Patents by Inventor Takuya Karaki

Takuya Karaki 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: 11951695
    Abstract: Provided are methods for producing a fiber-reinforced plastic having high mechanical properties and high productivity during molding of a complicated shape. In one aspect, the method produces a fiber-reinforced plastic using a tape substrate A and a sheet substrate B, the tape substrate A being a tape-shaped substrate including one or more sheets of incised prepreg a; the incised prepreg a being a prepreg including unidirectionally oriented reinforcing fibers and a resin and having a plurality of incisions dividing the reinforcing fibers formed in the prepreg, and satisfying the following condition 1; the sheet substrate B being a substrate including randomly oriented reinforcing fibers and a resin.
    Type: Grant
    Filed: January 19, 2018
    Date of Patent: April 9, 2024
    Assignee: Toray Industries, Inc.
    Inventors: Yuzo Fujita, Kentaro Adachi, Takuya Karaki
  • Patent number: 11926129
    Abstract: A prepreg laminate is provided which includes: a woven fabric prepreg on at least one surface layer; and a discontinuous fiber prepreg; the woven fabric prepreg including reinforcing fibers R1 having a woven structure, and a thermosetting resin A, the discontinuous fiber prepreg including unidirectionally oriented discontinuous reinforcing fibers R2 and a thermosetting resin B, the thermosetting resin A and the thermosetting resin B satisfying the following calorific value condition: calorific value condition: when each of the thermosetting resin A and the thermosetting resin B is heated using a differential scanning calorimeter from 50° C. to 130° C. at 700° C./min under a nitrogen atmosphere followed by retention at 130° C.
    Type: Grant
    Filed: July 3, 2018
    Date of Patent: March 12, 2024
    Assignee: Toray Industries, Inc.
    Inventors: Kentaro Adachi, Yuzo Fujita, Takuya Karaki
  • Patent number: 11926111
    Abstract: Provided is a method for manufacturing a fiber-reinforced plastic composite containing a fiber-reinforced plastic part having a plate-like portion and a rib protruding from one surface of the plate-like portion, and a metal part, having an average thickness of 0.5-3.0 mm, laminated on part of or all of the plate-like portion of the fiber-reinforced plastic part, comprising: a lamination step for stacking a plurality of incised prepreg layers as a plurality of sheets of base material to form a base laminate, each prepreg layer containing unidirectionally oriented fibers and resin, and a plurality of incisions crossing the fibers, a base material heating step for heating the base laminate, and a molding step for integrating the base laminate and the metal part by pressing them between a rib molding member having a recessed portion for forming a rib and a skin molding member free of such a recessed portion in a pressing device.
    Type: Grant
    Filed: October 17, 2018
    Date of Patent: March 12, 2024
    Assignee: Toray Industries, Inc.
    Inventors: Yuzo Fujita, Takuya Karaki, Kentaro Adachi
  • Patent number: 11872773
    Abstract: Provided is a method for producing a fiber-reinforced plastic having high mechanical properties and high productivity during molding of a complicated shape.
    Type: Grant
    Filed: January 19, 2018
    Date of Patent: January 16, 2024
    Assignee: Toray Industries, Inc.
    Inventors: Kentaro Adachi, Yuzo Fujita, Takuya Karaki
  • Patent number: 11600975
    Abstract: A wire harness routing method is provided. A wire harness is routed on a protector base. A protective tape is wound around an outer periphery of the wire harness at a position outside an end portion of the protector base in a longitudinal direction. A cover is put on the protector base under the above state. The wire harness is fixed to, by winding a binding band at a position where the tape is wound, a wire harness-fixed protruding piece protruding outward in the longitudinal direction from an end portion of the cover in the longitudinal direction.
    Type: Grant
    Filed: January 10, 2022
    Date of Patent: March 7, 2023
    Assignee: YAZAKI CORPORATION
    Inventors: Tatsuya Tokuda, Takuya Karaki
  • Patent number: 11413788
    Abstract: Provided is an intermediate base material (incised prepreg) which has exceptional surface quality and mechanical properties when solidified and with which it is possible to obtain a fiber-reinforced plastic having excellent three-dimensional shape conformance properties. This incised prepreg has, in a prepreg that includes a resin and reinforcing fibers oriented in one direction, incisions substantially parallel to the orientation direction of the reinforcing fibers (the incisions substantially parallel to the orientation direction of the reinforcing fibers are referred to as parallel incisions) and incisions that cut across the reinforcing fibers (the incisions that cut across the reinforcing fibers are referred to as intersecting incisions).
