Patents by Inventor Kaya TOKUDA

Kaya TOKUDA 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: 20240375381
    Abstract: Provided is a transparent heat-resistant laminated film that has a sufficiently smooth surface to be used as a substrate in a flexible device, and that has excellent handling properties and suppressed warping. A transparent heat-resistant laminated film characterized by having an (a) layer, a (b) layer, and a blending layer located at the interface between the (a) layer and the (b) layer, the thickness of the blending layer being 3 ?m or greater. (a) layer: A layer that contains a polyimide composition. (b) layer: A layer that contains a polyimide composition and that has a higher inorganic filler content than the (a) layer.
    Type: Application
    Filed: July 15, 2022
    Publication date: November 14, 2024
    Applicant: TOYOBO CO., LTD.
    Inventors: Kaya TOKUDA, Hiroyuki WAKUI, Tetsuo OKUYAMA, Makoto NAKAMURA, Harumi YONEMUSHI, Denichirou MIZUGUCHI
  • Patent number: 12115755
    Abstract: The invention provides a laminate including a polyimide film and an inorganic substrate, which has a number density of blisters including carbide particles therein of 50/m2 or less, an average height of blisters of 2 ?m or less, a product of the number density of the blisters (blisters/m2) and the average height of the blisters (?m) of 20 or less. The inventive laminate can be obtained by laminating the polyimide film and the inorganic substrate after sufficiently purifying and cleaning to remove foreign bodies made of inorganic substance therefrom, followed by heat treating the laminate at a temperature of 350-600° C. and then rapidly cooling it to carbonize and reduce the organic foreign bodies, and also to rapidly cool the gas contained in the blisters, which leads to reduced height of blisters.
    Type: Grant
    Filed: May 24, 2018
    Date of Patent: October 15, 2024
    Assignee: TOYOBO CO., LTD.
    Inventors: Masahiro Yamashita, Tetsuo Okuyama, Toshiyuki Tsuchiya, Naoki Watanabe, Kaya Tokuda, Shota Hara
  • Publication number: 20240336033
    Abstract: Provided is a laminate that has excellent long-term heat resistance even when an inorganic substrate having a high surface roughness is used. This laminate is characterized by having an inorganic substrate, a silane coupling agent layer, and a heat-resistant polymer film in this order, and satisfying the following (A)-(C). (A) The peel strength F0 of the laminate, as measured by a 90° peeling method, is 1.0-20 N/cm. (B) In the surface of the inorganic substrate after peeling the heat-resistant polymer film from the laminate at 90°, the area of a peeled portion on the boundary surface between the inorganic substrate and the silane coupling agent layer is at most 20% of the entire peeled surface. (C) The peel strength F1 of the laminate, as measured by the 90° peeling method after heating in a nitrogen atmosphere at 350° C. for 500 hours, is greater than F0.
    Type: Application
    Filed: July 22, 2022
    Publication date: October 10, 2024
    Applicant: TOYOBO CO., LTD.
    Inventors: Kaya TOKUDA, Tetsuo OKUYAMA, Keisuke MATSUO
  • Publication number: 20240227373
    Abstract: The present invention provides a multilayer body of an inorganic substrate and a heat-resistant polymer film, the multilayer body being suppressed in vibrations during handling. A multilayer body of a heat-resistant polymer film and an inorganic substrate according to the present invention does not substantially use an adhesive and is characterized in that: the heat-resistant polymer film is transparent; the tensile elastic modulus E1 (GPa) and the thickness T1 (?m) of the multilayer body satisfy formula (1); and the storage elastic modulus E2 (GPa) at 280° C. and the thickness T1 (?m) of the multilayer body satisfy formula (2).
    Type: Application
    Filed: July 7, 2022
    Publication date: July 11, 2024
    Applicant: TOYOBO CO., LTD.
    Inventors: Kaya TOKUDA, Tetsuo OKUYAMA, Satoshi MAEDA, Harumi YONEMUSHI, Denichirou MIZUGUCHI
  • Publication number: 20240227363
    Abstract: Provided is an inorganic substrate/heat-resistant polymer film laminate in which vibration during handling is suppressed. A laminate of a heat-resistant polymer film and an inorganic substrate that uses substantially no adhesive is characterized by that a shear peel strength between the heat-resistant polymer film and the inorganic substrate is 0.8 MPa or more and a tensile modulus of the heat-resistant polymer film is 4-9 GPa.
    Type: Application
    Filed: July 7, 2022
    Publication date: July 11, 2024
    Applicant: TOYOBO CO., LTD.
