Patents by Inventor Jun Misumi

Jun Misumi 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: 20240066758
    Abstract: A problem to be solved by the present invention is to provide a prepreg and an integrally molded article, wherein the prepreg exhibits suitable flexibility and adhesiveness, excels in formability on a complicated mold face and adhesion to a mold face, causes no positional shift, and can be efficiently reinforced and stiffened at an intended position. A main object of the present invention is to provide a prepreg including (A) reinforcing fibers, (B) a thermosetting resin, and (C) a thermoplastic resin, wherein the (C) thermoplastic resin exists in at least a part of a face of the prepreg, and wherein the prepreg satisfies the condition [I], and satisfies the condition [II] or the condition [III]: [I]: the (B) thermosetting resin has a peak in the temperature range of more than 100° C. and 180° C.
    Type: Application
    Filed: December 21, 2021
    Publication date: February 29, 2024
    Applicant: Toray Industries, Inc.
    Inventors: Miho Onodera, Yoshiki Takebe, Yuta Naito, Jun Misumi, Yoshifumi Nakayama, Masato Honma
  • Patent number: 11878478
    Abstract: The present invention aims at providing a prepreg for producing a laminate suitable as a structural material, and a laminate, which have excellent tensile shear joining strength, fatigue joining strength, and interlaminar fractural toughness values, and can be firmly integrated with another structural member by welding. The present invention is a prepreg including the following structural components [A], [B], and [C], wherein [C] is present on a surface of the prepreg, [C] is a crystalline thermoplastic resin having a glass transition temperature of 100° C. or higher or an amorphous thermoplastic resin having a glass transition temperature of 180° C. or higher, and the reinforcing fibers [A] are present which are included in a resin area including [B] and a resin area including [C] across an interface between the two resin areas: [A] reinforcing fibers; [B] a thermosetting resin; and [C] a thermoplastic resin.
    Type: Grant
    Filed: May 15, 2020
    Date of Patent: January 23, 2024
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Jun Misumi, Masato Honma, Kyoko Shinohara
  • Publication number: 20230407018
    Abstract: An object is to provide a fiber-reinforced resin that can be welded to another member via a thermoplastic resin and that is less likely to be damaged even when welded at a high temperature, wherein the fiber-reinforced resin includes a reinforcing fiber and has a cured epoxy resin region and a thermoplastic resin region disposed at the surface wherein aromatic rings account for 50% or more and 90% or less of the cured epoxy resin present in the cured epoxy resin region.
    Type: Application
    Filed: October 27, 2021
    Publication date: December 21, 2023
    Applicant: Toray Industries, Inc.
    Inventors: Jun Misumi, Kyoko Shinohara, Masato Honma
  • Publication number: 20230406997
    Abstract: An epoxy resin composition is provided that is resistant to decomposition at high temperatures and a fiber-reinforced resin molding is provided that hardly suffers significant damage while being welded to another member even in the case where it is combined with a thermoplastic resin layer having a high melting point that works as an adhesive layer, as well as a prepreg that serves as a precursor therefor, where the epoxy resin composition includes an epoxy resin (A) that has a polycyclic aromatic hydrocarbon skeleton or a biphenyl skeleton and that has an epoxy equivalent weight of 220 g/eq or more and 290 g/eq or less and a polyamine compound having an average active hydrogen equivalent weight of 55 g/eq or more and 100 g/eq or less wherein the average epoxy equivalent weight over all epoxy resins contained is 160 g/eq or more and 255 g/eq or less.
    Type: Application
    Filed: October 27, 2021
    Publication date: December 21, 2023
    Applicant: Toray Industries, Inc.
