Patents by Inventor Atsuhito Arai

Atsuhito Arai 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: 10597503
    Abstract: A prepreg containing at least the following components [A]-[F], wherein the ratio Ne/Nd of the number of structures Ne of component [F] present in a range of outside 110% of the particle diameter of component [E] and the number of structures Nd of component [F] present in a range outside 110% of the particle diameter of component [D] is 0.25 or higher. [A]: Carbon fibers, [B] thermosetting resin, [C]: curing agent, [D]: particles composed mainly of thermoplastic resin having a primary particle number-average particle size of 5-50 ?m, [E]: conductive particles different from component [D] and having a primary particle number-average particle size in the range of a specific expression, [F]: filler comprising a carbon material.
    Type: Grant
    Filed: March 19, 2015
    Date of Patent: March 24, 2020
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Atsuhito Arai, Koji Furukawa, Naofumi Yamashita, Shinji Kochi, Yumi Kunimitsu, Yui Fujioka, Hiroshi Taiko
  • Publication number: 20200056005
    Abstract: A prepreg containing the following constituent elements [A] to [C], wherein a resin composition containing the constituent elements [B] and [C] has a higher-order structure derived from a diffraction angle 20 between 1.0° and 6.0° observed with X-ray diffraction after curing: [A]: carbon fibers [B]: epoxy resin [C]: curing agent of [B].
    Type: Application
    Filed: March 16, 2018
    Publication date: February 20, 2020
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Atsuhito ARAI, Koji FURUKAWA, Atsuki SUGIMOTO, Masahiro MINO, Mayumi MIHARA
  • Publication number: 20200010633
    Abstract: An object of the present invention is to provide an epoxy resin composition capable of providing a carbon fiber-reinforced composite material that is excellent in moldability, heat resistance, and mechanical properties such as tensile strength and compression strength, and a prepreg. The present invention provides an epoxy resin composition containing at least components [A] to [D] shown below: [A]: an epoxy resin having a xylene group; [B]: a glycidyl amine epoxy resin having three or more glycidyl groups in a molecule; [C]: a thermoplastic resin; and [D]: an aromatic polyamine, the epoxy resin composition containing 10 to 80 parts by mass of the component [A] and 20 to 90 parts by mass of the component [B] based on 100 parts by mass in total of epoxy resins, and also 1 to 25 parts by mass of the component [C] based on 100 parts by mass in total of epoxy resins.
    Type: Application
    Filed: March 5, 2018
    Publication date: January 9, 2020
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Junichi AOKI, Koji FURUKAWA, Atsuhito ARAI, Jun MISUMI, Hiroaki SAKATA, Takashi OCHI
  • Patent number: 10370757
    Abstract: A thin substrate processing device include a substrate processing unit configured to process a thin substrate, and a cooling unit configured to cool the thin substrate when the substrate processing unit is processing the thin substrate.
    Type: Grant
    Filed: January 28, 2014
    Date of Patent: August 6, 2019
    Assignee: ULVAC, INC.
    Inventors: Tetsushi Fujinaga, Masahiro Matsumoto, Makoto Arai, Eriko Mase, Harunori Iwai, Koji Takahashi, Atsuhito Ihori
  • Patent number: 10351700
    Abstract: A epoxy resin composition includes a given epoxy resin [A], an aromatic amine compound [B], an organic acid hydrazide compound [C] having a structural formula represented by general formula (I) or (II) (X is a structure selected from among monocyclic and polycyclic aromatic ring structures, polycyclic aromatic ring structures, and aromatic heterocyclic structures and optionally has, as a substituent, any of C4 or lower alkyl groups, a hydroxy group, and an amino group), and a thermoplastic resin [D], wherein the amount of the constituent element [C] is 1-25 parts by mass per 100 parts by mass of the constituent element [A], the epoxy resin composition, after having been held at 80° C. for 2 hours, having a viscosity which is up to 2.0 times the initial viscosity at 80° C.
