Patents by Inventor Hiroaki Sakata
Hiroaki Sakata 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: 20240051281Abstract: A lightweight laminate capable of maintaining mechanical properties while exhibiting excellent flame retardancy, a method for producing the laminate, and a prepreg are described, where the laminate includes fibers; a matrix resin; and a flame-retardant filler and satisfies 0.01<A/B<0.15 under the described conditions where A and B are as defined. The prepreg includes fibers; a matrix resin; and a flame-retardant filler and satisfies 0.01<A/B<0.15 under the described conditions where A and B are as defined.Type: ApplicationFiled: January 13, 2022Publication date: February 15, 2024Applicant: Toray Industries, Inc.Inventors: Yuki Sado, Hiroaki Sakata
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Publication number: 20230407024Abstract: A prepreg is described having good handleability and a low resin flow, facilitating the work in the process of a molded body and improving the dimensional accuracy of the molded body, where the prepreg includes a fiber substrate; and a resin layer containing a thermosetting resin composition containing at least components [A] and [B] below, stacked on one surface of the fiber substrate, wherein the fiber substrate is impregnated with a part of the thermosetting resin composition of the resin layer, the thermosetting resin composition having a complex viscosity ?3*24 at 24° C. of 20,000 to 100,000 Pa·s and a complex viscosity ?3*70 at 70° C. of 100 to 5,000 Pa·s, and a volatile amount of the thermosetting resin composition is 1 mass % or less when a total mass of the prepreg is 100 mass %.Type: ApplicationFiled: November 24, 2021Publication date: December 21, 2023Applicant: Toray Industries, Inc.Inventors: Ginpei Machida, Ichiro Taketa, Hiroaki Sakata
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Publication number: 20230357561Abstract: A prepreg is provided that has excellent processability and handleability and that can be processed into a cured product with high heat resistance. Also provided is a method to produce such a prepreg in an industrially advantageous way without being restricted by the types and contents of the matrix resin components used. The prepreg includes at least components [A] to [D] as given below and a preliminary reaction product that is a reaction product of the component [B] and the component [C], at least one surface resin in the prepreg having a storage elastic modulus G? in the range of 1.0×103 to 2.0×108 Pa as measured at a temperature of 40° C. and an angular frequency in the range of 0.06 to 314 rad/s: [A] carbon fiber, [B] epoxy resin comprising a m- or p-aminophenol epoxy resin [b1] and either a glycidyl ether epoxy resin or a glycidyl amine epoxy resin [b2] that has two or more glycidyl groups in a molecule, [C] curing agent, and [D] thermoplastic resin.Type: ApplicationFiled: June 6, 2023Publication date: November 9, 2023Applicant: Toray Industries, Inc.Inventors: Hiroshi Kobayashi, Taiki Maeyama, Hiroaki Sakata
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Patent number: 11708487Abstract: A prepreg is provided that has excellent processability and handleability and that can be processed into a cured product with high heat resistance. Also provided is a method to produce such a prepreg in an industrially advantageous way without being restricted by the types and contents of the matrix resin components used. The prepreg includes at least components [A] to [D] as given below and a preliminary reaction product that is a reaction product of the component [B] and the component [C], at least one surface resin in the prepreg having a storage elastic modulus G? in the range of 1.0×103 to 2.0×108 Pa as measured at a temperature of 40° C. and an angular frequency in the range of 0.06 to 314 rad/s: [A] carbon fiber, [B] epoxy resin, [C] curing agent, and [D] thermoplastic resin.Type: GrantFiled: January 18, 2018Date of Patent: July 25, 2023Assignee: TORAY INDUSTRIES, INC.Inventors: Hiroshi Kobayashi, Taiki Maeyama, Hiroaki Sakata
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Publication number: 20230064166Abstract: A surface protect material is described that is high in UV resistance, able to protect the surface of the prepreg used as the parent material, able to prevent a fiber composite material from being deteriorated by UV, able to prevent defects during painting, able to serve for control of the resin flow, and is low in the volatilization percentage during curing, where the surface protect material is a coating agent for spraying or manual application comprising an epoxy resin composition containing at least the components [A] to [D]: [A] non-aromatic epoxy resin, [B] pigment having an number average particle size of 0.1 to 10 ?m, [C] non-aromatic thermoplastic resin, and [D] cationic curing agent or anionic curing agent.Type: ApplicationFiled: January 25, 2021Publication date: March 2, 2023Applicant: Toray Industries, Inc.Inventors: Ginpei Machida, Shizue Koyanagi, Ichiro Taketa, Hiroaki Sakata