    Inventors: Jun Misumi, Masato Honma, Kyoko Shinohara
  • Patent number: 11840612
    Abstract: An object of the present invention is to provide a prepreg and a laminate for producing a laminate suitable as a structural material, which have excellent compressive strength and interlaminar fractural toughness values, and can be firmly integrated with another structural member by welding. The present invention provides a prepreg including the following structural components [A] reinforcing fibers, [B] a thermosetting resin, and [C] a thermoplastic resin, in which [B] has a rubbery state elastic modulus of 10 MPa or more at a temperature obtained by adding 50° C. to a glass transition temperature in a state in which a degree of cure is 90% or more, [C] is present in a surface of the prepreg, and the reinforcing fibers [A] are present, which are included in a resin area including {B] and a resin area including [C] across an interface between the two resin areas.
    Type: Grant
    Filed: May 15, 2020
    Date of Patent: December 12, 2023
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Jun Misumi, Masato Honma, Kyoko Shinohara, Noriyuki Hirano
  • Publication number: 20230106362
    Abstract: The present invention provides a fiber-reinforced resin which has excellent tensile shear joining strength and is able to be integrated with another structural member with high productivity by means of thermal welding, thereby being suitable as a structural material. The present invention is a fiber-reinforced resin which contains constituents (A), (B) and (C), while having a multilayer structure that is composed of a thermosetting resin layer that is formed of (B) a thermosetting resin, a thermoplastic resin layer that is formed of (C) a thermoplastic resin, and a mixed layer that is present between the thermoplastic resin layer and the thermosetting resin layer, while being obtained by mixing the thermoplastic resin (C) and the thermosetting resin (B), in such a manner that the thermoplastic resin layer is present in the surface. With respect to this fiber-reinforced resin, at least some of (A) reinforcing fibers are present in the mixed layer.
    Type: Application
    Filed: March 5, 2021
    Publication date: April 6, 2023
    Applicant: Toray Industries, Inc.
    Inventors: Jun Misumi, Masato Honma, Genki Matsubara, Kyoko Shinohara
  • Publication number: 20230017689
    Abstract: A prepreg includes composition elements [A], [B], and [C] described below, [A] a reinforcing fiber, [B] a thermosetting resin, and [C] a thermoplastic resin. [C] is present on a surface of the prepreg, [B] contains a first curing agent [b1] and a second curing agent [b2], and the reinforcing fiber of [A] that crosses over a boundary surface between a resin region containing [B] and a resin region containing [C] and that is in contact with both resin regions is present.
    Type: Application
    Filed: November 20, 2020
    Publication date: January 19, 2023
    Applicant: Toray Industries, Inc.
    Inventors: Jun Misumi, Masato Honma, Kyoko Shinohara, Koji Furukawa, Atsuhito Arai
  • Publication number: 20230001651
    Abstract: A prepreg includes composition elements [A], [B], and [C] described below, [A] a reinforcing fiber, [B] a thermosetting resin, and [C] a thermoplastic resin. [B] contains a thermoplastic resin having an aromatic ring with an amount of 10% or more by mass, a resin region containing [B] is present on one surface of the prepreg, a resin region containing [C] is present on another surface of the prepreg, and [A] that crosses over a boundary surface between the resin region containing [B] and the resin region containing [C] and that is in contact with both resin regions is present.
    Type: Application
    Filed: November 20, 2020
    Publication date: January 5, 2023
    Applicant: Toray Industries, Inc.
    Inventors: Kyoko Shinohara, Masato Honma, Jun Misumi
  • Publication number: 20220388289
    Abstract: A prepreg includes [A], [B], and [C] described below. The [B] further comprises [B?]; a ratio of a mole number of an active hydrogen contained in [B?] to a mole number of an epoxy group in an epoxy resin contained in [B] is in a range of 0.6 to 1.1 both inclusive; [C] is present on a surface of the prepreg; and [A] that crosses over a boundary surface between a resin region containing [B] and a resin region containing [C] and that is in contact with both resin regions is present: [A] a reinforcing fiber; [B] an epoxy resin composition; an amine compound; and [C] a thermoplastic resin composition.
    Type: Application
    Filed: November 20, 2020
    Publication date: December 8, 2022
    Applicant: Toray Industries, Inc.