    Inventors: Kaya TOKUDA, Tetsuo OKUYAMA, Satoshi MAEDA, Harumi YONEMUSHI, Denichirou MIZUGUCHI
  • Publication number: 20240116274
    Abstract: An inorganic substrate/polymer film laminate with an attached protective film that allows for easy individual removal even when stored in a stacked state for a long period of time is provided. A first laminate is characterized by including an inorganic substrate, a polymer film layer and a first protective film, in that order, wherein the surface roughness Ra of the surface of the inorganic substrate opposite of the polymer film layer is 0.02-1.2 ?m.
    Type: Application
    Filed: February 22, 2022
    Publication date: April 11, 2024
    Applicant: TOYOBO CO., LTD.
    Inventors: Kaya TOKUDA, Satoshi MAEDA, Tetsuo OKUYAMA, Naoki WATANABE
  • Publication number: 20240075718
    Abstract: The invention provides a laminate having a protective film release auxiliary tape and comprising a rigid temporary support body (inorganic substrate) and a polymer film provided with a protective film. The laminate is configured such that the protective film can be peeled from the polymer film without separating the polymer film from the temporary support body. The laminate comprises an inorganic substrate, a heat-resistant polymer film, a protective film, and a protective film release auxiliary tape in this order. The adhesion strength F1 according to a 90 degree peeling method between the inorganic substrate and the heat-resistant polymer film, the adhesion strength F2 according to a 90 degree peeling method between the heat-resistant polymer film and the protective film, and the adhesion strength F3 according to a 90 degree peeling method between the protective film and the protective film release auxiliary tape satisfy the relationship F3>F1>F2.
    Type: Application
    Filed: June 9, 2022
    Publication date: March 7, 2024
    Applicant: TOYOBO CO., LTD.
    Inventors: Kaya TOKUDA, Satoshi MAEDA, Tetsuo OKUYAMA, Harumi YONEMUSHI, Denichirou MIZUGUCHI
  • Publication number: 20240059057
    Abstract: Provided is a laminated film that includes a heat-resistant polymer film and a first protective film laminated on one of the surfaces of the heat-resistant polymer film, wherein: the first protective film has a first substrate and a first adhesive layer provided on the first substrate; the first substrate, the first adhesive layer, and the heat-resistant polymer film are laminated in this order; the first substrate is a polyester film or a polyolefin film; the first adhesive layer contains a urethane-based resin; and the maximum diameter of a gelled product in the first adhesive layer is equal to or less than 14 ?m.
    Type: Application
    Filed: October 28, 2021
    Publication date: February 22, 2024
    Applicant: TOYOBO CO., LTD.
    Inventors: Kaya TOKUDA, Tetsuo OKUYAMA, Satoshi MAEDA, Naoki WATANABE, Mayumi AKASHI
  • Patent number: 11833795
    Abstract: The invention provides a multilayer body of an inorganic substrate and a highly heat-resistant film, wherein the surface of the inorganic substrate is sufficiently smooth after removal of the highly heat-resistant film from the multilayer body, and the inorganic substrate is re-usable. The multilayer body uses substantially no adhesive and is characterized by (1) a tensile elastic modulus of the highly heat-resistant film of 4 GPa or more, (2) a bonding strength between the highly heat-resistant film and the inorganic substrate of 0.3 N/cm or less, (3) a surface roughness Ra of a surface of the highly heat-resistant film, said surface being in contact with the inorganic substrate, of 5 nm or less, and (4) a surface roughness Ra of the surface of the inorganic substrate after removal of the highly heat-resistant film from the multilayer body of 3 nm or less.
    Type: Grant
    Filed: June 9, 2021
    Date of Patent: December 5, 2023
    Assignee: TOYOBO CO., LTD.
    Inventors: Kaya Tokuda, Tetsuo Okuyama, Satoshi Maeda, Naoki Watanabe, Harumi Yonemushi, Denichirou Mizuguchi
  • Publication number: 20230312852
    Abstract: Provided is a layered body including glass and a polyamic acid heat-cured product that is readily releasable from an inorganic substrate after being heated at 250° C. A layered body including an inorganic substrate and a polyamic acid heat-cured product, the layered body being characterized by a weight average molecular weight of 30,000 or greater for the polyamic acid, and a peel strength of 0.3 N/cm or weaker between the polyamic acid heat-cured product layer and the inorganic substrate, after the layered body has been heated at 250° C.
    Type: Application
    Filed: August 10, 2021
    Publication date: October 5, 2023
    Applicant: TOYOBO CO., LTD.
