Patents by Inventor Alfred P. Haro
Alfred P. Haro 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).
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Publication number: 20240093003Abstract: This invention relates to a flame retardant fiber-reinforced composite material based on an epoxy resin composition which includes at least one epoxy resin having an epoxy functionality of at least 2 as well as at least one organic phosphinic acid or derivative thereof (e.g., an organic phosphinic acid-modified epoxy resin), reinforced with a fiber having a thermal conductivity?3 W/m·K at room temperature, as well as a prepreg for making such a flame retardant fiber-reinforced composite material. More specifically, a composite material is provided that contains a combination of particular types of epoxy resins, curatives, and reinforcing fibers that provide sufficient flame retardance for thin-ply laminates when cured at 163° C. for 15 minutes. These cured composites are also suitable for a variety of applications requiring flame retardancy.Type: ApplicationFiled: October 14, 2020Publication date: March 21, 2024Applicant: Toray Industries, Inc.Inventors: Katrina P. Vizzini, Benjamin Lehman, Jonathan Hughes, Alfred P. Haro, Toshiya Kamae
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Publication number: 20240043636Abstract: A prepreg is provided. The prepreg includes sizing agent-coated carbon fibers and a thermosetting resin composition (B) impregnated between the sizing agent-coated carbon fibers. The sizing agent includes a reactive component (A) having at least three reactive groups per molecule: (i) two or more first functional groups capable of reacting with the thermosetting resin composition (B), and (ii) at least one second functional group different from the two or more first functional groups (i). The second functional group includes at least one of amide, imide, urethane, urea, carbonyl, ester, sulfonyl, aromatic ring, or combinations thereof. The thermosetting resin composition (B) includes at least one thermosetting resin other than an epoxy resin and has a glass transition temperature of 220° C. or more after being cured.Type: ApplicationFiled: December 2, 2021Publication date: February 8, 2024Applicant: Toray Composite Materials America, Inc.Inventors: Alfred P. Haro, Jonathan C. Hughes, Naoki Matsuura, Jeffrey P. Sitthi, Hiroshi Kobayashi, Toshiya Kamae
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Publication number: 20240010805Abstract: A fiber reinforced prepreg comprising reinforcement fibers; particles (D1) and (D2); and a thermosetting resin composition is provided. The resin includes maleimide compound (A), and co-monomer (B). Co-monomer (B) has least one of an alkenylphenol, an alkenylphenoxy, or a diamine group. Particles (D1) are smaller than (D2) and particles (D1) and (D2) are insoluble in the thermosetting resin. Particles (D1) range in diameter from 1 to 10 microns and have a mode on a volume basis from 3 to 6 microns and are present from 3 to 12 percent by volume of the thermosetting resin. Particles (D2) range from 10 to 100 microns diameter and a mode of 20 to 60 microns and are present from 1 to 6 percent by volume of the thermosetting resin composition. After cure, at least 90% by volume of particles (D1) and (D2) remain in the prepreg interlayers.Type: ApplicationFiled: December 2, 2021Publication date: January 11, 2024Applicant: Toray Composite Materials America, Inc.Inventors: Madelyn Milligan, Jonathan C. Hughes, Alfred P. Haro, Toshiya Kamae, Naoki Matsuura, Koji Furukawa
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Patent number: 11565497Abstract: A laminate body is provided which contains a thin prepreg having a component (A) containing a matrix of reinforcing fiber, a component (B) containing a thermosetting resin, and a component (C) containing particles of a thermoplastic resin. When molded and cured out of autoclave, the laminate body achieves a fiber-reinforced composite having a low void ratio and providing excellent mechanical performance.Type: GrantFiled: March 26, 2019Date of Patent: January 31, 2023Assignee: TORAY INDUSTRIES, INC.Inventors: Alfred P. Haro, Nobuyuki Arai, Andrew Hideo Koyanagi
