Patents by Inventor Atsuki Tsuchiya

Atsuki Tsuchiya 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).

  • Publication number: 20200139641
    Abstract: A fiber reinforced thermoplastic resin molded article contains inorganic fibers (A), organic fibers (B), and a thermoplastic resin (C), the fiber reinforced thermoplastic resin molded article containing 5 to 45 parts by weight of the inorganic fibers (A), 1 to 45 parts by weight of the organic fibers (B), and 10 to 94 parts by weight of the thermoplastic resin (C), based on 100 parts by weight of the total of the inorganic fibers (A), the organic fibers (B), and the thermoplastic resin (C), the inorganic fibers (A) in the fiber reinforced thermoplastic resin molded article having a weight average fiber length (Lwa) of 0.01 mm or more and 3 mm or less, the organic fibers (B) having a weight average fiber length (Lwb) of more than 4 mm and 20 mm or less.
    Type: Application
    Filed: July 30, 2018
    Publication date: May 7, 2020
    Inventors: Shin Hirata, Yuki Nitsutsuji, Atsuki Tsuchiya
  • Patent number: 10619017
    Abstract: A fiber reinforced thermoplastic resin molded article includes 5 to 45 parts by weight of carbon fibers (A), 1 to 45 parts by weight of organic fibers (B), and 10 to 94 parts by weight of a thermoplastic resin (C), based on 100 parts by weight of the total amount of the carbon fibers (A), the organic fibers (B), and the thermoplastic resin (C). The carbon fibers (A) in the fiber reinforced thermoplastic resin molded article have an average fiber length (LA) of 0.3 to 3 mm. The organic fibers (B) in the fiber reinforced thermoplastic resin molded article have an average fiber length (LB) of 0.5 to 5 mm, and a number average fiber diameter (dB) of 1 to 10 ?m. The fiber reinforced thermoplastic resin molded article excellent in impact strength.
    Type: Grant
    Filed: October 21, 2016
    Date of Patent: April 14, 2020
    Assignee: Toray Industries, Inc.
    Inventors: Yuki Mitsutsuji, Shin Hirata, Atsuki Tsuchiya
  • Patent number: 10583591
    Abstract: A fiber reinforced thermoplastic resin molded article includes (A) carbon fibers, (B) graphite and (C) a thermoplastic resin, wherein the carbon fibers (A), the graphite (B) and the thermoplastic resin (C) are contained in amounts of 1 to 30 parts by weight, 1 to 40 parts by weight and 30 to 98 parts by weight, respectively, relative to 100 parts by weight, of the carbon fibers (A), the graphite (B) and the thermoplastic resin (C), the weight average fiber length of the carbon fibers (A) is 0.3 to 3 mm and the specific gravity of the molded article is 1.1 to 1.9 g/cm3. The fiber reinforced thermoplastic resin molded article has excellent bending strength and heat conductivity.
    Type: Grant
    Filed: October 20, 2015
    Date of Patent: March 10, 2020
    Assignee: Toray Industries, Inc.
    Inventors: Yuki Mitsutsuji, Sora Bang, Shin Hirata, Atsuki Tsuchiya
  • Patent number: 10584218
    Abstract: A fiber reinforced thermoplastic resin molded article includes 5 to 45 parts by weight of carbon fibers (A), 1 to 45 parts by weight of organic fibers (B), and 10 to 94 parts by weight of a thermoplastic resin (C), based on 100 parts by weight of the total amount of the carbon fibers (A), the organic fibers (B), and the thermoplastic resin (C). The carbon fibers (A) in the fiber reinforced thermoplastic resin molded article have an average fiber length (LA) of 0.3 to 3 mm. The organic fibers (B) in the fiber reinforced thermoplastic resin molded article have an average fiber length (LB) of 0.5 to 5 mm, and a number average fiber diameter (dB) of 35 to 300 ?m. The fiber reinforced thermoplastic resin molded article is excellent in impact strength and surface appearance.