    Type: Grant
    Filed: August 7, 2017
    Date of Patent: August 16, 2022
    Assignee: Toray Industries, Inc.
    Inventors: Terumasa Tsuda, Kentaro Adachi, Yuzo Fujita, Takuya Karaki
  • Publication number: 20220224089
    Abstract: A wire harness routing method is provided. A wire harness is routed on a protector base. A protective tape is wound around an outer periphery of the wire harness at a position outside an end portion of the protector base in a longitudinal direction. A cover is put on the protector base under the above state. The wire harness is fixed to, by winding a binding band at a position where the tape is wound, a wire harness-fixed protruding piece protruding outward in the longitudinal direction from an end portion of the cover in the longitudinal direction.
    Type: Application
    Filed: January 10, 2022
    Publication date: July 14, 2022
    Inventors: Tatsuya Tokuda, Takuya Karaki
  • Publication number: 20210217058
    Abstract: An advertisement presentation system includes an output device provided on a mobile object, an information processing device, and a management device. The management device obtains advertisement information to be generated from the output device of the mobile object scheduled to travel via a particular location, based on related information in which attribute information of people and location information at which the people having the attributes are present are related to each other in advance, and sends the advertisement information to the information processing device. The information processing device receives the advertisement information from the management device, and outputs the advertisement information to the output device, when the mobile object is present at the particular location.
    Type: Application
    Filed: January 12, 2021
    Publication date: July 15, 2021
    Inventors: Toshihiro NAKAICHI, Hideyuki SAKURAI, Masaya MIURA, Kazuki OHTAKE, Takuya KARAKI
  • Publication number: 20210213691
    Abstract: Provided is a method for manufacturing a fiber-reinforced plastic composite containing a fiber-reinforced plastic part having a plate-like portion and a rib protruding from one surface of the plate-like portion, and a metal part, having an average thickness of 0.5-3.0 mm, laminated on part of or all of the plate-like portion of the fiber-reinforced plastic part, comprising: a lamination step for stacking a plurality of incised prepreg layers as a plurality of sheets of base material to form a base laminate, each prepreg layer containing unidirectionally oriented fibers and resin, and a plurality of incisions crossing the fibers, a base material heating step for heating the base laminate, and a molding step for integrating the base laminate and the metal part by pressing them between a rib molding member having a recessed portion for forming a rib and a skin molding member free of such a recessed portion in a pressing device.
    Type: Application
    Filed: October 17, 2018
    Publication date: July 15, 2021
    Applicant: Toray Industries, Inc.
    Inventors: Yuzo Fujita, Takuya Karaki, Kentaro Adachi
  • Patent number: 11053363
    Abstract: A random mat material including fiber bundles, said fiber bundles including fibers having an average fiber length of 5 to 100 mm, and having an average number N of fibers in the fiber bundle that satisfies: 1.5 × 10 5 D 2 < N < 4.5 × 10 5 D 2 wherein D is the average diameter of fibers in the fiber bundle, expressed in micrometers, and the standard deviation SDN of the number of fibers in a fiber bundle satisfies: 1,000<SDN<6,000 wherein at an end of the fiber bundle, the number of the fibers in a fiber bundle becomes less from center to edge of the fiber bundle in a fiber direction.
    Type: Grant
    Filed: July 12, 2017
    Date of Patent: July 6, 2021
    Assignee: Toray Industries, Inc.
