Patents by Inventor Masato Honma

Masato Honma has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 11312825
    Abstract: Provided is a structure having excellent flexibility represented by elastic restoring from compression or tensile elongation at break, and excellent lightness. A structure according to the present invention includes reinforced fibers, first plastic, and second plastic that exhibits rubber elasticity at room temperature, the reinforced fibers being discontinuous fibers, and the first plastic and/or the second plastic coating a crossing point between the reinforced fibers in contact with each other.
    Type: Grant
    Filed: December 20, 2017
    Date of Patent: April 26, 2022
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Yoshiki Takebe, Takashi Fujioka, Masato Honma
  • Patent number: 11225037
    Abstract: A production method for a fiber reinforced composite material includes heating a preform formed by laminating a prepreg layer (I) including a reinforcement fiber (A) and a thermosetting resin (B-1) with a resin layer (II) including a thermosetting resin (B-2) and a solid additive (C) to cure the thermosetting resin (B-1) and the thermosetting resin (B-2), the cured resin layer (II?) formed by curing the resin layer (II) having an average thickness of 35 ?m or more and 300 ?m or less.
    Type: Grant
    Filed: October 8, 2015
    Date of Patent: January 18, 2022
    Assignee: Toray Industries, Inc.
    Inventors: Tomohiro Takehara, Satoshi Seike, Masato Honma, Satomi Matsuo
  • Patent number: 11141893
    Abstract: In order to solve reduction in strength and rigidity at a weldline which is a problem of an injection molding body, and enable free design such as thin wall molding or complex shape molding of the injection molding body, there is provided an integrally molded body in which a substrate for reinforcement (a) having a discontinuous fiber (a1) and a resin (a2) and an injection molding body (b) having a discontinuous fiber (b1) and a resin (b2) are integrated, in which the substrate for reinforcement (a) has a difference in an orientation angle of the discontinuous fiber (a1) in each of regions obtained by dividing a major axis direction of the substrate for reinforcement (a) into 10 equal parts of within 10°, and the substrate for reinforcement (a) covers a part or all of a weldline of the injection molding body (b) to be integrated with the injection molding body (b).
    Type: Grant
    Filed: August 24, 2018
    Date of Patent: October 12, 2021
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Takafumi Suzuki, Yuichiro Sento, Naokichi Imai, Mitsushige Hamaguchi, Masato Honma
  • Publication number: 20210244118
    Abstract: In order to provide a layered article in which shape deformation is suppressed while exhibiting compression properties that are an index of impact absorption, and further, a layered article that can control feeling when receiving impact on demand, provided is a layered article including a porous structure material containing discontinuous reinforcing fibers (A), resin (B) and voids (C), and a skin layer formed on a surface of the porous structure material, in which the porous structure material has an elastic resilience from 50% compression of 1 MPa or more, and the layered article has a plastic deformation amount of 20 ?m or less in a falling-weight impact test performed on the surface on which the skin layer is formed.
    Type: Application
    Filed: June 4, 2019
    Publication date: August 12, 2021
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Takashi FUJIOKA, Kentaro ADACHI, Masato HONMA
  • Patent number: 11072098
    Abstract: A method for manufacturing a composite structure in which a first member and a structure material as a second member are integrated, the method including: an arrangement step of arranging a structure precursor including a resin and reinforced fibers in a mold made of the first member; a heating step of heating the structure precursor to equal to or higher than a temperature at which a storage elastic modulus (G?) of the structure precursor is less than 1.2×108 Pa; a shaping step of expanding the structure precursor by heating to form a structure material as a second member, and bringing the structure material into close contact with the first member to obtain a composite structure; and a cooling step of cooling the composite structure.
    Type: Grant
    Filed: December 20, 2017
    Date of Patent: July 27, 2021
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Takashi Fujioka, Yoshiki Takebe, Masato Honma
  • Patent number: 11034809
    Abstract: A resin supply material used for press molding or vacuum-pressure molding of a fiber-reinforced resin, the resin supply material including a continuous porous material and a thermosetting resin, wherein an average pore cross-sectional area ratio P expressed by formula (I) is 1.1 or more: P=AII/AI??(I) AI: average pore cross-sectional area in region I AII: average pore cross-sectional area in region II Region I: region occupying 10% of total volume of continuous porous material from surface layer on both surfaces thereof Region II: whole region of continuous porous material.
    Type: Grant
    Filed: February 24, 2016
    Date of Patent: June 15, 2021
    Assignee: Toray Industries, Inc.
    Inventors: Tomohiro Takehara, Satoshi Seike, Masato Honma, Naokichi Imai, Satomi Hiasa
  • Publication number: 20210154952
    Abstract: Provided is a molded article that has both a low specific gravity and high rigidity and further has suppressed wrinkles and scrapes, and a manufacturing method for the same.