    Type: Grant
    Filed: October 21, 2016
    Date of Patent: March 10, 2020
    Assignee: Toray Industries, Inc.
    Inventors: Yuki Mitsutsuji, Shin Hirata, Atsuki Tsuchiya
  • Patent number: 10501605
    Abstract: A carbon fiber-reinforced resin composition of the present invention includes: sizing agent-coated carbon fibers in which carbon fibers are coated with a sizing agent; and a matrix resin. The sizing agent includes at least an aliphatic epoxy compound (A) and an aromatic epoxy compound (B1) as an aromatic compound (B). The sizing agent-coated carbon fibers have a ratio (a)/(b) of 0.50 to 0.90 where (a) is the height (cps) of a component having a binding energy (284.6 eV) attributed to CHx, C—C, and C?C and (b) is the height (cps) of a component having binding energy (286.1 eV) attributed to C—O in a C1s core spectrum of the surface of the sizing agent measured by X-ray photoelectron spectroscopy at a photoelectron takeoff angle of 15°.
    Type: Grant
    Filed: August 6, 2013
    Date of Patent: December 10, 2019
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Tomoko Ichikawa, Atsuki Tsuchiya, Makoto Endo
  • Patent number: 10385174
    Abstract: A fiber reinforced thermoplastic resin molding material includes a thermoplastic resin; a resin impregnated reinforcing fiber filament obtained by impregnating reinforcing fibers with a resin having a melt viscosity at 200° C. lower than a melt viscosity of the thermoplastic resin; and a reinforcing fiber modifier having a melt viscosity at 200° C. lower than the melt viscosity of the thermoplastic resin and a difference in solubility parameter value from the thermoplastic resin equal to or larger than 1.0, the molding material including 50 to 98.9 parts by weight of the thermoplastic resin; 1 to 40 parts by weight of the reinforcing fiber; 0.1 to 10 parts by weight of the reinforcing fiber modifier; and 0.2 to 12 parts by weight of the resin relative to total 100 parts by weight of the thermoplastic resin, the reinforcing fiber, and the reinforcing fiber modifier.
    Type: Grant
    Filed: July 30, 2015
    Date of Patent: August 20, 2019
    Assignee: Toray Industries, Inc.
    Inventors: Shin Hirata, Yuki Mitsutsuji, Sora Bang, Atsuki Tsuchiya
  • Patent number: 10308775
    Abstract: A fiber-reinforced resin composition includes a polyarylene sulfide (A), a carbodiimide compound (B) and carbon fibers (C) in specific blending amounts and in which the carbon fibers (C) are surface-treated with a sizing agent (D), the carbodiimide compound (B) is an aliphatic carbodiimide compound, and the sizing agent (D) is a compound having three or more specific functional groups in one molecule; and a fiber-reinforced composite material includes a thermoplastic resin (A?), an adhesive compound (B?) and reinforcing fibers (C?) and in which the adhesive compound (B?) is a compound having two or more specific structures in one molecule, the thermoplastic resin (A?) is a thermoplastic resin containing an element other than carbon in a repeating unit structure of a main chain, and an abundance ratio Rb of the adhesive compound (B?) is 1.2 or more.
    Type: Grant
    Filed: October 24, 2014
    Date of Patent: June 4, 2019
    Assignee: Toray Industries Inc.
    Inventors: Naokichi Imai, Keisuke Inose, Kentaro Sano, Atsuki Tsuchiya
  • Publication number: 20180362760
    Abstract: Provided is a molding material which includes a composite of 1 to 50 wt % of a continuous reinforcing fiber bundle (A) and 0.1 to 20 wt % of a poly(phenylene ether ether ketone) oligomer (B); and 30 to 98.9 wt % of a thermoplastic resin (C) adhering to the composite, wherein the component (B) has a melting point of not higher than 270° C. Also provided are a method for molding the molding material, a method for producing the molding material, and a method for producing a fiber-reinforced composite material. A molded article having high heat resistance and dynamic properties can be easily produced without impairing the economic efficiency and productivity during the process for producing a molding material. In addition, a fiber-reinforced composite material can be produced with more ease and high productivity.