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Publication number: 20210371612Abstract: The void content of a cured fiber-reinforced composite material is advantageously reduced, particularly when the composite material article is large in size or fabricated using an out-of-autoclave procedure, by using prepreg sheets impregnated with a thermosettable resin composition containing thermoplastic particles and modified to have one or more characteristics such as a certain level of average surface roughness. Such characteristics may be imparted to the prepreg sheet by, for example, conditioning the prepreg sheet by subjecting it to vacuum conditions in advance of being consolidated and cured as part of a prepreg stack.Type: ApplicationFiled: January 30, 2019Publication date: December 2, 2021Applicant: Toray Industries, Inc.Inventors: Andrew Hideo Koyanagi, Alfred P. Haro, Nobuyuki Arai
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Patent number: 11028244Abstract: A permeable laminate body containing at least one partially impregnated prepreg which includes at least component (A) containing a matrix of reinforcing fiber, component (B) containing a thermosetting resin, and, optionally, component (C) containing a particle or a fiber of a thermoplastic resin exhibits long out time processability with good storage stability, achieving when molded and cured a fiber reinforced composite having a low void ratio and providing excellent mechanical performance.Type: GrantFiled: December 14, 2016Date of Patent: June 8, 2021Assignee: TORAY INDUSTRIES, INC.Inventors: Alfred P. Haro, Nobuyuki Arai
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Publication number: 20210024712Abstract: A laminate body is provided which contains a thin prepreg having a component (A) containing a matrix of reinforcing fiber, a component (B) containing a thermosetting resin, and a component (C) containing particles of a thermoplastic resin. When molded and cured out of autoclave, the laminate body achieves a fiber-reinforced composite having a low void ratio and providing excellent mechanical performance.Type: ApplicationFiled: March 26, 2019Publication date: January 28, 2021Applicant: Toray Industries, Inc.Inventors: Alfred P. Haro, Nobuyuki Arai, Andrew Hideo Koyanagi
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Patent number: 10668647Abstract: A prepreg comprising a layer of impregnated reinforcing fibers comprising at least one layer of reinforcing fibers impregnated by a resin composition comprising at least a thermosetting resin, a curing agent and an accelerator, such that the accelerator has a gradient concentration which is more concentrated in the resin composition in the vicinity of the reinforcing fibers than further away. The resin composition comprising a first resin composition impregnates the reinforcing fibers to provide a layer of impregnated reinforcing fibers and a surface layer comprising a second resin composition is formed on the layer of impregnated reinforcing fibers, wherein the first resin composition has at least one peak exotherm occurring at a time earlier than and/or at a temperature lower than any peak exotherm of the second resin composition.Type: GrantFiled: September 27, 2016Date of Patent: June 2, 2020Assignee: TORAY INDUSTRIES, INC.Inventors: Felix N. Nguyen, Alfred P. Haro, Bradley R. Fenbert
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Publication number: 20180355132Abstract: A permeable laminate body containing at least one partially impregnated prepreg which includes at least component (A) containing a matrix of reinforcing fiber, component (B) containing a thermosetting resin, and, optionally, component (C) containing a particle or a fiber of a thermoplastic resin exhibits long out time processability with good storage stability, achieving when molded and cured a fiber reinforced composite having a low void ratio and providing excellent mechanical performance.Type: ApplicationFiled: December 14, 2016Publication date: December 13, 2018Applicant: TORAY INDUSTRIES, INC.Inventors: Alfred P. Haro, Nobuyuki Arai
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Publication number: 20180290339Abstract: A prepreg comprising a layer of impregnated reinforcing fibers comprising at least one layer of reinforcing fibers impregnated by a resin composition comprising at least a thermosetting resin, a curing agent and an accelerator, such that the accelerator has a gradient concentration which is more concentrated in the resin composition in the vicinity of the reinforcing fibers than further away. The resin composition comprising a first resin composition impregnates the reinforcing fibers to provide a layer of impregnated reinforcing fibers and a surface layer comprising a second resin composition is formed on the layer of impregnated reinforcing fibers, wherein the first resin composition has at least one peak exotherm occurring at a time earlier than and/or at a temperature lower than any peak exotherm of the second resin composition.Type: ApplicationFiled: September 27, 2016Publication date: October 11, 2018Applicant: TORAY INDUSTRIES, INC.Inventors: Felix N. Nguyen, Alfred P. Haro, Bradley R. Fenbert