    Type: Grant
    Filed: November 6, 2015
    Date of Patent: July 16, 2019
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Koji Furukawa, Atsuhito Arai, Hiroaki Sakata
  • Patent number: 10280251
    Abstract: Provided is an epoxy resin composition for giving a carbon fiber-reinforced composite material that simultaneously achieves tensile strength and compressive strength. An epoxy resin composition containing at least the following constituent elements [A]-[D] wherein the epoxy resin composition contains 5-50 mass % of constituent element [A] and 20-95 mass % of constituent element [B] relative to 100 mass % of total epoxy resin weight. [A]: at least one epoxy resin selected from 1,2-bis(glycidyloxy)benzene, 1,3-bis(glycidyloxy)benzene, 1,4-bis(glycidyloxy)benzene, derivatives of these, and epoxy resins having a structure represented by general formula [1] (in general formula [1], at least one of R1-R5 and at least one of R6-R10 is a glycidyl ether group, and the other R1-R10 represent any of a hydrogen atom, halogen atom, or aliphatic hydrocarbon group having four or fewer carbon atoms.
    Type: Grant
    Filed: March 16, 2016
    Date of Patent: May 7, 2019
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Junichi Aoki, Atsuhito Arai, Hiroaki Sakata, Takashi Ochi
  • Publication number: 20180244880
    Abstract: Provided are: an epoxy resin composition that gives a carbon fiber-reinforced composite material having excellent moldability, heat resistance, and mechanical properties such as tensile strength and compressive strength; and a prepreg. An epoxy resin composition containing at least the following constituent elements [A]-[D]. The epoxy resin composition contains 5-50 parts by mass of constituent element [A] and 20-95 parts by mass of constituent element [B], as well as 1-25 parts by mass of constituent element [C], relative to 100 parts by mass of the total amount of epoxy resin. Constituent element [A] is an epoxy resin having primarily two epoxy groups and one or more condensed polycyclic aromatic hydrocarbon skeletons within a repeating unit of a specific structure; [B] is a glycidylamine epoxy resin having three or more glycidyl groups in the molecule; [C] is a sulfone or imide thermoplastic resin; and [D] is an epoxy resin curing agent.
    Type: Application
    Filed: August 31, 2016
    Publication date: August 30, 2018
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Junichi Aoki, Koji Furukawa, Kyoko Tamaru, Atsuhito Arai, Hiroaki Sakata, Takashi Ochi
  • Publication number: 20180134837
    Abstract: Provided is an epoxy resin composition including the following component [A]: a tri- or more functional binaphthalene epoxy resin represented by the following general formula (A-1) and component [B]: an aromatic amine compound, in which the glass transition temperature of a cured product, which is obtained by curing the epoxy resin composition at 180° C. for 2 hours, after immersing in boiling water at 1 atm for 48 hours is 180° C. or more. An epoxy resin composition and a prepreg which can form a fiber-reinforced composite material excellent in heat resistance under high humidity are provided.
    Type: Application
    Filed: June 15, 2016
    Publication date: May 17, 2018
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Koji Furukawa, Atsuhito Arai, Hiroaki Sakata
  • Patent number: 9963586
    Abstract: 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: Grant
    Filed: December 26, 2012
    Date of Patent: May 8, 2018
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Jonathan C Hughes, Jeffrey A Satterwhite, Nobuyuki Arai, Atsuhito Arai, Alfred P Haro, Kenichi Yoshioka
  • Publication number: 20180051125
    Abstract: Provided is an epoxy resin composition for giving a carbon fiber-reinforced composite material that simultaneously achieves tensile strength and compressive strength. An epoxy resin composition containing at least the following constituent elements [A]-[D] wherein the epoxy resin composition contains 5-50 mass % of constituent element [A] and 20-95 mass % of constituent element [B] relative to 100 mass % of total epoxy resin weight. [A]: at least one epoxy resin selected from 1,2-bis(glycidyloxy)benzene, 1,3-bis(glycidyloxy)benzene, 1,4-bis(glycidyloxy)benzene, derivatives of these, and epoxy resins having a structure represented by general formula [1] (in general formula [1], at least one of R1-R5 and at least one of R6-R10 is a glycidyl ether group, and the other R1-R10 represent any of a hydrogen atom, halogen atom, or aliphatic hydrocarbon group having four or fewer carbon atoms.