    Type: Application
    Filed: June 14, 2018
    Publication date: December 20, 2018
    Applicant: Toray Industries, Inc.
    Inventors: Naokichi Imai, Atsuki Tsuchiya, Masato Honma, Kohei Yamashita, Shunsuke Horiuchi, Koji Yamauchi
  • Publication number: 20180312648
    Abstract: A fiber reinforced thermoplastic resin molded article includes 5 to 45 parts by weight of carbon fibers (A), 1 to 45 parts by weight of organic fibers (B), and 10 to 94 parts by weight of a thermoplastic resin (C), based on 100 parts by weight of the total amount of the carbon fibers (A), the organic fibers (B), and the thermoplastic resin (C). The carbon fibers (A) in the fiber reinforced thermoplastic resin molded article have an average fiber length (LA) of 0.3 to 3 mm. The organic fibers (B) in the fiber reinforced thermoplastic resin molded article have an average fiber length (LB) of 0.5 to 5 mm, and a number average fiber diameter (dB) of 35 to 300 ?m. The fiber reinforced thermoplastic resin molded article is excellent in impact strength and surface appearance.
    Type: Application
    Filed: October 21, 2016
    Publication date: November 1, 2018
    Inventors: Yuki Mitsutsuji, Shin Hirata, Atsuki Tsuchiya
  • Publication number: 20180305507
    Abstract: A fiber reinforced thermoplastic resin molded article includes 5 to 45 parts by weight of carbon fibers (A), 1 to 45 parts by weight of organic fibers (B), and 10 to 94 parts by weight of a thermoplastic resin (C), based on 100 parts by weight of the total amount of the carbon fibers (A), the organic fibers (B), and the thermoplastic resin (C). The carbon fibers (A) in the fiber reinforced thermoplastic resin molded article have an average fiber length (LA) of 0.3 to 3 mm. The organic fibers (B) in the fiber reinforced thermoplastic resin molded article have an average fiber length (LB) of 0.5 to 5 mm, and a number average fiber diameter (dB) of 1 to 10 ?m. The fiber reinforced thermoplastic resin molded article excellent in impact strength.
    Type: Application
    Filed: October 21, 2016
    Publication date: October 25, 2018
    Inventors: Yuki Mitsutsuji, Shin Hirata, Atsuki Tsuchiya
  • Patent number: 10093802
    Abstract: A molding material includes 5 to 50 parts by mass of reinforcing fibers (A) with a sizing agent (s) deposited thereon, 1 to 20 parts by mass of a component (B) containing a polycarbodiimide compound (B-1) that is liquid at 50° C., and 30 to 94 parts by mass of a thermoplastic resin (C) containing an element other than carbon in the repeating unit structure of the main chain, based on 100 parts by mass of the total of the components (A) to (C), wherein the molding material is a composite in which a composite fiber bundle (D) with the component (A) impregnated with the component (B) is covered with the component (C).
    Type: Grant
    Filed: October 24, 2014
    Date of Patent: October 9, 2018
    Assignee: Toray Industries, Inc.
    Inventors: Kentaro Sano, Keisuke Inose, Naokichi Imai, Atsuki Tsuchiya
  • Patent number: 10023737
    Abstract: Provided is a molding material comprising a composite of 1 to 50 wt % of a continuous reinforcing fiber bundle (A) and 0.1 to 20 wt % of a poly (phenylene ether ether ketone) oligomer (B); and 30 to 98.9 wt % of a thermoplastic resin (C) adhering to the composite, wherein the component (B) has a melting point of not higher than 270° C. Also provided are a method for molding the molding material, a method for producing the molding material, and a method for producing a fiber-reinforced composite material. A molded article having high heat resistance and dynamic properties can be easily produced without impairing the economic efficiency and productivity during the process for producing a molding material. In addition, a fiber-reinforced composite material can be produced with more ease and high productivity.