    Type: Application
    Filed: March 25, 2019
    Publication date: May 27, 2021
    Applicant: Toray Industries, Inc.
    Inventors: Yoshiki Takebe, Kotaro Shinohara, Masato Honma
  • Patent number: 11001011
    Abstract: A method of producing a fiber reinforced composite material satisfies condition 1: a thermosetting resin base material (B) includes a thermosetting resin (a) and a nonwoven fabric-shaped base material (a thermosetting resin base material satisfying the condition 1 is referred to as a thermosetting resin base material (B-1)); and condition 2: the thermosetting resin base material (B) is a base material including the thermosetting resin (a), and a porous sheet-shaped base material (b) or a film-shaped base material (c), the thermosetting resin (a) has a viscosity of 1,000 Pa·s or more at 40° C., and the thermosetting resin (a) has a minimum viscosity of 10 Pa·s or less during heating from 30° C. at a temperature rise rate of 1.5° C./min (a thermosetting resin base material satisfying the condition 2 is referred to as a thermosetting resin base material (B-2)).
    Type: Grant
    Filed: February 14, 2017
    Date of Patent: May 11, 2021
    Assignee: Toray Industries, Inc.
    Inventors: Tomohiro Takehara, Masato Honma, Terry Sakurai Brown, Noriyuki Hirano
  • Patent number: 10994510
    Abstract: A composite structure includes a structure that contains first reinforced fibers and first resin and a laminate that is disposed on at least one surface of the structure and has a plurality of layers containing second reinforced fibers and second resin, with the structure and the laminate integrated, the first reinforced fibers being discontinuous fibers and having a thickness-wise average fiber orientation angle in a range of 5 to 60°, the second reinforced fibers being discontinuous fibers and having a thickness-wise average fiber orientation angle in a range of 0 to 5°, the structure having a density in a range of 0.01 to 1 g/cm3, the laminate having a variation in volume content of the second reinforced fibers in a range of 0 to 10%, and the composite structure having a protruding portion on a laminate's surface opposite from a laminate's surface in contact with the structure.
    Type: Grant
    Filed: December 20, 2017
    Date of Patent: May 4, 2021
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Yoshiki Takebe, Masato Honma
  • Publication number: 20210106293
    Abstract: An imaging table for a mammography apparatus is formed by a planar body and is to be supported in a cantilever state on a body of the mammography apparatus. At least an X-ray irradiation surface in the planar body has at least one of the following configurations (1) and (2): (1) the X-ray irradiation surface is formed by a carbon fiber composite material including a unidirectional carbon fiber composite material containing carbon fibers and a matrix resin, the carbon fibers being aligned in one direction; and (2) the X-ray irradiation surface is formed by a skin material and a resin sheet, the skin material including a carbon fiber composite material containing continuous fibers and a matrix resin, the resin sheet being disposed on an inner layer side from the skin material.
    Type: Application
    Filed: March 20, 2019
    Publication date: April 15, 2021
    Applicant: Toray Industries, Inc.
    Inventors: Tomohiro Takehara, Mitsushige Hamaguchi, Masato Honma
  • Patent number: 10947352
    Abstract: Provided is a mountain-shaped structure material being excellent in stiffness and lightness. The present invention is a structure material including a resin, reinforced fibers and voids. The structure material has a specific bending stiffness represented as Ec1/3·??1 being 2.5 or more where a bending modulus is Ec and a density is ?. The structure material has a mountain shape.
    Type: Grant
    Filed: December 20, 2017
    Date of Patent: March 16, 2021
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Takashi Fujioka, Yoshiki Takebe, Masato Honma
  • Publication number: 20210039291
    Abstract: A molded product having both small specific gravity and high stiffness and also suffering few sink marks is described along with a method for the production thereof, where the molded product includes a porous body (A) integrated with an injection molded body (B), the porous body (A) having an apparent density of 0.05 to 0.8 g/cm3, the average thickness (tA) of the porous body (A) and the average thickness (tB) of the injection molded body (B) satisfying the relation tA?3×tB, and the injection molded body (B) covering at least one face of the porous body (A).
    Type: Application
    Filed: March 28, 2019
    Publication date: February 11, 2021
    Applicant: Toray Industries, Inc.
    Inventors: Yoshiki Takebe, Masato Honma
  • Publication number: 20210030376
    Abstract: An imaging table to be supported in a cantilever state on an X-ray imaging apparatus, includes a planar body including an opening portion in a surface to be connected to the apparatus, and a coupling member to be connected to the apparatus. The planar body includes a first member forming a top surface including an X-ray irradiation surface, and a second member forming a bottom surface opposed to the X-ray irradiation surface and a standing wall portion erectly provided on an outer circumference of the bottom surface. The second member is bonded to the first member in the standing wall portion. The first member and the coupling member are bonded to each other. The first member has an aluminum-equivalent X-ray transmission dose of 0.5 mmAL or less at any point in the X-ray irradiation surface.