    Inventors: Maurice Geli, Yann Buzare, Takuya Karaki, Ichiro Taketa
  • Publication number: 20210122136
    Abstract: A prepreg laminate is provided which includes: a woven fabric prepreg on at least one surface layer; and a discontinuous fiber prepreg; the woven fabric prepreg including reinforcing fibers R1 having a woven structure, and a thermosetting resin A, the discontinuous fiber prepreg including unidirectionally oriented discontinuous reinforcing fibers R2 and a thermosetting resin B, the thermosetting resin A and the thermosetting resin B satisfying the following calorific value condition: calorific value condition: when each of the thermosetting resin A and the thermosetting resin B is heated using a differential scanning calorimeter from 50° C. to 130° C. at 700° C./min under a nitrogen atmosphere followed by retention at 130° C.
    Type: Application
    Filed: July 3, 2018
    Publication date: April 29, 2021
    Applicant: Toray Industries, Inc.
    Inventors: Kentaro Adachi, Yuzo Fujita, Takuya Karaki
  • Publication number: 20200247071
    Abstract: Provided is a method for producing a fiber-reinforced plastic having high mechanical properties and high productivity during molding of a complicated shape.
    Type: Application
    Filed: January 19, 2018
    Publication date: August 6, 2020
    Applicant: Toray Industries, Inc.
    Inventors: Kentaro Adachi, Yuzo Fujita, Takuya Karaki
  • Publication number: 20200001550
    Abstract: Provided are methods for producing a fiber-reinforced plastic having high mechanical properties and high productivity during molding of a complicated shape. In one aspect, the method produces a fiber-reinforced plastic using a tape substrate A and a sheet substrate B, the tape substrate A being a tape-shaped substrate including one or more sheets of incised prepreg a; the incised prepreg a being a prepreg including unidirectionally oriented reinforcing fibers and a resin and having a plurality of incisions dividing the reinforcing fibers formed in the prepreg, and satisfying the following condition 1; the sheet substrate B being a substrate including randomly oriented reinforcing fibers and a resin.
    Type: Application
    Filed: January 19, 2018
    Publication date: January 2, 2020
    Applicant: Toray Industries, Inc.
    Inventors: Yuzo Fujita, Kentaro Adachi, Takuya Karaki
  • Publication number: 20190256673
    Abstract: A random mat material including fiber bundles, said fiber bundles including fibers having an average fiber length of 5 to 100 mm, and having an average number N of fibers in the fiber bundle that satisfies: 1.5 × 10 5 D 2 < N < 4.5 × 10 5 D 2 wherein D is the average diameter of fibers in the fiber bundle, expressed in micrometers, and the standard deviation SDN of the number of fibers in a fiber bundle satisfies: 1,000<SDN<6,000 wherein at an end of the fiber bundle, the number of the fibers in a fiber bundle becomes less from center to edge of the fiber bundle in a fiber direction.
    Type: Application
    Filed: July 12, 2017
    Publication date: August 22, 2019
    Inventors: Maurice Geli, Yann Buzare, Takuya Karaki, Ichiro Taketa
  • Publication number: 20190232528
    Abstract: Provided is an intermediate base material (incised prepreg) which has exceptional surface quality and mechanical properties when solidified and with which it is possible to obtain a fiber-reinforced plastic having excellent three-dimensional shape conformance properties. This incised prepreg has, in a prepreg that includes a resin and reinforcing fibers oriented in one direction, incisions substantially parallel to the orientation direction of the reinforcing fibers (the incisions substantially parallel to the orientation direction of the reinforcing fibers are referred to as parallel incisions) and incisions that cut across the reinforcing fibers (the incisions that cut across the reinforcing fibers are referred to as intersecting incisions).
    Type: Application
    Filed: August 7, 2017
    Publication date: August 1, 2019
    Applicant: Toray Industries, Inc.
    Inventors: Terumasa Tsuda, Kentaro Adachi, Yuzo Fujita, Takuya Karaki
  • Publication number: 20190210301
    Abstract: A prepreg, including: a fiber layer containing unidirectionally arranged discontinuous carbon fibers and a thermosetting resin; and a resin layer existing on at least one side of said fiber layer and containing a thermosetting resin and a thermoplastic resin; in which said prepreg contains carbon fibers having an areal weight of fibers of 120 to 300 g/m2, and has a mass fraction of resin of 25 to 50% with respect to the whole mass of said prepreg; and in which a temperature at which a coefficient of interlayer friction is 0.05 or less is in a temperature range of from 40 to 80° C., the interlayer friction being caused at the contact interface between layers of said prepreg when the middle one of three layers that are each made of said prepreg and laid up is pulled out, said coefficient of interlayer friction being measured at 10° C. intervals in a temperature range of from 40 to 80° C. under conditions including a pulling speed of 0.2 mm/min, a perpendicular stress of 0.08 MPa, and a pulling length of 1 mm.
