Patents Assigned to K-Plasheet Corporation
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Patent number: 11920015Abstract: To provide an expansion molded product not only excellent in sound absorption properties and rigidity but also resistant to tearing after bending deformation, and a web and a stampable sheet suitable for producing the expansion molded product. The presently disclosed web, stampable sheet, and expansion molded product contain a reinforcing fiber containing an inorganic fiber and an organic fiber, a thermoplastic resin, and a thermal expandable particle, where the proportion of the reinforcing fiber is 20 mass % or more and 55 mass % or less based on a total amount of the reinforcing fiber and the thermoplastic resin, the proportion of the organic fiber is 25 mass % or more and 77 mass % or less based on a total amount of the organic and inorganic fibers, the reinforcing fiber has an average length of 8 mm or more, and the organic fiber has a breaking elongation of 15% or more.Type: GrantFiled: December 5, 2019Date of Patent: March 5, 2024Assignees: K-PLASHEET CORPORATION, TOYOTA BOSHOKU KABUSHIKI KAISHAInventors: Yutaka Araki, Seiji Hanatani, Tadaaki Yasumi, Tsutomu Takagi, Atsuhiro Hattori
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Patent number: 11511683Abstract: The vehicle headliner includes a base layer, a skin layer disposed on one side of the base layer, and an infrared reflecting layer and a protection layer, in this order, disposed on the other side of the base layer. The base layer contains thermoplastic resin and fiber. The protection layer is a non-stretched resin layer containing a thermoplastic resin having a melting point of 200° C. or more.Type: GrantFiled: October 10, 2018Date of Patent: November 29, 2022Assignees: TOYOTA BOSHOKU KABUSHIKI KAISHA, K-PLASHEET CORPORATIONInventors: Takayuki Kumamoto, Tsutomu Takagi, Atsuhiro Hattori
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Publication number: 20200407527Abstract: To provide an expansion molded product not only excellent in sound absorption properties and rigidity but also resistant to tearing after bending deformation, and a web and a stampable sheet suitable for producing the expansion molded product. The presently disclosed web, stampable sheet, and expansion molded product contain a reinforcing fiber containing an inorganic fiber and an organic fiber, a thermoplastic resin, and a thermal expandable particle, where the proportion of the reinforcing fiber is 20 mass % or more and 55 mass % or less based on a total amount of the reinforcing fiber and the thermoplastic resin, the proportion of the organic fiber is 25 mass % or more and 77 mass % or less based on a total amount of the organic and inorganic fibers, the reinforcing fiber has an average length of 8 mm or more, and the organic fiber has a breaking elongation of 15% or more.Type: ApplicationFiled: December 5, 2019Publication date: December 31, 2020Applicants: K-PLASHEET CORPORATION, TOYOTA BOSHOKU KABUSHIKI KAISHAInventors: Yutaka ARAKI, Seiji HANATANI, Tadaaki YASUMI, Tsutomu TAKAGI, Atsuhiro HATTORI
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Patent number: 8815056Abstract: Web containing a thermoplastic resin, reinforcing fibers and thermal expandable particles dispersed therein. The thermoplastic resin and the reinforcing fibers are uniformly dispersed in a thickness direction and the thermal expandable particles are eccentrically located toward one-side surface of the web, wherein opposite sides of the web have substantially different specific gravity and density.Type: GrantFiled: July 2, 2013Date of Patent: August 26, 2014Assignee: K-Plasheet CorporationInventors: Yutaka Araki, Seiji Hanatani
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Patent number: 8491754Abstract: There is disclosed an expansion molded product, and a web and stampable sheet suitable for use in the production thereof as well as a method of producing the same. A disclosed method of producing a web, stampable sheet and expansion molded product of a stampable sheet comprises uniformly dispersing reinforcing fibers, thermoplastic resin and thermal expandable particles in an aqueous medium containing a surfactant with fine foams to prepare a foamy solution, filtering the foamy solution to form a web, heating pressing and cooling the web to form a stampable sheet, heating the stampable sheet to expand the thermal expandable particles, and shaping and cooling the stampable sheet, wherein the expanded thermal expandable particles are eccentrically located toward one-side surface of the expansion molded product of the stampable sheet by removing foams by suction during the filtering and eccentrically locating the thermal expandable particles toward one-side surface of the web.Type: GrantFiled: June 7, 2006Date of Patent: July 23, 2013Assignee: K-Plasheet CorporationInventors: Yutaka Araki, Seiji Hanatani