    Type: Application
    Filed: March 16, 2016
    Publication date: February 22, 2018
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Junichi Aoki, Atsuhito Arai, Hiroaki Sakata, Takashi Ochi
  • Publication number: 20170362427
    Abstract: A epoxy resin composition includes a given epoxy resin [A], an aromatic amine compound [B], an organic acid hydrazide compound [C] having a structural formula represented by general formula (I) or (II) (X is a structure selected from among monocyclic and polycyclic aromatic ring structures, polycyclic aromatic ring structures, and aromatic heterocyclic structures and optionally has, as a substituent, any of C4 or lower alkyl groups, a hydroxy group, and an amino group), and a thermoplastic resin [D], wherein the amount of the constituent element [C] is 1-25 parts by mass per 100 parts by mass of the constituent element [A], the epoxy resin composition, after having been held at 80° C. for 2 hours, having a viscosity which is up to 2.0 times the initial viscosity at 80° C.
    Type: Application
    Filed: November 6, 2015
    Publication date: December 21, 2017
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Koji Furukawa, Atsuhito Arai, Hiroaki Sakata
  • Patent number: 9777155
    Abstract: The embodiments herein relate to a benzoxazine resin composition, a prepreg, and a carbon fiber-reinforced composite material. More specifically, the embodiments herein relate to a benzoxazine resin composition that provides a carbon fiber-reinforced composite material that is suitable for use as a manufacture material due to its superior mechanical strength in extreme use environments, such as high temperature and high moisture, as well as a prepreg, and a carbon fiber-reinforced composite material. An embodiment comprises a benzoxazine resin composition having a multifunctional benzoxazine resin; a multifunctional epoxy resin that is a liquid at 40° C. and has three or more glycidyl groups; a sulfonate ester; and optionally at least one thermoplastic resin. The resin may include an interpenetrating network structure after curing.
    Type: Grant
    Filed: June 27, 2013
    Date of Patent: October 3, 2017
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Atsuhito Arai, Jeffrey A Satterwhite, Johnathan C Hughes, Hiroaki Sakata, Kenichi Yoshioka
  • Publication number: 20170226299
    Abstract: A prepreg containing at least the following components [A]-[F], wherein the ratio Ne/Nd of the number of structures Ne of component [F] present in a range of outside 110% of the particle diameter of component [E] and the number of structures Nd of component [F] present in a range outside 110% of the particle diameter of component [D] is 0.25 or higher. [A]: Carbon fibers, [B] thermosetting resin, [C]: curing agent, [D]: particles composed mainly of thermoplastic resin having a primary particle number-average particle size of 5-50 ?m, [E]: conductive particles different from component [D] and having a primary particle number-average particle size in the range of a specific expression, [F]: filler comprising a carbon material.
    Type: Application
    Filed: March 19, 2015
    Publication date: August 10, 2017
    Applicant: TORAY INDUSTRIES, INC.
    Inventor: Atsuhito Arai
  • Patent number: 9434811
    Abstract: Disclosed is a carbon-fiber-reinforced composite material that is suitable for use as a construction material and exhibits high mechanical strength in harsh usage environments such as low-temperature environments and high-temperature moisture-absorbing environments. Also disclosed are an epoxy resin composition for producing the aforementioned carbon-fiber-rein-forced composite material and a prepreg obtained through the use of said epoxy resin composition. Said epoxy resin composition comprises at least the following constituents, by mass with respect to the total mass of the composition: (A) between 20% and 80% of an epoxy resin having the structure represented by formula (1); and (B) between 10% and 50% of an epoxy resin that has at least two ring structures with four or more members each and also has one amine glycidyl or ether glycidyl directly connected to a ring structure.
    Type: Grant
    Filed: December 24, 2010
    Date of Patent: September 6, 2016
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Atsuhito Arai, Hiroaki Sakata, Hiroshi Taiko, Michiya Ishikawa, Hidetoshi Kato, Jiro Nakatani
  • Publication number: 20150141583
    Abstract: The embodiments herein relate to a benzoxazine resin composition, a prepreg, and a carbon fiber-reinforced composite material. More specifically, the embodiments herein relate to a benzoxazine resin composition that provides a carbon fiber-reinforced composite material that is suitable for use as a manufacture material due to its superior mechanical strength in extreme use environments, such as high temperature and high moisture, as well as a prepreg, and a carbon fiber-reinforced composite material. An embodiment comprises a benzoxazine resin composition having a multifunctional benzoxazine resin; a multifunctional epoxy resin that is a liquid at 40° C. and has three or more glycidyl groups; a sulfonate ester; and optionally at least one thermoplastic resin. The resin may include an interpenetrating network structure after curing.