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Publication number: 20230044019Abstract: An epoxy resin composition comprises the following components [A] to [E]: [A] epoxy resin, [B] amine-type curing agent, [C] cure accelerator, and [D] red phosphorus. The epoxy resin composition contains, per 100 mass parts for the total amount of [A], 25-45 mass parts of [A1] a liquid bisphenolic epoxy resin and 20-40 mass parts of [A2] a phenol novolac-type epoxy resin, and has a content ratio of [E] to [D] ([E]/[D]) of at least 1. Provided are a light-weight fiber-reinforced composite material that exhibits an excellent flame retardancy and mechanical properties and does not produce halogen gas during combustion, and an epoxy resin composition that has a viscosity suitable for obtaining the fiber-reinforced composite material as well as prepregs.Type: ApplicationFiled: January 28, 2021Publication date: February 9, 2023Applicant: TORAY INDUSTRIES, INC.Inventors: Takahiro MINO, Akihiko ITO, Hiroaki SAKATA
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Publication number: 20220372209Abstract: The purpose of the present invention is to provide: an epoxy resin composition which enables the achievement of a resin cured product that has high flame retardancy and excellent mechanical characteristics; and a prepreg and a fiber-reinforced composite material, each of which uses this epoxy resin composition. One embodiment of the epoxy resin composition according to the present invention, said epoxy resin composition having achieved the above-described purpose, contains the components (A) and (B) described below.Type: ApplicationFiled: January 22, 2021Publication date: November 24, 2022Applicant: TORAY INDUSTRIES, INC.Inventors: Akihiko ITO, Hiroaki SAKATA
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Patent number: 11441027Abstract: The purpose of the present invention is to provide an epoxy resin composition which has excellent viscosity stability, and when cured, can provide a resin cured product which has high flame retardancy and excellent mechanical properties, and a prepreg and fiber-reinforced composite material using the epoxy resin composition. An embodiment of the epoxy resin composition according to the present invention which achieves the purpose contains all components [A]-[C]. [A]: A reactive diluent having a specific structure and a viscosity of 2 Pa·s or less at 25° C. [B]: An epoxy resin having three of more functional groups. [C]: An amine-based curing agent having a specific structure.Type: GrantFiled: September 28, 2018Date of Patent: September 13, 2022Assignee: TORAY INDUSTRIES, INC.Inventors: Akihiko Ito, Hiroaki Sakata
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Patent number: 11319435Abstract: A thermosetting resin composition at least including: [A] an epoxy resin containing two or more glycidyl groups; [B] a cyanate ester resin containing two or more cyanate groups; and [C] an amine compound; and satisfying the following conditions (1) and (2): (1) 0.25?the number of moles of glycidyl groups in the thermosetting resin composition/the number of moles of cyanate groups in the thermosetting resin composition?1.5; and (2) 0.05?the number of moles of active hydrogen contained in the amino groups in the thermosetting resin composition/the number of moles of cyanate groups in the thermosetting resin composition<0.5; and a prepreg and a fiber reinforced composite material using the thermosetting resin composition.Type: GrantFiled: February 6, 2019Date of Patent: May 3, 2022Assignee: TORAY INDUSTRIES, INC.Inventors: Jun Misumi, Ginpei Machida, Hiroaki Sakata
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Patent number: 11034810Abstract: 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: GrantFiled: March 5, 2018Date of Patent: June 15, 2021Assignee: TORAY INDUSTRIES, INC.Inventors: Junichi Aoki, Koji Furukawa, Atsuhito Arai, Jun Misumi, Hiroaki Sakata, Takashi Ochi
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Publication number: 20200399462Abstract: A thermosetting resin composition at least including: [A] an epoxy resin containing two or more glycidyl groups; [B] a cyanate ester resin containing two or more cyanate groups; and [C] an amine compound; and satisfying the following conditions (1) and (2): (1) 0.25?the number of moles of glycidyl groups in the thermosetting resin composition/the number of moles of cyanate groups in the thermosetting resin composition?1.5; and (2) 0.05?the number of moles of active hydrogen contained in the amino groups in the thermosetting resin composition/the number of moles of cyanate groups in the thermosetting resin composition<0.5; and a prepreg and a fiber reinforced composite material using the thermosetting resin composition.Type: ApplicationFiled: February 6, 2019Publication date: December 24, 2020Applicant: Toray Industries, Inc.Inventors: Jun Misumi, Ginpei Machida, Hiroaki Sakata
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Patent number: 10851217Abstract: 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: GrantFiled: August 31, 2016Date of Patent: December 1, 2020Assignee: TORAY INDUSTRIES, INC.Inventors: Junichi Aoki, Koji Furukawa, Kyoko Tamaru, Atsuhito Arai, Hiroaki Sakata, Takashi Ochi
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Publication number: 20200247986Abstract: The purpose of the present invention is to provide an epoxy resin composition which has excellent viscosity stability, and when cured, can provide a resin cured product which has high flame retardancy and excellent mechanical properties, and a prepreg and fiber-reinforced composite material using the epoxy resin composition. An embodiment of the epoxy resin composition according to the present invention which achieves the purpose contains all components [A]-[C]. [A]: A reactive diluent having a specific structure and a viscosity of 2 Pa·s or less at 25° C. [B]: An epoxy resin having three of more functional groups. [C]: An amine-based curing agent having a specific structure.Type: ApplicationFiled: September 28, 2018Publication date: August 6, 2020Applicant: Toray Industries, Inc.Inventors: Akihiko Ito, Hiroaki Sakata