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Patent number: 9963586Abstract: Embodiments herein relate to a prepreg comprising a thermosetting resin, and reinforcing fibers in the thermosetting resin, wherein when the prepreg is cured in vacuum bag only conditions, and a method of making the same. The method also applies for autoclave processing. Embodiments also relate to a cured fiber reinforced composite material made by thermally curing the prepreg.Type: GrantFiled: December 26, 2012Date of Patent: May 8, 2018Assignee: TORAY INDUSTRIES, INC.Inventors: Jonathan C Hughes, Jeffrey A Satterwhite, Nobuyuki Arai, Atsuhito Arai, Alfred P Haro, Kenichi Yoshioka
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Patent number: 9957387Abstract: An epoxy resin composition having components (A), (B), (C), and (D), wherein the epoxy resin composition has a viscosity at 40° C. of about 1×103 to about 1×104 Pa·s, a curing start temperature of about 90 to about 110° C., and a minimum viscosity at the curing start temperature of about 2 to about 20 Pa·s, wherein the components (A), (B), (C), and (D) are as follows: (A) About 60 weight parts or more of a tetraglycidyl amine type epoxy resin per 100 weight parts of the epoxy resin blend; (B) Dicyandiamide; (C) Diaminodiphenyl sulfone and (D) Urea compound.Type: GrantFiled: November 7, 2011Date of Patent: May 1, 2018Assignee: TORAY INDUSTRIES, INC.Inventors: Nobuyuki Arai, Alfred P. Haro, Jonathan C. Hughes, Norimitsu Natsume
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Patent number: 9688891Abstract: A fiber reinforced polymer composition is provided comprising a fiber and an adhesive composition, wherein the adhesive composition comprises at least a thermosetting resin, a curing agent, and a hard interfacial material. When cured, the adhesive composition forms good bonds to the reinforcing fiber, and an interfacial region between the reinforcing fiber and the adhesive composition is formed which comprises the hard interfacial material. Additional embodiments include a prepreg and a method of manufacturing a composite article by curing the adhesive composition and the reinforcing fiber.Type: GrantFiled: December 23, 2013Date of Patent: June 27, 2017Assignee: TORAY INDUSTRIES, INC.Inventors: Felix N. Nguyen, Kenichi Yoshioka, Swezin Than Tun, Alfred P. Haro
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Publication number: 20150315430Abstract: A fiber reinforced polymer composition is provided comprising a fiber and an adhesive composition, wherein the adhesive composition comprises at least a thermosetting resin, a curing agent, and a hard interfacial material. When cured, the adhesive composition forms good bonds to the reinforcing fiber, and an interfacial region between the reinforcing fiber and the adhesive composition is formed which comprises the hard interfacial material. Additional embodiments include a prepreg and a method of manufacturing a composite article by curing the adhesive composition and the reinforcing fiber.Type: ApplicationFiled: December 23, 2013Publication date: November 5, 2015Applicant: Toray Industries, Inc.Inventors: Felix N. NGUYEN, Kenichi YOSHIOKA, Swezin Than TUN, Alfred P. HARO
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Publication number: 20150259580Abstract: A fiber reinforced polymer composition is disclosed comprising a reinforcing fiber and an adhesive composition, wherein the adhesive composition comprises at least a thermosetting resin, a curing agent, and an interfacial material, the fiber is suitable for concentrating the interfacial material in an interfacial region between the fiber and the adhesive composition upon curing of the adhesive composition, and the cured adhesive has a resin modulus of at least 4.0 GPa. Also provided is a prepreg comprising the fiber reinforced polymer composition and a method of manufacturing a composite article by curing the reinforced polymer composition. The resulting interfacial region, viz., the reinforced interphase, is reinforced by one or more layers of the interfacial material such that substantial improvements in tensile, compression and fracture toughness may be observed.Type: ApplicationFiled: October 10, 2013Publication date: September 17, 2015Applicant: Toray Industries, Inc.Inventors: Felix N. Nguyen, Alfred P. Haro, Kenichi Yoshioka
