Patents by Inventor Kouki Wakabayashi

Kouki Wakabayashi 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: 11959197
    Abstract: A first aspect of the present invention is carbon fiber wherein the surface of a monofilament has a center line average roughness Ra of 6.0 nm or more and 13 nm or less, and the monofilament has a long diameter/short diameter ratio of 1.11 or more and 1.245 or less. A second aspect of the present invention is carbon fiber precursor acrylic fiber wherein the surface of a monofilament has a center line average roughness Ra of 18 nm or more and 27 nm or less, and the monofilament has a long diameter/short diameter ratio of 1.11 or more and 1.245 or less. The carbon fiber according to the first aspect is obtained by stabilizing and carbonizing under specific conditions the carbon fiber precursor acrylic fiber according to the second aspect.
    Type: Grant
    Filed: August 15, 2019
    Date of Patent: April 16, 2024
    Assignee: Mitsubishi Chemical Corporation
    Inventors: Naomasa Matsuyama, Yuutarou Nakamura, Norifumi Hirota, Hiroko Matsumura, Katsuhiko Ikeda, Kouki Wakabayashi, Tadashi Ootani, Akihiro Itou, Kenji Hirano, Akito Hatayama, Kenji Kaneta, Atsushi Nakajima
  • Patent number: 11787913
    Abstract: A sizing agent for carbon fiber includes component (A), component (B), and component (C), in which the component (A) is at least one selected from the group consisting of component (A-1), component (A-2), and component (A-3); the component (A-1) is a urethane compound having a structure of Formula (1-1) in the molecule, the component (A-2) is an ester compound having a structure represented by Formula (1-2) in the molecule, the component (A-3) is an amide compound having a structure of Formula (1-3) in the molecule; the component (B) is an epoxy compound selected from the group consisting of an epoxy compound represented by Formula (2), an epoxy compound represented by Formula (3), and an epoxy compound represented by Formula (4); and the component (C) is a bisphenol type epoxy compound.
    Type: Grant
    Filed: April 23, 2019
    Date of Patent: October 17, 2023
    Assignee: Mitsubishi Chemical Corporation
    Inventors: Kenji Kaneta, Takaaki Suzuki, Kouki Wakabayashi, Akihiro Ito, Naoki Sugiura
  • Publication number: 20210309820
    Abstract: Use of a sizing agent having a heat weight loss B-1 of 65% or more as determined by a specific measurement method, or a sizing agent containing a surfactant and a compound represented by formula (1):
    Type: Application
    Filed: June 22, 2021
    Publication date: October 7, 2021
    Applicant: Mitsubishi Chemical Corporation
    Inventors: Kenji KANETA, Naoki SUGIURA, Kouki WAKABAYASHI
  • Publication number: 20210108363
    Abstract: A sizing agent is provided, the sizing agent being blended with a component (A) and a component (B), wherein a mass ratio A/B of the component (A) to the component (B) is 0.5 to 20, and a proportion of a total mass of the component (A) and the component (B) with respect to a total mass of the sizing agent is 80% by mass or more, wherein the component (A) is an epoxy resin having a viscosity of 1 to 180,000 Pa·s at 30° C., and the component (B) is an aliphatic ester compound having a freezing point of 50° C. or lower.
    Type: Application
    Filed: December 22, 2020
    Publication date: April 15, 2021
    Applicant: Mitsubishi Chemical Corporation
    Inventors: Kenji KANETA, Kouki WAKABAYASHI, Tsuyoshi TAKADA, Hiroyuki NAKAO
  • Publication number: 20200002850
    Abstract: A first aspect of the present invention is carbon fiber wherein the surface of a monofilament has a center line average roughness Ra of 6.0 nm or more and 13 nm or less, and the monofilament has a long diameter/short diameter ratio of 1.11 or more and 1.245 or less. A second aspect of the present invention is carbon fiber precursor acrylic fiber wherein the surface of a monofilament has a center line average roughness Ra of 18 nm or more and 27 nm or less, and the monofilament has a long diameter/short diameter ratio of 1.11 or more and 1.245 or less. The carbon fiber according to the first aspect is obtained by stabilizing and carbonizing under specific conditions the carbon fiber precursor acrylic fiber according to the second aspect.
    Type: Application
    Filed: August 15, 2019
    Publication date: January 2, 2020
    Applicant: Mitsubishi Chemical Corporation
    Inventors: Naomasa Matsuyama, Yuutarou Nakamura, Norifumi Hirota, Hiroko Matsumura, Katsuhiko Ikeda, Kouki Wakabayashi, Tadashi Ootani, Akihiro Itou, Kenji Hirano, Akito Hatayama, Kenji Kaneta, Atsushi Nakajima
  • Publication number: 20190249358
    Abstract: A sizing agent for carbon fiber includes component (A), component (B), and component (C), in which the component (A) is at least one selected from the group consisting of component (A-1), component (A-2), and component (A-3); the component (A-1) is a urethane compound having a structure of Formula (1-1) in the molecule, the component (A-2) is an ester compound having a structure represented by Formula (1-2) in the molecule, the component (A-3) is an amide compound having a structure of Formula (1-3) in the molecule; the component (B) is an epoxy compound selected from the group consisting of an epoxy compound represented by Formula (2), an epoxy compound represented by Formula (3), and an epoxy compound represented by Formula (4); and the component (C) is a bisphenol type epoxy compound.