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Publication number: 20130095277Abstract: The present plate-like fiber base material has fibers and a thermoplastic resin. The fibers are bound by the thermoplastic resin, and the fiber base material includes a plurality of areas that differ in basis weight. The fiber base material may have a cut, and the basis weight of a cut-surrounding area positioned around the cut may be higher than that of an area positioned around the cut-surrounding area. The present interior material has the fiber base material and a surface layer that is disposed on one side of the fiber base material.Type: ApplicationFiled: October 5, 2012Publication date: April 18, 2013Applicants: K-PLASHEET CORPORATION, TOYOTA BOSHOKU KABUSHIKI KAISHAInventors: Toyota Boshoku Kabushiki Kaisha, K-Plasheet Corporation
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Publication number: 20090223644Abstract: There are proposed an expansion molded product used as an internal material, engine cover or the like of an automobile but also a sound absorbing material, sound absorbing wall or the like in the building field and being light in the weight and excellent in not only sound absorbing property but also the surface property and mechanical strength, a web and a stampable sheet suitable for use in the production thereof as well as a method of producing the same.Type: ApplicationFiled: June 7, 2006Publication date: September 10, 2009Applicant: K-PLASHEET CORPORATIONInventors: Yutaka Araki, Seiji Hanatani
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Patent number: 6756099Abstract: This invention provides a laminated resin material comprising (1) a fiber reinforced thermoplastic resin layer made by a dispersion method, (2) a gas impermeable resin layer on the fiber reinforced thermoplastic resin layer, and (3) an adhesive resin layer having a melt viscosity of not more than 5000 Pa.s under a shear rate of 10 s−1 at 150° C. and not more than 250 Pa.s under a shear rate of 2000 s−1 at 150° C. on the gas impermeable resin layer. Among them, a laminated resin material in which the fiber reinforced thermoplastic resin layer made by the dispersion method is an expansion molded stampable sheet and which has a skin material further on the adhesive resin layer is a material excellent in both of the characteristics of adhesion and rigidity and suitable as automotive interior materials.Type: GrantFiled: January 14, 2003Date of Patent: June 29, 2004Assignees: JFE Steel Corporation, K-Plasheet CorporationInventors: Yutaka Araki, Shigeru Takano, Yukio Nagashima
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Patent number: 5981046Abstract: A sound absorbing component contains a fiber-reinforced thermoplastic resin expanded body having a percentage of void being not less than 50 vol %, and a resin molded body. An air layer is provided between the fiber-reinforced thermoplastic resin expanded body and the resin molded body. This sound absorbing component can effectively absorb the sound especially in the frequency region of 500 to 3000 Hz corresponding to the exterior noise problematic in automobiles, even if it is lightweight and thin.Type: GrantFiled: November 12, 1996Date of Patent: November 9, 1999Assignees: Sumitomo Chemical Company, Limited, Kawasaki Steel Corporation, K-Plasheet CorporationInventors: Syohei Masui, Satoru Funakoshi, Taiji Matsumoto, Katsuhiro Nagayama, Masami Fujimaki, Hiroyuki Yoshitake, Mituaki Sunada
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Patent number: 5854149Abstract: As a paper-made stampable sheet having a high rigidity and, if necessary, improved adhesiveness and non-permeability and a light weight stampable sheet shaped body made from this sheet and a method of producing the same, there are proposed a paper-made stampable sheet obtained by paper-making a mixture of thermoplastic resin and reinforcing fibers to obtain a sheet-like web, piling a thermoplastic resin film of a single layer or multi layer or an organic fiber nonwoven fabric having at least one excellent property selected from rigidity, non-permeability and adhesiveness on at least one-side surface of the sheet-like web in accordance with use purpose, compressing them under heating above a melting point of the thermoplastic resin constituting the web, cooling and solidifying at a compressed state as well as a light weight stampable sheet shaped body made from this sheet and a method of producing the same.Type: GrantFiled: November 15, 1996Date of Patent: December 29, 1998Assignees: Kawasaki Steel Corporation Sumitomo Chemical Co., Ltd., K-Plasheet CorporationInventors: Katsuhiro Nagayama, Masami Fujimaki, Shigeru Takano, Taiji Matsumoto, Tomoshige Ono, Yukio Nagashima, Syohei Masui, Satoru Funakoshi, Yuji Kobayashi, Hiroyuki Yoshitake, Mitsuaki Sunada