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Publication number: 20150240042Abstract: A fiber reinforced polymer composition is provided comprising a fiber and an adhesive composition, wherein the adhesive composition comprises at least a thermosetting resin and a curing agent, the reinforcing fiber has a tensile modulus of at least 300 GPa and the cured adhesive has a resin modulus of at least 3.2 GPa, and the adhesive composition when cured makes good bonds to the reinforcing fiber. Additional embodiments include a prepreg comprising the fiber reinforced polymer composition and a method of manufacturing a composite article by curing the adhesive composition and a reinforcing fiber.Type: ApplicationFiled: October 10, 2013Publication date: August 27, 2015Applicant: Toray Industries, Inc.Inventors: Felix N. Nguyen, Alfred P. Haro, Kenichi Yoshioka, Kenichi Yoshioka
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Publication number: 20140309336Abstract: Embodiments herein relate to a prepreg comprising a thermosetting resin, and reinforcing fibers in the thermosetting resin, wherein when the prepreg is cured in vacuum bag only conditions, and a method of making the same. The method also applies for autoclave processing. Embodiments also relate to a cured fiber reinforced composite material made by thermally curing the prepreg.Type: ApplicationFiled: December 26, 2012Publication date: October 16, 2014Applicant: TORAY INDUSTRIES. INCInventors: Jonathan C Hughes, Jeffrey A Satterwhite, Nobuyuki Arai, Atsuhito Arai, Alfred P Haro, Kenichi Yoshioka
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Publication number: 20140087178Abstract: An embodiment relates to a prepreg having a structure comprising a first layer and a second layer, wherein the prepreg comprises component (A) comprising a reinforcing fiber, component (B) comprising a thermosetting resin, and component (C) comprising a particle or a fiber of a thermoplastic resin, the component (C) is substantially locally distributed in the first layer and the prepreg is a partially impregnated prepreg.Type: ApplicationFiled: March 30, 2012Publication date: March 27, 2014Applicant: TORAY INDUSTRIES, INC.Inventors: Nobuyuki Arai, Jonathan C. Hughes, Jeffrey A. Satterwhite, Atsuhito Arai, Alfred P. Haro, Kenichi Yoshioka
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Publication number: 20130344325Abstract: Embodiments disclosed herein include a structure comprising an adherend and an adhesive composition, wherein the adhesive composition comprises at least a thermosetting resin, a curing agent, and an interfacial material, wherein the adherend is suitable for concentrating the interfacial material in an interfacial region between the adherend and the adhesive composition upon curing of the adhesive composition; a method of manufacturing a composite article by curing the adhesive composition and a reinforcing fiber; and a method of manufacturing an adhesive bonded joint comprising applying the adhesive composition to a surface of one of the two or of different kinds the adherend, and curing the adhesive composition to form an adhesive bond between the adherends. The resulting interfacial region, viz., the reinforced interphase, is reinforced by one or more layers of the interfacial material such that substantial improvements in bond strength and fracture toughness are observed.Type: ApplicationFiled: February 24, 2012Publication date: December 26, 2013Applicant: TORAY INDUSTRIES, INC.Inventors: Felix N. Nguyen, Kenichi Yoshioka, Alfred P. Haro, Nobuyuki Arai
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Publication number: 20130217283Abstract: An epoxy resin composition having components (A), (B), (C), and (D), wherein the epoxy resin composition has a viscosity at 40° C. of about 1×103 to about 1×104 Pa·s, a curing start temperature of about 90 to about 110° C., and a minimum viscosity at the curing start temperature of about 2 to about 20 Pa·s, wherein the components (A), (B), (C), and (D) are as follows: (A) About 60 weight parts or more of a tetraglycidyl amine type epoxy resin per 100 weight parts of the epoxy resin blend; (B) Dicyandiamide; (C) Diaminodiphenyl sulfone and (D) Urea compound.Type: ApplicationFiled: November 7, 2011Publication date: August 22, 2013Applicant: TORAY INDUSTRIES, INC.Inventors: Nobuyuki Arai, Alfred P. Haro, Jonathan C. Hughes, Norimitsu Natsume