    Type: Application
    Filed: March 20, 2019
    Publication date: February 4, 2021
    Applicant: Toray Industries, Inc.
    Inventors: Tomohiro Takehara, Mitsushige Hamaguchi, Masato Honma
  • Patent number: 10908651
    Abstract: An electronic device housing includes: a bottom cover; a top cover; a partition structure that is disposed in a space divided by the bottom cover and the top cover and has an opening; and a heat generation member. The partition structure is joined to the bottom cover or the top cover to form a hollow structure, and the heat generation member is disposed on a surface of the partition structure on the hollow structure side.
    Type: Grant
    Filed: September 6, 2016
    Date of Patent: February 2, 2021
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Masato Honma, Yoshiki Takebe, Naokichi Imai, Takashi Fujioka
  • Publication number: 20210016549
    Abstract: A molded article includes a continuous porous body provided with a thin film layer, the continuous porous body having a void that is continuous in a thickness direction of the continuous porous body, the thin film layer including a solid additive and a resin. A permeation rate of water from a surface of the molded article on a side of the thin film layer is 10% or less.
    Type: Application
    Filed: March 28, 2019
    Publication date: January 21, 2021
    Applicant: Toray Industries, Inc.
    Inventors: Takashi Fujioka, Kotaro Shinohara, Masato Honma
  • Publication number: 20210016474
    Abstract: A method is described for manufacturing a molded product having a recessed/protruding part from a molded substrate (A) including reinforcing fibers and a matrix resin by press molding, the method comprising: a step (I) of placing the molded substrate (A) between molds including an upper mold and a lower mold and deforming the molded substrate (A) in an in-plane direction by heating and pressing the molds; and a step (II) of deforming the molded substrate (A) in an out-of-plane direction by depressurizing the molds subsequent to the step (I), wherein a deformation rate ratio T represented by the following formula (1) is within a range of 0.1 to 1: T=X/Z ??(1) where X and Z are as defined.
    Type: Application
    Filed: March 27, 2019
    Publication date: January 21, 2021
    Applicant: Toray Industries, Inc.
    Inventors: Kotaro Shinohara, Masato Honma, Yoshiki Takebe
  • Publication number: 20210009783
    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).
    Type: Application
    Filed: March 28, 2019
    Publication date: January 14, 2021
    Applicant: Toray Industries, Inc.
    Inventors: Takashi Fujioka, Kotaro Shinohara, Masato Honma
  • Publication number: 20210001536
    Abstract: Provided is a method for producing a molded article obtained by integrating a decoration layer onto a surface of a porous body including a reinforcing fiber. The method includes: a preheating process at which the decoration layer is preheated; and a shaping and integrating process at which the porous body is pressed to the decoration layer or the decoration layer is pressed to the porous body to shape the decoration layer, and the porous body and the decoration layer are integrated to each other.
    Type: Application
    Filed: March 28, 2019
    Publication date: January 7, 2021
    Applicant: Toray Industries, Inc.
    Inventors: Takashi Fujioka, Kotaro Shinohara, Masato Honma
  • Patent number: 10882224
    Abstract: A method for manufacturing a structure material is a method for manufacturing a structure material that includes a thermoplastic resin, reinforced fibers, and voids. The method includes: a first process for arranging a structure precursor comprising the thermoplastic resin and the reinforced fibers in a mold with a surface temperature of 80° C. or less; a second process for raising the surface temperature of the mold up to a temperature at which a storage elastic modulus (G?) of the structure precursor is less than 1.2×108 Pa; a third process for lowering the surface temperature of the mold down to a temperature at which the storage elastic modulus (G?) of the structure precursor is 1.2×108 Pa or more; and a fourth process for removing a structure material obtained after end of the third process from the mold.
    Type: Grant
    Filed: December 9, 2016
    Date of Patent: January 5, 2021
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Takashi Fujioka, Yoshiki Takebe, Masato Honma
  • Patent number: 10822463
    Abstract: A resin supply material is used for molding a fiber-reinforced resin and includes a continuous porous material and a resin. The continuous porous material has a bending resistance Grt of 10 mN·cm or more at 23° C., and a bending resistance ratio Gr of 0.7 or less, the bending resistance ratio Gr being expressed by the formula: Gr=Gmt/Grt Gmt: bending resistance of continuous porous material at 70° C.
    Type: Grant
    Filed: February 24, 2016
    Date of Patent: November 3, 2020
    Assignee: Toray Industries, Inc.
    Inventors: Tomohiro Takehara, Satoshi Seike, Masato Honma, Takashi Fujioka, Satomi Hiasa