# US 10,309,045 B2 · Fiber-reinforced resin forming material and method of producing same

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- Number: US 10,309,045 B2
- Document ID: US10309045B2
- Status: Granted
- Kind: B2
- Application number: 15/562,510
- Filed: 2016-03-17
- Published: 2018-04-05
- Granted: 2019-06-04
- Earliest claimed: 2015-03-30
- Assignees: Toray Industries, Inc.
- Applicants: Toray Industries, Inc.
- Inventors: Kenta Bamba; Tetsuya Motohashi; Katsuhiro Miyoshi; Takafumi Hashimoto
- Web page: https://patentgrep.com/patent/US10309045B2

## CPC

- D04H 1/4242: Carbon fibres
- C08J 5/042: {with carbon fibres}
- C08J 5/06: using pretreated fibrous materials
- C08K 3/013: Fillers, pigments or reinforcing additives
- C08K 3/046: {Carbon nanorods, nanowires, nanoplatelets or nanofibres}
- C08J 2300/22: Thermoplastic resins
- C08J 2300/24: Thermosetting resins
- C08J 2363/10: Epoxy resins modified by unsaturated compounds
- D04H: MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL (weaving D03; knitting D04B; braiding D04C; net-making D04G; sewing D05B; tufting D05C; finishing non-woven fabrics D06); FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING {; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION}(non-woven fabrics having an intermediate or external layer of a different kind, e.g. of woven fabric, B32B)
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09)

## Abstract

A fiber-reinforced resin forming material contains at least a matrix resin and bundled aggregates of discontinuous reinforcing fibers, wherein: the bundled aggregates include both reinforcing fiber aggregates A having a shape formed by cutting after having performed a splitting treatment to completely split the strands of continuous reinforcing fibers into a plurality of bundles of strands, and reinforcing fiber aggregates B1 having a shape that includes unsplit parts where splitting treatment was inadequate and/or reinforcing fiber aggregates B2 having a shape not subjected to splitting treatment; and both the ratio of the weight of the reinforcing fiber aggregates B1 with respect to the total weight of reinforcing fibers in the fiber-reinforced resin forming material, and the ratio of the total weight of the reinforcing fiber aggregates B1 and the reinforcing fiber aggregates B2 with respect to the total weight of reinforcing fibers in the fiber-reinforced resin forming material, are 50-95%.

## Claims

### Claim 1

A fiber-reinforced resin forming material containing at least a bundled aggregate of discontinuous reinforcing fibers and a matrix resin, wherein
the bundled aggregate of reinforcing fibers includes both a reinforcing fiber aggregate A formed by cutting a strand of continuous reinforcing fibers after a splitting treatment is performed to completely split the strand into a plurality of bundles, and
a reinforcing fiber aggregate B1 having a shape of an unsplit part to which the splitting treatment is not complete and/or
a reinforcing fiber aggregate B2 having a shape to which the splitting treatment is not performed, wherein
both a ratio (i) of weight of the reinforcing fiber aggregate B1 with respect to a total weight of reinforcing fibers in the fiber-reinforced resin forming material, and a ratio (ii) of a total weight of the reinforcing fiber aggregate B1 and the reinforcing fiber aggregate B2 with respect to the total weight of reinforcing fibers in the fiber-reinforced resin forming material, are 50 to 95%, and
a ratio of the weight of the reinforcing fiber aggregate B1 with respect to the total weight of the reinforcing fiber aggregate B1 and the reinforcing fiber aggregate B2 is more than 4%.

### Claim 2 (depends on 1)

The fiber-reinforced resin forming material according to claim 1, wherein the reinforcing fiber aggregate A, the reinforcing fiber aggregate B1 and the reinforcing fiber aggregate B2 have an average fiber length of 5 to 100 mm.

### Claim 3 (depends on 1)

The fiber-reinforced resin forming material according to claim 1, wherein the reinforcing fiber aggregate A has a number of single yarns of 800 to 10,000 pieces.

### Claim 4 (depends on 1)

The fiber-reinforced resin forming material according to claim 1, wherein the reinforcing fiber comprises a carbon fiber.

### Claim 5 (depends on 1)

The fiber-reinforced resin forming material according to claim 1, wherein the matrix resin comprises a thermosetting resin or a thermoplastic resin.