    Type: Grant
    Filed: June 20, 2012
    Date of Patent: July 17, 2018
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Naokichi Imai, Atsuki Tsuchiya, Masato Honma, Kohei Yamashita, Shunsuke Horiuchi, Koji Yamauchi
  • Patent number: 9962904
    Abstract: Provided are the following: a sandwich structure formed from a core component comprising a discontinuous reinforcing fiber, a thermoplastic resin and voids, and a skin component comprising a continuous reinforcing fiber and a matrix resin, wherein in the core component, 30% or more of the discontinuous reinforcing fiber is covered with the thermoplastic resin and monofilaments of the discontinuous reinforcing fiber intersect one another via the thermoplastic resin; an integrally formed article using the sandwich structure; and methods for the production therefor.
    Type: Grant
    Filed: July 17, 2014
    Date of Patent: May 8, 2018
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Kazuhiro Hatanaka, Satomi Matsuo, Atsuki Tsuchiya
  • Patent number: 9963576
    Abstract: The present invention provides a light-weight fiber-reinforced composite material that has excellent flame retardance and mechanical properties and never emits a halogen gas. The present invention also provides a prepreg and en epoxy resin composition suited to obtain the above described fiber-reinforced composite material. The present invention also provides an integrated molding which is produced using the above described fiber-reinforced composite material, thereby suitable for use in electric/electronic casings. The epoxy resin composition is such that it contains the following components [A], [B] and [C]: [A] epoxy resin, [B] amine curing agent, and [C] phosphorus compound, wherein the concentration of the component [C] is 0.2 to 15% by weight in terms of phosphorus atom concentration.
    Type: Grant
    Filed: October 2, 2014
    Date of Patent: May 8, 2018
    Assignee: Toray Industríes, Inc.
    Inventors: Atsuki Tsuchiya, Masato Honma, Ryuji Sawaoka
  • Patent number: 9879123
    Abstract: A molded article excellent in dynamic characteristics and water degradation resistance can be obtained by using a fiber-reinforced polypropylene resin composition including a carbodiimide-modified polyolefin (a), a polypropylene resin (b) and reinforcing fibers (c), wherein the content of the carbodiimide group contained in a resin component in the fiber-reinforced polypropylene resin composition is 0.0005 to 140 mmol based on 100 g of a matrix resin component, and the reinforcing fibers (c) are sizing-treated with a polyfunctional compound (s); and a molding material using the fiber-reinforced polypropylene resin composition.
    Type: Grant
    Filed: January 17, 2013
    Date of Patent: January 30, 2018
    Assignee: Toray Industries, Inc.
    Inventors: Kentaro Sano, Noriyuki Hirano, Masato Honma, Atsuki Tsuchiya
  • Publication number: 20170260346
    Abstract: A fiber reinforced thermoplastic resin molding material includes a thermoplastic resin; a resin impregnated reinforcing fiber filament obtained by impregnating reinforcing fibers with a resin having a melt viscosity at 200° C. lower than a melt viscosity of the thermoplastic resin; and a reinforcing fiber modifier having a melt viscosity at 200° C. lower than the melt viscosity of the thermoplastic resin and a difference in solubility parameter value from the thermoplastic resin equal to or larger than 1.0, the molding material including 50 to 98.9 parts by weight of the thermoplastic resin; 1 to 40 parts by weight of the reinforcing fiber; 0.1 to 10 parts by weight of the reinforcing fiber modifier; and 0.2 to 12 parts by weight of the resin relative to total 100 parts by weight of the thermoplastic resin, the reinforcing fiber, and the reinforcing fiber modifier.