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Patent number: 10723087Abstract: A prepreg includes a fiber layer containing unidirectionally arranged carbon fibers impregnated with a thermosetting resin and a resin layer existing on at least one side of the fiber layer and containing a thermosetting resin and a thermoplastic resin insoluble in the thermosetting resin. The prepreg contains carbon fibers having an areal weight of fibers of 120 to 300 g/m2 and has a weight fraction of resin of 25 to 50 mass %. An extreme value frequency of a surface geometry along a straight line perpendicular to the fibers of the prepreg is 30 points/mm or less when the prepreg has been exposed, for 24 hours, to a temperature at which a coefficient of interlayer friction is the lowest. Using sheets of the prepreg which are laid up, the coefficient of interlayer friction of the prepreg is measured at 10° C. intervals in a temperature range of 40 to 80° C. under the conditions: a pulling speed of 0.2 mm/min, a perpendicular stress of 0.1 bar, and a pulling displacement of 1 mm.Type: GrantFiled: December 22, 2016Date of Patent: July 28, 2020Assignee: Toray Industries, Inc.Inventors: Ichiro Taketa, Shiori Kawamoto, Hiroaki Sakata
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Publication number: 20200010633Abstract: 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: ApplicationFiled: March 5, 2018Publication date: January 9, 2020Applicant: TORAY INDUSTRIES, INC.Inventors: Junichi AOKI, Koji FURUKAWA, Atsuhito ARAI, Jun MISUMI, Hiroaki SAKATA, Takashi OCHI
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Publication number: 20190359763Abstract: The purpose of the present invention is to provide: an epoxy resin composition which enables the achievement of an epoxy resin cured product that exhibits excellent heat resistance, and which has both good pot life at production process temperatures and excellent curability that enables curing in a short time; and a prepreg and a fiber-reinforced composite material, each of which uses this epoxy resin composition. In order to achieve the above-described purpose, the present invention has the following configurations. Namely, an epoxy resin composition which contains at least the constituent elements [A]-[C] described below, and wherein the functional group equivalent ratio of the amino groups of the constituent element [B] to the epoxy groups of the constituent element [A] is from 0.7 to 1.Type: ApplicationFiled: February 27, 2018Publication date: November 28, 2019Applicant: TORAY INDUSTRIES, INC.Inventors: Jun MISUMI, Hiroaki SAKATA
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Publication number: 20190330433Abstract: A prepreg is provided that has excellent processability and handleability and that can be processed into a cured product with high heat resistance. Also provided is a method to produce such a prepreg in an industrially advantageous way without being restricted by the types and contents of the matrix resin components used. The prepreg includes at least components [A] to [D] as given below and a preliminary reaction product that is a reaction product of the component [B] and the component [C], at least one surface resin in the prepreg having a storage elastic modulus G? in the range of 1.0×103 to 2.0×108 Pa as measured at a temperature of 40° C. and an angular frequency in the range of 0.06 to 314 rad/s: [A] carbon fiber, [B] epoxy resin, [C] curing agent, and [D] thermoplastic resin.Type: ApplicationFiled: January 18, 2018Publication date: October 31, 2019Applicant: Toray Industries, Inc.Inventors: Hiroshi Kobayashi, Taiki Maeyama, Hiroaki Sakata
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Patent number: 10351700Abstract: 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: GrantFiled: November 6, 2015Date of Patent: July 16, 2019Assignee: TORAY INDUSTRIES, INC.Inventors: Koji Furukawa, Atsuhito Arai, Hiroaki Sakata
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Patent number: 10344132Abstract: Provided are an epoxy resin composition for manufacturing a fiber reinforced composite material having excellent curability allowing for curing in a short time, and excellent storage stability and heat resistance, and a prepreg and a fiber reinforced composite material using the same. The epoxy resin composition includes at least an epoxy resin [A], a curing agent [B] having an exothermic onset temperature higher than the exothermic onset temperature of a component [C], as measured by a differential scanning calorimeter, and the component [C] contains a compound represented by a particular formula (a), and a prepreg and a fiber reinforced composite material using the same.Type: GrantFiled: January 6, 2017Date of Patent: July 9, 2019Assignee: TORAY INDUSTRIES, INC.Inventors: Jun Misumi, Hiroaki Sakata
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Patent number: 10280251Abstract: 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: GrantFiled: March 16, 2016Date of Patent: May 7, 2019Assignee: TORAY INDUSTRIES, INC.Inventors: Junichi Aoki, Atsuhito Arai, Hiroaki Sakata, Takashi Ochi