    Type: Application
    Filed: June 23, 2017
    Publication date: July 11, 2019
    Applicant: Toray Industries, Inc.
    Inventors: Yuta Naito, Shiori Kawamoto, Narumichi Sato, Ichiro Taketa, Yuzo Fujita, Takuya Karaki
  • Patent number: 7458450
    Abstract: This invention is an impact energy absorption device, in which a long part (1) made of a high strength material is disposed with its lengthwise direction kept different from an impact direction, and both terminals of the long part (1) are connected with columns (2) through upper platens (3) covering the upper faces of the columns (2) kept standing apart from each other with a predetermined distance (L), comprising a structural system, in which a deformation of the long part (1) caused by the impact force applied to it, causes the upper platens (3) to move for compressing or deflecting the columns (2), thereby absorbing the impact energy. The conventional column type energy absorption member is weak against an impact applied in a direction within a wide angle (?) such as an impact applied in an oblique direction.
    Type: Grant
    Filed: December 17, 2001
    Date of Patent: December 2, 2008
    Assignee: Toray Industries, Inc.
    Inventors: Takuya Karaki, Akihiko Kitano, Shoji Murai
  • Publication number: 20040056469
    Abstract: This invention is an impact energy absorption device, in which a long part (1) made of a high strength material is disposed with its lengthwise direction kept different from an impact direction, and both terminals of the long part (1) are connected with columns (2) through upper platens (3) covering the upper faces of the columns (2) kept standing apart from each other with a predetermined distance (L), comprising a structural system, in which a deformation of the long part (1) caused by the impact force applied to it, causes the upper platens (3) to move for compressing or deflecting the columns (2), thereby absorbing the impact energy.
    Type: Application
    Filed: June 18, 2003
    Publication date: March 25, 2004
    Inventors: Takuya Karaki, Akihiko Kitano, Shoji Murai
  • Patent number: 6591949
    Abstract: The present invention is an impact energy absorption member that is characterized by comprising a long member of fiber reinforced resin having a lengthwise direction and a thickness direction, wherein the ratio of the thickness t (mm) of the long member to the length L (mm) thereof is within the range of 1/11000 to 6/1000 as well as the direction of an external force is substantially in agreement with the thickness direction of the impact member. The member of the present invention sufficiently absorbs impact energy from a moving body when collision occurs and greatly increases safety to collision of transportation equipment, for example, a motor car and the like as well as is light in weight and compact, whereby the member can improve resistance against environment and saves energy. Further, when this member is applied to a house and a building against which the transportation equipment may collide, it can reduce the loss of social properties.
    Type: Grant
    Filed: October 15, 2001
    Date of Patent: July 15, 2003
    Assignee: Toray Industries, Inc.
    Inventors: Akihiko Kitano, Tomoyuki Shinoda, Hitoshi Nishiyama, Takuya Karaki
  • Publication number: 20020179390
    Abstract: The present invention is an impact energy absorption member that is characterized by comprising a long member of fiber reinforced resin having a lengthwise direction and a thickness direction, wherein the ratio of the thickness t (mm) of the long member to the length L (mm) thereof is within the range of 1/11000 to 6/1000 as well as the direction of an external force is substantially in agreement with the thickness direction of the impact member. The member of the present invention sufficiently absorbs impact energy from a moving body when collision occurs and greatly increases safety to collision of transportation equipment, for example, a motor car and the like as well as is light in weight and compact, whereby the member can improve resistance against environment and saves energy. Further, when this member is applied to a house and a building against which the transportation equipment may collide, it can reduce the loss of social properties.
    Type: Application
    Filed: October 15, 2001
    Publication date: December 5, 2002
    Inventors: Akihiko Kitano, Tomoyuki Shinoda, Hitoshi Nishiyama, Takuya Karaki