    Inventors: Jun Misumi, Masato Honma, Kyoko Shinohara
  • Publication number: 20220324184
    Abstract: An object of the present invention is to provide a prepreg and a laminate for producing a laminate suitable as a structural material, which have excellent compressive strength and interlaminar fractural toughness values, and can be firmly integrated with another structural member by welding. The present invention provides a prepreg including the following structural components [A] reinforcing fibers, [B] a thermosetting resin, and [C] a thermoplastic resin, in which [B] has a rubbery state elastic modulus of 10 MPa or more at a temperature obtained by adding 50° C. to a glass transition temperature in a state in which a degree of cure is 90% or more, [C] is present in a surface of the prepreg, and the reinforcing fibers [A] are present, which are included in a resin area including {B] and a resin area including [C] across an interface between the two resin areas.
    Type: Application
    Filed: May 15, 2020
    Publication date: October 13, 2022
    Applicant: Toray Industries, Inc.
    Inventors: Jun Misumi, Masato Honma, Kyoko Shinohara, Noriyuki Hirano
  • Publication number: 20220315762
    Abstract: The present invention has an object of providing a prepreg for producing a laminate suitable as a structural material, and a laminate, which have excellent combustion resistance, compressive strength and interlaminar fractural toughness values, and can be firmly integrated with another structural member by welding. The present invention is a prepreg including structural components: [A] reinforcing fibers, [B] a thermosetting resin, and [C] a thermoplastic resin [C], wherein [B] includes at least one resin selected from a cyanate ester resin having an average cyanate equivalent of 220 or less, a bismaleimide resin having an average maleimide equivalent of 210 or less, and a benzoxazine resin having an average oxazine equivalent of 300 or less, [C] is present on a surface of the prepreg, and the reinforcing fibers [A] are present which are included in a resin area including [B] and a resin area including [C] across an interface between the two resin areas.
    Type: Application
    Filed: May 15, 2020
    Publication date: October 6, 2022
    Applicant: Toray Industries, Inc.
    Inventors: Kyoko Shinohara, Masato Honma, Jun Misumi
  • Publication number: 20220251317
    Abstract: An object of the present invention is to provide a prepreg and a laminate for producing a laminate suitable as a structural material, which have excellent joining strength and interlaminar fractural toughness values and can be firmly integrated with another structural member by welding. The present invention provides a prepreg including the following structural components, [A] reinforcing fibers, [B] an epoxy resin, and [C] a thermoplastic resin, wherein all epoxy resins included in [B] have an average epoxy value of 2.0 meq./g or more and 5.0 meq./g or less, [C] is present in a surface of the prepreg, and the reinforcing fibers [A] are present, which are included in a resin area including [B] and a resin area including [C] across an interface between the two resin areas.
    Type: Application
    Filed: May 15, 2020
    Publication date: August 11, 2022
    Applicant: Toray Industries, Inc.
    Inventors: Jun Misumi, Masato Honma, Kyoko Shinohara, Noriyuki Hirano
  • Publication number: 20220213284
    Abstract: The present invention aims at providing a prepreg for producing a laminate suitable as a structural material, and a laminate, which have excellent tensile shear joining strength, fatigue joining strength, and interlaminar fractural toughness values, and can be firmly integrated with another structural member by welding. The present invention is a prepreg including the following structural components [A], [B], and [C], wherein [C] is present on a surface of the prepreg, [C] is a crystalline thermoplastic resin having a glass transition temperature of 100° C. or higher or an amorphous thermoplastic resin having a glass transition temperature of 180° C. or higher, and the reinforcing fibers [A] are present which are included in a resin area including [B] and a resin area including [C] across an interface between the two resin areas: [A] reinforcing fibers; [B] a thermosetting resin; and [C] a thermoplastic resin.
    Type: Application
    Filed: May 15, 2020
    Publication date: July 7, 2022
    Applicant: Toray Industries, Inc.
