# US 11,993,687 B2 · Method for manufacturing molded article and preform of molded article

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 11,993,687 B2
- Document ID: US11993687B2
- Status: Granted
- Kind: B2
- Application number: 16/980,634
- Filed: 2019-03-28
- Published: 2021-01-14
- Granted: 2024-05-28
- Earliest claimed: 2018-03-30
- Assignees: Toray Industries, Inc.
- Applicants: Toray Industries, Inc.
- Inventors: Takashi Fujioka; Kotaro Shinohara; Masato Honma
- Web page: https://patentgrep.com/patent/US11993687B2

## CPC

- C08J 5/042: {with carbon fibres}
- B29B 11/00: Making preforms (B29C61/06 takes precedence {; combined with blow-moulding B29C49/02, with thermoforming B29C51/02; making preforms for manufacturing of light guides B29D11/00721})
- B29C 44/06: Making multilayered articles {(B29C44/0407 - B29C44/0492 take precedence)}
- B29C 44/08: using several expanding {or moulding} steps
- B29C 70/0035: {comprising two or more matrix materials}
- B29C 70/086: {and with one or more layers of pure plastics material, e.g. foam layers (applying a non-preformed coating, e.g. a gel-coat, B29C37/0025; with foam blocks B29C70/86)}
- B29C 70/12: using fibres of short length, e.g. in the form of a mat {(non-woven fabrics per se D04H1/00)}
- B29C 70/42: for producing articles of definite length, i.e. discrete articles
- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 5/28: impregnated with or embedded in a plastic substance {(not used)}
- C08J 7/042: {with two or more layers, where at least one layer of a composition contains a polymer binder}
- C08J 7/043: Improving the adhesiveness of the coatings per se, e.g. forming primers (adhesives in the form of films or foils characterised by the primer layers between the polymer carriers and the adhesives C09J7/50)
- C08J 7/056: Forming hydrophilic coatings
- C08J 9/365: {Coating}
- C08J 2323/12: Polypropene
- C08J 2400/22: Thermoplastic resins
- C08J 2423/12: Polypropene
- C08J 2463/02: Polyglycidyl ethers of bis-phenols
- 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)
- B29B: PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM

## Abstract

Provided is a method for producing a molded article having a thin film layer (B) formed on a surface of a porous body (A). The method includes a process (I) and a process (II) described below in this order: process (I): forming the thin film layer (B) on a surface of a precursor (a) of the porous body (A) to obtain a preform, and process (II): expanding and molding the precursor (a) to the porous body (A).

## Claims

### Claim 1

A method for producing a molded article having a thin film layer (B) formed on a surface of a porous body (A), the method comprising a process (I) and a process (II) described below in this order:
process (I): forming the thin film layer (B) on a surface of a precursor (a) of the porous body (A) to obtain a preform, and
process (II): expanding and molding the precursor (a) to the porous body (A)
wherein in the preform obtained in the process (I), an adhesion property of the thin film (B) to the precursor (a) belongs to classes 0 to 3 in accordance with JIS K5600-5-6 (1999),
wherein in the process (I), the thin film layer (B) is formed on the surface of the precursor (a) by wet coating, and
wherein a content rate by volume of a void included in the precursor (a) is 10% or less by volume.

### Claim 2 (depends on 1)

The method for producing a molded article according to claim 1, wherein the thin film layer (B) is at least one of a primer layer, a coating film layer, and a waterproof layer.

### Claim 3 (depends on 1)

The method for producing a molded article according to claim 1, wherein the thin film layer (B) comprises an additive (B1) and a thermosetting resin (B2).

### Claim 4 (depends on 1)

The method for producing a molded article according to claim 1, wherein the thin film layer (B) comprises an additive (B1) and a thermoplastic resin (B3).

### Claim 5 (depends on 3)

The method for producing a molded article according to claim 3, wherein a maximum size of the additive (B1) is 200 μm or less.

### Claim 6 (depends on 1)

The method for producing a molded article according to claim 1, wherein a thickness of the thin film layer (B) is in a range of 10 to 500 μm.

### Claim 7 (depends on 1)

The method for producing a molded article according to claim 1, wherein a surface roughness Ra1 of the thin film layer (B) formed at the process (I) is 50 μm or less.

### Claim 8 (depends on 1)

The method for producing a molded article according to claim 1, wherein a surface roughness Ra2 of the thin film layer (B) after the process (II) is 100 μm or less.

### Claim 9 (depends on 1)

The method for producing a molded article according to claim 1, further comprising a process (III): changing a shape of the porous body (A) at the same time with the process (II) or after completion of the process (II).

### Claim 10 (depends on 1)

The method for producing a molded article according to claim 1, wherein a difference in expansion rates in a thickness direction of the porous body (A) is 300% or less.

### Claim 11 (depends on 1)

The method for producing a molded article according to claim 1, wherein the porous body (A) comprises a reinforcing fiber (A1), a resin (A2), and a void (A3).

### Claim 12 (depends on 1)

The method for producing a molded article according to claim 1, wherein the porous body (A) has a void (A3) that is continuous in a thickness direction of the porous body (A).

### Claim 13 (depends on 11)

The method for producing a molded article according to claim 11, wherein the porous body (A) expands by a restoring force of the reinforcing fiber (A1) at the process (II).