    Inventors: Kaya TOKUDA, Tetsuo OKUYAMA, Naoki WATANABE, Hiroyuki WAKUI, Harumi YONEMUSHI, Denichirou MIZUGUCHI
  • Publication number: 20230271367
    Abstract: Provided is a laminate that is useful as a temporary support for producing a large-area, high-definition, flexible electronic device, the laminate having stably low adhesive strength between a heat-resistant polymer film and an inorganic substrate even in the case of a large surface area, and having few blister defects. This laminate has an inorganic substrate, a silane coupling agent layer that includes amino groups, and a heat-resistant polymer film in the stated order, the laminate being characterized in that the elemental nitrogen component ratio in an inorganic-substrate-side peel surface after the heat-resistant polymer film has been peeled from the inorganic substrate at 90° is greater than 3.5 at % and no greater than 11 at %.
    Type: Application
    Filed: July 30, 2021
    Publication date: August 31, 2023
    Applicant: TOYOBO CO., LTD.
    Inventors: Tetsuo OKUYAMA, Kazuyuki OUYA, Kaya TOKUDA
  • Publication number: 20230211584
    Abstract: Provided is a layered product that uses a high temperature-resistant transparent film having sufficient heat resistance, and that is capable of being mechanically released from an inorganic substrate after various processes are performed on the inorganic substrate since the adhesive strength between the high temperature-resistant transparent film and the inorganic substrate is appropriately weak, and that is less warped along with the inorganic substrate. In this layered product, no adhesive is used between the high temperature-resistant transparent film and the inorganic substrate, the release strength between the high temperature-resistant transparent film and the inorganic substrate is at most 0.3 N/cm, and the warpage amount of the layered product when heated at 300° C. is at most 400 µm.
    Type: Application
    Filed: May 25, 2021
    Publication date: July 6, 2023
    Applicant: TOYOBO CO., LTD.
    Inventors: Tetsuo OKUYAMA, Makoto NAKAMURA, Denichirou MIZUGUCHI, Harumi YONEMUSHI, Hiroyuki WAKUI, Kaya TOKUDA
  • Publication number: 20230173800
    Abstract: The present invention provides a multilayer body of an inorganic substrate and a highly heat-resistant transparent film which has sufficient heat resistance and is able to be mechanically separated from the inorganic substrate after being subjected to various processes on the inorganic substrate since the adhesion between the highly heat-resistant transparent film and the inorganic substance is adequately weak. A multilayer body of a highly heat-resistant transparent film and an inorganic substrate, wherein: an adhesive is not substantially used; the peel strength between the highly heat-resistant transparent film and the inorganic substrate is 0.3 N/cm or less; and the CTE of the highly heat-resistant transparent film is 50 ppm/K or less.
    Type: Application
    Filed: May 25, 2021
    Publication date: June 8, 2023
    Applicant: TOYOBO CO., LTD.
    Inventors: Tetsuo OKUYAMA, Makoto NAKAMURA, Denichirou MIZUGUCHI, Harumi YONEMUSHI, Hiroyuki WAKUI, Kaya TOKUDA
  • Patent number: 11655118
    Abstract: The purpose of the present invention is to provide a storage state in which a reactive compound layer can be stably maintained in a polymer film having a reactive compound layer on the surface. The film roll is obtained by winding together: a first polymer film having a reactive compound layer on the surface, and a second polymer film having a surface roughness (Ra) of 0.1 ?m or more and a modulus of elasticity of 300 MPa or more and 10 GPa or less. The film bundle is obtained by laminating the first and second polymer films. Preferably, storing the film roll and the film bundle at a low temperature enables a thin layer of a reactive compound to be stably maintained.
    Type: Grant
    Filed: July 13, 2018
    Date of Patent: May 23, 2023
    Assignee: TOYOBO CO., LTD.
    Inventors: Kaya Tokuda, Masahiro Yamashita, Tetsuo Okuyama, Toshiyuki Tsuchiya, Naoki Watanabe, Shunsuke Ichimura
  • Publication number: 20230150252
    Abstract: The invention provides a multilayer body of an inorganic substrate and a highly heat-resistant film, wherein the surface of the inorganic substrate is sufficiently smooth after removal of the highly heat-resistant film from the multilayer body, and the inorganic substrate is re-usable. The multilayer body uses substantially no adhesive and is characterized by (1) a tensile elastic modulus of the highly heat-resistant film of 4 GPa or more, (2) a bonding strength between the highly heat-resistant film and the inorganic substrate of 0.3 N/cm or less, (3) a surface roughness Ra of a surface of the highly heat-resistant film, said surface being in contact with the inorganic substrate, of 5 nm or less, and (4) a surface roughness Ra of the surface of the inorganic substrate after removal of the highly heat-resistant film from the multilayer body of 3 nm or less.
    Type: Application
    Filed: June 9, 2021
    Publication date: May 18, 2023
    Applicant: TOYOBO CO., LTD.