    Inventors: Jun Misumi, Masato Honma, Kyoko Shinohara
  • Patent number: 11319435
    Abstract: 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: Grant
    Filed: February 6, 2019
    Date of Patent: May 3, 2022
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Jun Misumi, Ginpei Machida, Hiroaki Sakata
  • Patent number: 11286359
    Abstract: A prepreg includes; sizing agent-coated carbon fibers coated with a sizing agent; and a thermosetting resin composition impregnated into the sizing agent-coated carbon fibers. The sizing agent includes an aliphatic epoxy compound (A) and an aromatic compound (B) at least containing an aromatic epoxy compound (B1). The thermosetting resin composition includes a thermosetting resin (D) and a latent hardener (E), and optionally includes an additive (F) other than the thermosetting resin (D) and the latent hardener (E). The (a)/(b) ratio is within a predetermined range where (a) is the height of a component at a binding energy assigned to CHx, C—C, and C?C and (b) is the height of a component at a binding energy assigned to C—O in a C1s core spectrum of the surfaces of the sizing agent-coated carbon fibers analyzed by X-ray photoelectron spectroscopy.
    Type: Grant
    Filed: August 6, 2019
    Date of Patent: March 29, 2022
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Nobuyuki Arai, Tomoko Ichikawa, Hiroshi Taiko, Makoto Endo, Masanobu Kobayashi, Jun Misumi
  • Patent number: 11111345
    Abstract: A prepreg includes; sizing agent-coated carbon fibers coated with a sizing agent; and a thermosetting resin composition impregnated into the sizing agent-coated carbon fibers. The sizing agent includes an aliphatic epoxy compound (A) and an aromatic compound (B) at least containing an aromatic epoxy compound (B1). The thermosetting resin composition includes a thermosetting resin (D) and a latent hardener (E), and optionally includes an additive (F) other than the thermosetting resin (D) and the latent hardener (E). The (a)/(b) ratio is within a predetermined range where (a) is the height of a component at a binding energy assigned to CHx, C—C, and C?C and (b) is the height of a component at a binding energy assigned to C—O in a C1s core spectrum of the surfaces of the sizing agent-coated carbon fibers analyzed by X-ray photoelectron spectroscopy.
    Type: Grant
    Filed: August 4, 2017
    Date of Patent: September 7, 2021
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Nobuyuki Arai, Tomoko Ichikawa, Hiroshi Taiko, Makoto Endo, Masanobu Kobayashi, Jun Misumi
  • Patent number: 11034810
    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: Grant
    Filed: March 5, 2018
    Date of Patent: June 15, 2021
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Junichi Aoki, Koji Furukawa, Atsuhito Arai, Jun Misumi, Hiroaki Sakata, Takashi Ochi
  • Publication number: 20200399462
    Abstract: 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: Application
    Filed: February 6, 2019
    Publication date: December 24, 2020
    Applicant: Toray Industries, Inc.
    Inventors: Jun Misumi, Ginpei Machida, Hiroaki Sakata
  • 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
  • Publication number: 20190359785
    Abstract: A prepreg includes; sizing agent-coated carbon fibers coated with a sizing agent; and a thermosetting resin composition impregnated into the sizing agent-coated carbon fibers. The sizing agent includes an aliphatic epoxy compound (A) and an aromatic compound (B) at least containing an aromatic epoxy compound (B1). The thermosetting resin composition includes a thermosetting resin (D) and a latent hardener (E), and optionally includes an additive (F) other than the thermosetting resin (D) and the latent hardener (E). The (a)/(b) ratio is within a predetermined range where (a) is the height of a component at a binding energy assigned to CHx, C—C, and C?C and (b) is the height of a component at a binding energy assigned to C—) in a C1s core spectrum of the surfaces of the sizing agent-coated carbon fibers analyzed by X-ray photoelectron spectroscopy.
    Type: Application
    Filed: August 6, 2019
    Publication date: November 28, 2019
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Nobuyuki ARAI, Tomoko ICHIKAWA, Hiroshi TAIKO, Makoto ENDO, Masanobu KOBAYASHI, Jun MISUMI