Jump to main content

Jump to global navigation

Jump to local navigation

Jump to header utility

Jump to footer

HOME > Research and Development > R&D Network > R&D Centers > Composite Materials Research Laboratories

R&D Network

  • Research and Development
  • R&D Philosophy
  • Technical Fields
  • Nanotechnology
  • Technology News
  • Articles
  • R&D Network
  • R&D Centers
  • Fibers & Textiles Research Laboratories
  • Films & Films Products Research Laboratories
  • Chemicals Research Laboratories
  • Composite Materials Research Laboratories
  • Electronic & Imaging Materials Research Laboratories
  • Global Environment Research Laboratories
  • Pharmaceutical Research Laboratories
  • New Frontiers Research Laboratories
  • Specialty Materials Research Laboratories
  • Engineering Division
  • Technology Development Division
  • Technical Departments of the Manufacturing Division
  • Cross-Sector Collaboration Among Industry, Government and Academia
  • Research Fellows and Engineering Fellows
  • Commercialization Promotion Scheme
  • Results of R&D Efforts
  • Milestones in R&D

R&D Centers

Composite Materials Research Laboratories

The Laboratories dated from 1990, unifying the Ehime Research Laboratory of the Fibers & Textiles Research Laboratories and the Composite Research Laboratory of the Polymer Research Laboratories. Research targets the carbon fiber Torayca*, matrix resins and other composite materials, fabric, prepreg and other intermediate materials, composite materials processing, designing and analysis.

The Composite Materials Research Laboratories advances integrated research from acrylic fiber as the precursor of Torayca* carbon fiber through the carbonization used in final production. Control of the carbon crystallization structure design inside the fiber, fiber surface modification and other know-how enabled marketing of Torayca* T1000, a carbon fiber with the world's greatest tensile strength, and Torayca* M70J noted for ultra-high tensile modulus. The Laboratories also developed the Torayca* T800S high compression intermediate modulus carbon fiber adopted as the primary structural material in the Airbus A380 aircraft, scheduled to be in service in 2006.

For matrix resins, the Laboratories applied thermoplastic particles to toughen interlayer domain with a technology to suppress crack propagation when materials fracture and improve composite impact resistance. This was adopted in the Torayca* T800H/3900-2 high-toughness composite materials. T800H/3900-2 was qualified as the first composite materials for primary structures of Boeing's civil transport and applied to its 777 aircraft. Years since have witnessed a steady stream of expanding applications, such as the 2004 contract for exclusive supply of Torayca* prepreg for the Boeing 787 next generation medium-size aircraft.
In athletics, the Torayca* prepreg Tufbeam*, with highly toughened resin for super-high impact resistance, is a key for lightweight golf club shafts.

The Torayca* flat yarn woven fabric, utilizing technology that pulls carbon fibers into a tape-like configuration for weaving, is used as an reinforcing material for retrofitting of bridge piers and aircraft.

For composite production, the Laboratories has developed technologies that produce carbon fiber reinforced plastics in combination with filament type materials and long carbon fiber pellet on thermoplastic resin for injection molding.

For advanced application of carbon fiber reinforced composite materials in automobile structural parts, the Laboratories advances research within “Innovative Technological Program Against Global Warming” — a national project running from 2003 to 2007.

In addition to aerospace, sports and other fields, the Composite Materials Research Laboratories targets progress in energy and other crucial domains from here on. This facility carries on the mission to expand Toray exploits in the composite materials business, promoting research to further the evolution and fusion of base materials, intermediate materials and fabrication technologies.

Milestones in Toray R&D

1971 Commenced production of TORAYCA* carbon fiber.
1986 Developed carbon fiber-yarn TORAYCA* T1000 with the tensile strength of 7GPa.
1992 Commenced production of TORAYCA* carbon fiber prepreg T800H/3900-2 for use as primary structural material in civil aircraft.
1996 Commenced production of carbon-fiber-reinforced PC chassis with superior electromagnetic wave shielding properties.
2000 Developed impact energy-absorbent CFRP for automotive materials.
2003 Developed super-lightweight and high rigid PC chassis.
2004 Reached comprehensive agreement to supply carbon fiber prepreg (T800S/3900-2) for Boeing's B787 through 2021.
2005 Started production of CFRP for ultra-lightweight and high strength laptop PC chassis.

PAGETOP