    Type: Application
    Filed: July 30, 2015
    Publication date: September 14, 2017
    Inventors: Shin Hirata, Yuki Mitsutsuji, Sora Bang, Atsuki Tsuchiya
  • Patent number: 9731440
    Abstract: A molding material comprising the following components (A) to (D) at the following ratios, in which the component (D) is bonded to a composite comprising the components (A) to (C) and the order in the weight average molecular weight is component (D)>component (B)>component (C); (A) 1 to 75 wt % of a reinforcing fiber bundle; (B) 0.01 to 10 wt % of a first propylene-based resin; (C) 0.01 to 10 wt % of a second propylene-based resin having carboxylate groups bound to the polymer chains thereof; and (D) 5 to 98.98 wt % of a third propylene-based resin. A molding material of this invention provides a long fiber-reinforced thermoplastic resin molding material containing a propylene-based resin as the matrix resin, which allows the reinforcing fibers to be well dispersed into the molded article produced at the time of injection molding and allows the molded article produced to have excellent mechanical properties.
    Type: Grant
    Filed: December 24, 2009
    Date of Patent: August 15, 2017
    Assignee: Toray Industries, Inc.
    Inventors: Masato Honma, Atsuki Tsuchiya, Keiichi Asami
  • Publication number: 20170225373
    Abstract: A fiber reinforced thermoplastic resin molded article includes (A) carbon fibers, (B) graphite and (C) a thermoplastic resin, wherein the carbon fibers (A), the graphite (B) and the thermoplastic resin (C) are contained in amounts of 1 to 30 parts by weight, 1 to 40 parts by weight and 30 to 98 parts by weight, respectively, relative to 100 parts by weight, of the carbon fibers (A), the graphite (B) and the thermoplastic resin (C), the weight average fiber length of the carbon fibers (A) is 0.3 to 3 mm and the specific gravity of the molded article is 1.1 to 1.9 g/cm3. The fiber reinforced thermoplastic resin molded article has excellent bending strength and heat conductivity.
    Type: Application
    Filed: October 20, 2015
    Publication date: August 10, 2017
    Inventors: Yuki Mitsutsuji, Sora Bang, Shin Hirata, Atsuki Tsuchiya
  • Patent number: 9475929
    Abstract: The present invention relates to fiber-reinforced thermoplastic resin composition comprising 0.1 to 10 mass % of a (meth)acrylic-based polymer, 1 to 70 mass % of reinforcing fiber, and 20 to 98.9 mass % of thermoplastic resin, wherein the (meth)acrylic-based polymer has, in a side chain, at least one functional group selected from a hydroxyl group, a carboxyl group, an amide group, and an urea group, and has a cohesive energy density (CED) of 385 to 550 MPa. The present invention provides, particularly in the case of using a polyolefin-based resin as matrix resin, a fiber-reinforced thermoplastic resin composition and a reinforcing fiber bundle which have high adhesiveness and good mechanical characteristics.
    Type: Grant
    Filed: January 26, 2011
    Date of Patent: October 25, 2016
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Atsuki Tsuchiya, Hideaki Sasaki, Masato Honma, Yumi Ando
  • Publication number: 20160272814
    Abstract: A molding material includes 5 to 50 parts by mass of reinforcing fibers (A) with a sizing agent (s) deposited thereon, 1 to 20 parts by mass of a component (B) containing a polycarbodiimide compound (B-1) that is liquid at 50° C., and 30 to 94 parts by mass of a thermoplastic resin (C) containing an element other than carbon in the repeating unit structure of the main chain, based on 100 parts by mass of the total of the components (A) to (C), wherein the molding material is a composite in which a composite fiber bundle (D) with the component (A) impregnated with the component (B) is covered with the component (C).
    Type: Application
    Filed: October 24, 2014
    Publication date: September 22, 2016
    Inventors: Kentaro Sano, Keisuke Inose, Naokichi Imai, Atsuki Tsuchiya