    Type: Application
    Filed: June 27, 2013
    Publication date: May 21, 2015
    Inventors: Atsuhito Arai, Jeffrey A Satterwhite, Johnathan C Hughes, Hiroaki Sakata, Kenichi Yoshioka
  • Publication number: 20140309336
    Abstract: 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: Application
    Filed: December 26, 2012
    Publication date: October 16, 2014
    Applicant: TORAY INDUSTRIES. INC
    Inventors: Jonathan C Hughes, Jeffrey A Satterwhite, Nobuyuki Arai, Atsuhito Arai, Alfred P Haro, Kenichi Yoshioka
  • Publication number: 20140087178
    Abstract: 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: Application
    Filed: March 30, 2012
    Publication date: March 27, 2014
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Nobuyuki Arai, Jonathan C. Hughes, Jeffrey A. Satterwhite, Atsuhito Arai, Alfred P. Haro, Kenichi Yoshioka
  • Patent number: 8664413
    Abstract: An epoxy compound of high-purity N,N,N?,N?-tetraglycidyl-3,4?-diaminodiphenyl ether is produced by: an addition reaction step of reacting 3,4?-diaminodiphenyl ether with epichlorohydrin in a polar protic solvent at 65 to 100° C. for 12 hours or longer to form N,N,N?,N?-tetrakis(3-chloro-2-hydroxypropyl)-3,4?-diaminodiphenyl ether; and a cyclization reaction step of reacting the N,N,N?,N?-tetrakis(3-chloro-2-hydroxypropyl)-3,4?-diaminodiphenyl ether with an alkali compound for dehydrochlorination.
    Type: Grant
    Filed: March 2, 2011
    Date of Patent: March 4, 2014
    Assignee: Toray Fine Chemicals Co., Ltd.
    Inventors: Michiya Ishikawa, Hidetoshi Kato, Jiro Nakatani, Atsuhito Arai, Hiroaki Sakata, Hiroshi Taiko
  • Publication number: 20130012730
    Abstract: An epoxy compound of high-purity N,N,N?,N?-tetraglycidyl-3,4?-diaminodiphenyl ether is produced by: an addition reaction step of reacting 3,4?-diaminodiphenyl ether with epichloro-hydrin in a polar protic solvent at 65 to 100° C. for 12 hours or longer to form N,N,N?,N?-tetrakis(3-chloro-2-hydroxypropyl)-3,4?-diaminodiphenyl ether; and a cyclization reaction step of reacting the N,N,N?,N?-tetrakis(3-chloro-2-hydroxypropyl)-3,4?-diaminodiphenyl ether with an alkali compound for dehydrochlorination.
    Type: Application
    Filed: March 2, 2011
    Publication date: January 10, 2013
    Applicant: TORAY FINE CHEMICALS CO., LTD.
    Inventors: Michiya Ishikawa, Hidetoshi Kato, Jiro Nakatani, Atsuhito Arai, Hiroaki Sakata, Hiroshi Taiko
  • Publication number: 20130005855
    Abstract: Disclosed is a carbon-fiber-reinforced composite material that is suitable for use as a construction material and exhibits high mechanical strength in harsh usage environments such as low-temperature environments and high-temperature moisture-absorbing environments. Also disclosed are an epoxy resin composition for producing the aforementioned carbon-fiber-rein-forced composite material and a prepreg obtained through the use of said epoxy resin composition. Said epoxy resin composition comprises at least the following constituents, by mass with respect to the total mass of the composition: (A) between 20% and 80% of an epoxy resin having the structure represented by formula (1); and (B) between 10% and 50% of an epoxy resin that has at least two ring structures with four or more members each and also has one amine glycidyl or ether glycidyl directly connected to a ring structure.
    Type: Application
    Filed: December 24, 2010
    Publication date: January 3, 2013
    Inventors: Atsuhito Arai, Hiroaki Sakata, Hiroshi Taiko, Michiya Ishikawa, Hidetoshi Kato, Jiro Nakatani