    Inventors: Kaya TOKUDA, Tetsuo OKUYAMA, Satoshi MAEDA, Naoki WATANABE, Harumi YONEMUSHI, Denichirou MIZUGUCHI
  • Publication number: 20220274314
    Abstract: This apparatus for manufacturing a laminate comprises: a first sheet transporting device for transporting a first sheet; a water supply device for supplying an aqueous medium to the surface of the first sheet coated with a silane coupling agent and/or the surface of a second sheet coated with a silane coupling agent; and a laminating device for attaching the first sheet and the second sheet which have been supplied with the aqueous medium.
    Type: Application
    Filed: June 18, 2020
    Publication date: September 1, 2022
    Applicant: TOYOBO CO., LTD.
    Inventors: Tetsuo OKUYAMA, Kaya TOKUDA, Kazuyuki OUYA, Naoki WATANABE
  • Publication number: 20220143964
    Abstract: The present invention enables the achievement of a laminate of heat-resistant polymer films, which does not use a bonding material having inferior heat resistance. According to the present invention, a polyvalent amine compound serving as a reactive compound is applied to heat-resistant polymer films such as PET, PEN or PI films, and the resulting polymer films are superposed upon each other and subsequently subjected to a heat treatment under predetermined conditions, thereby obtaining a laminate of heat-resistant polymer films. Since the thus-obtained laminate does not use a bonding material, the heat resistance is not decreased and the film properties before lamination are not deteriorated. Since the process for obtaining this laminate has excellent productivity, this laminate is useful as a low-cost thick heat-resistant polymer film or sheet of high performance.
    Type: Application
    Filed: March 30, 2020
    Publication date: May 12, 2022
    Applicant: TOYOBO CO., LTD.
    Inventors: Masahiro YAMASHITA, Kaya TOKUDA, Tetsuo OKUYAMA
  • Patent number: 11267216
    Abstract: [Problem] To provide a polyimide film laminated substrate in which stable peeling with a constant low force from an inorganic substrate is enabled when a polyimide film is to be peeled from an inorganic substrate even after heat treatment at a temperature exceeding 500° C. is performed. [Solution] Silane coupling agent treatment is performed on an inorganic substrate on which a thin film of an aluminum oxide, a thin film of a composite oxide of aluminum and silicon, a thin film of molybdenum or tungsten, or an alloy thin film of molybdenum and tungsten is formed continuously or discontinuously on a part of at least one surface thereof, and a polyimide film layer is further laminated on the silane coupling agent layer. In the obtained laminate, the part where the aluminum oxide thin film layer is present functions as an easily-peelable layer, the part where no aluminum oxide thin film layer functions as an easily-bondable part.
    Type: Grant
    Filed: January 23, 2018
    Date of Patent: March 8, 2022
    Assignee: TOYOBO CO., LTD.
    Inventors: Tetsuo Okuyama, Naoki Watanabe, Toshiyuki Tsuchiya, Masahiro Yamashita, Kaya Tokuda
  • Publication number: 20210308987
    Abstract: A laminate comprising a heat-resistant polymer film, an inorganic substrate, and a polyamine compound layer formed using a polyamine compound, wherein the polyamine compound layer is formed between the heat-resistant polymer film and the inorganic substrate.
    Type: Application
    Filed: August 7, 2019
    Publication date: October 7, 2021
    Applicant: TOYOBO CO., LTD.
    Inventors: Tetsuo OKUYAMA, Miyuki HAYASHI, Shunsuke ICHIMURA, Kaya TOKUDA, Masahiro YAMASHITA
  • Publication number: 20210122143
    Abstract: The invention provides a laminate including a polyimide film and an inorganic substrate, which has a number density of blisters including carbide particles therein of 50/m2 or less, an average height of blisters of 2 ?m or less, a product of the number density of the blisters (blisters/m2) and the average height of the blisters (?m) of 20 or less. The inventive laminate can be obtained by laminating the polyimide film and the inorganic substrate after sufficiently purifying and cleaning to remove foreign bodies made of inorganic substance therefrom, followed by heat treating the laminate at a temperature of 350-600° C. and then rapidly cooling it to carbonize and reduce the organic foreign bodies, and also to rapidly cool the gas contained in the blisters, which leads to reduced height of blisters.
    Type: Application
    Filed: May 24, 2018
    Publication date: April 29, 2021
    Applicant: TOYOBO CO., LTD.
    Inventors: Masahiro YAMASHITA, Tetsuo OKUYAMA, Toshiyuki TSUCHIYA, Naoki WATANABE, Kaya TOKUDA, Shota HARA