile based carbon fiber, performing pre-carbonization treatment, and performing carbonization treatment in this order, followed by cutting the resulting carbon fiber bundle in the form of continuous fiber to a single fiber length of 10 cm or less, the twist count of the fiber bundle during the carbonization treatment step being 16 turns/m or more.

公开(公告)号：US20240229304A9

公开(公告)日：2024-07-11

申请号：US18573812

申请日：2022-07-20

Applicant: TORAY INDUSTRIES, INC.

Inventor： Kiminori ONO ,  Yuki SADO ,  Fumihiko TANAKA ,  Masahiro MATSUMOTO

IPC: D01F9/22

CPC classification number: D01F9/22 ,  D10B2101/12

Abstract: To provide a carbon fiber bundle capable of suppressing winding due to ring-shaped fuzzes, which occurs when the carbon fiber bundle is rolled out for advanced processing, and a production method for producing the same. Disclosed is a carbon fiber bundle wherein an average single-fiber diameter B is 6.9 to 11.0 μm, a tensile modulus E of resin-impregnated strands is 230 to 310 GPa, the number of fuzzes inherent in the carbon fiber bundle is 40 fuzzes/m or less, and a proportion of fuzzes with a structure having a difference between skin and core is 1 to 25% of fuzzes inherent in the carbon fiber bundle. Such a carbon fiber bundle is preferably obtained by a method including, in a process of heat-treating a polyacrylonitrile-based precursor fiber bundle with a single-fiber fineness of 0.9 to 2.2 dtex in an oxidizing atmosphere at 200 to 300° C., heat-treating the polyacrylonitrile-based precursor fiber bundle so that a heat generation rate Q, which is the left side of the formula (3), is 150 to 500 J/m2/s until the density is 1.22 to 1.24 g/cm3, when q (J/g/s) is the heat generation rate of the single fiber, N is the number of filaments, d (dtex) is a single-fiber fineness of the stabilized fiber bundle and W (mm) is a yarn width, heat-treating the fiber bundle while applying a tension of 1.6 to 4.0 mN/dtex until the density is 1.38 to 1.50 g/cm3 to obtain a stabilized fiber bundle, and heat-treating the stabilized fiber bundle in an inert atmosphere at 1,200 to 1,600° C.


Q=q×N×d/W/10  (3)

公开(公告)号：US20240166840A1

公开(公告)日：2024-05-23

申请号：US17773119

申请日：2020-11-04

Applicant: TORAY INDUSTRIES, INC.

Inventor： Haruki OKUDA ,  Jun WATANABE ,  Fumihiko TANAKA

IPC: C08K3/04 ,  C08K7/06

CPC classification number: C08K3/04 ,  C08K7/06

Abstract: The present invention aims to provide a resin composition that is high in moldability in producing a member of a complicated shape by injection molding and also high in flexural modulus and impact property. A molding material including a resin composition containing a thermoplastic resin and carbon fibers, wherein the carbon fibers have substantially the same length as the length of the molding material; the twist angle of the carbon fiber surface layer is 2.0° to 30.5°; the core ratio A/(A+B) is 0.1 to 0.5 where A is the areal fraction of the core portion containing carbon fibers and B is the areal fraction of the remaining portion, that is, the sheath portion, in a cross section perpendicular to the carbon fiber axis direction in the molding material; and the areal void fraction in a cross section perpendicular to the carbon fiber axis direction in the molding material is 5% or less.

公开(公告)号：US20240337048A1

公开(公告)日：2024-10-10

申请号：US18681673

申请日：2022-08-18

Applicant: TORAY INDUSTRIES, INC.

Inventor： Yuki SUGA ,  Fumihiko TANAKA ,  Jun WATANABE

IPC: D01F9/22

CPC classification number: D01F9/22 ,  D10B2101/12 ,  D10B2401/063

Abstract: According to the present invention, a carbon fiber composite material, which has excellent energy absorption and is composed of a carbon fiber having high strength and high elongation, is provided by a production method yielding an excellent production amount. This carbon fiber bundle having a plurality of single fibers has a strand elastic modulus of 260-350 GPa, a strength of 6.5-8.5 GPa, an elongation of at least 1.8%, a filament number of 1,000-9,000, and a total fineness of 0.15-0.35 g/m, wherein the average value of major axis/minor axis ratios in single fiber cross sections is 1.01-1.08, the coefficient of variation is 1-4%, and the skewness is 0.3-1.2.

公开(公告)号：US20230087492A1

公开(公告)日：2023-03-23

申请号：US17801834

申请日：2021-03-05

Applicant: TORAY Industries, Inc.

Inventor： Fumihiko TANAKA ,  Yuki SUGA

IPC: D01F9/22 ,  D01F6/18

Abstract: Provided is a carbon fiber with a strand modulus of elasticity from 240 to 300 GPa, an elongation of 2.65% or more, and a strain energy density of 95 J/mm3 or more, which can improve the impact resistance of carbon fiber composite materials.

公开(公告)号：US20240133081A1

公开(公告)日：2024-04-25

申请号：US18573812

申请日：2022-07-19

Applicant: TORAY INDUSTRIES, INC.

Inventor： Kiminori ONO ,  Yuki SADO ,  Fumihiko TANAKA ,  Masahiro MATSUMOTO

IPC: D01F9/22

CPC classification number: D01F9/22 ,  D10B2101/12

Abstract: To provide a carbon fiber bundle capable of suppressing winding due to ring-shaped fuzzes, which occurs when the carbon fiber bundle is rolled out for advanced processing, and a production method for producing the same. Disclosed is a carbon fiber bundle wherein an average single-fiber diameter B is 6.9 to 11.0 μm, a tensile modulus E of resin-impregnated strands is 230 to 310 GPa, the number of fuzzes inherent in the carbon fiber bundle is 40 fuzzes/m or less, and a proportion of fuzzes with a structure having a difference between skin and core is 1 to 25% of fuzzes inherent in the carbon fiber bundle. Such a carbon fiber bundle is preferably obtained by a method including, in a process of heat-treating a polyacrylonitrile-based precursor fiber bundle with a single-fiber fineness of 0.9 to 2.2 dtex in an oxidizing atmosphere at 200 to 300° C., heat-treating the polyacrylonitrile-based precursor fiber bundle so that a heat generation rate Q, which is the left side of the formula (3), is 150 to 500 J/m2/s until the density is 1.22 to 1.24 g/cm3, when q (J/g/s) is the heat generation rate of the single fiber, N is the number of filaments, d (dtex) is a single-fiber fineness of the stabilized fiber bundle and W (mm) is a yarn width, heat-treating the fiber bundle while applying a tension of 1.6 to 4.0 mN/dtex until the density is 1.38 to 1.50 g/cm3 to obtain a stabilized fiber bundle, and heat-treating the stabilized fiber bundle in an inert atmosphere at 1,200 to 1,600° C.


Q=q×N×d/W/10  (3)

公开(公告)号：US20220282058A1

公开(公告)日：2022-09-08

申请号：US17637912

申请日：2020-08-27

Applicant: TORAY INDUSTRIES, INC.

Inventor： Haruki OKUDA ,  Fumihiko TANAKA ,  Jun WATANABE

IPC: C08K3/04 ,  C08K7/06

Abstract: Provided is a resin composition including carbon fibers and a thermoplastic resin, in which the carbon fibers have a tensile elastic modulus E of 350 to 500 GPa, and the tensile elastic modulus E (GPa) and a loop fracture load A (N) satisfy the relationship of A≥−0.0017×E+1.02. This resin composition not only has a high moldability into a member of a complex shape by injection molding, but also can yield a molded article having excellent flexural modulus and excellent impact characteristics.