    Type: Application
    Filed: April 23, 2019
    Publication date: August 15, 2019
    Applicant: Mitsubishi Chemical Corporation
    Inventors: Kenji KANETA, Takaaki SUZUKI, Kouki WAKABAYASHI, Akihiro ITO, Naoki SUGIURA
  • Publication number: 20190233975
    Abstract: Provided is a carbon fiber bundle for obtaining a fiber-reinforced plastic having high mechanical characteristics. An acrylonitrile swollen fiber for a carbon fiber having openings of 10 nm or more in width in the circumference direction of the swollen fiber at a ratio in the range of 0.3 openings/?m2 or more and 2 openings/?m2 or less on the surface of the swollen fiber, and the swollen fiber is not treated with a finishing oil agent. A precursor fiber obtained by treating the swollen fiber with a silicone-based finishing oil agent has a silicon content of 1700 ppm or more and 5000 ppm or less, and the silicon content is 50 ppm or more and 300 ppm or less after the finishing oil agent is washed away with methyl ethyl ketone by using a Soxhlet extraction apparatus for 8 hours. The fiber is preferably an acrylonitrile copolymer containing acrylonitrile in an amount of 96.0 mass % or more and 99.7 mass % or less and an unsaturated hydrocarbon having at least one carboxyl group or ester group in an amount of 0.
    Type: Application
    Filed: April 4, 2019
    Publication date: August 1, 2019
    Applicant: MITSUBISHI CHEMICAL CORPORATION
    Inventors: Hiroshi HASHIMOTO, Naoki SUGIURA, Yasuyuki FUJII, Hiroko MATSUMURA, Takahiro OKUYA, lsao OOKI, Masahiro HATA, Kouki WAKABAYASHI, Akiyoshi KOGAME, Kazunori SUMIYA, Akito HATAYAMA
  • Publication number: 20190040549
    Abstract: Provided is a carbon fiber bundle for obtaining a fiber-reinforced resin having high mechanical characteristics. A carbon fiber bundle formed of single carbon fibers, each of which has no uneven surface structure of 0.6 ?m or more in length extending in the longitudinal direction of the single fiber; which has an uneven structure having a difference in height (Rp?v) of 5 to 25 nm between the highest portion and the lowest portion of the surface of the single fiber and having an average roughness Ra of 2 to 6 nm; and which has a ratio of the major axis to the minor axis (major axis/minor axis) of a cross-section of the single fiber of 1.00 to 1.01, wherein a mass of the single fiber per unit length falls within the range of 0.030 to 0.042 mg/m; a strand strength is 5900 MPa or more; a strand elastic modulus measured by the ASTM method is 250 to 380 GPa; and a knot tenacity is 900 N/mm2 or more.
    Type: Application
    Filed: October 12, 2018
    Publication date: February 7, 2019
    Applicant: Mitsubishi Chemical Corporation
    Inventors: Naoki SUGIURA, Takahiro OKUYA, Hiroshi HASHIMOTO, Isao OOKI, Hiroko MATSUMURA, Masahiro HATA, Kouki WAKABAYASHI, Akito HATAYAMA
  • Patent number: 9862824
    Abstract: The present invention provides: a carbon fiber sizing agent that can obtain a carbon fiber bundle having a superior effect of improving mechanical properties when composited using a resin; an aqueous dispersion thereof; a carbon fiber bundle; a sheet-shaped article having a carbon fiber bundle; and a composite material. The carbon fiber sizing agent contains: a compound (A) that is an ester of an unsaturated monobasic acid and an epoxy compound having a plurality of epoxy groups in the molecule, and that has at least one epoxy group in the molecule; a urethane acrylate oligomer (B) that is bifunctional and that has a tensile elongation rate of the cured product of at least 40%; and a polyurethane resin (C) having a tensile elongation rate of a dried coating film of 350-900% inclusive. The amounts of A-C contained satisfy the conditions described in the description. The aqueous dispersion disperses the sizing agent. The carbon fiber bundle contains 0.6-3.0 mass % inclusive of the sizing agent.
    Type: Grant
    Filed: August 21, 2012
    Date of Patent: January 9, 2018
    Assignee: Mitsubishi Chemical Corporation
    Inventors: Kouki Wakabayashi, Naoki Sugiura, Masahiro Hata, Shigekazu Takeda, Keigo Yoshida, Shuuichi Nakamura
  • Publication number: 20140256855
    Abstract: The present invention provides: a carbon fiber sizing agent that can obtain a carbon fiber bundle having a superior effect of improving mechanical properties when composited using a resin; an aqueous dispersion thereof; a carbon fiber bundle; a sheet-shaped article having a carbon fiber bundle; and a composite material. The carbon fiber sizing agent contains: a compound (A) that is an ester of an unsaturated monobasic acid and an epoxy compound having a plurality of epoxy groups in the molecule, and that has at least one epoxy group in the molecule; a urethane acrylate oligomer (B) that is bifunctional and that has a tensile elongation rate of the cured product of at least 40%; and a polyurethane resin (C) having a tensile elongation rate of a dried coating film of 350-900% inclusive. The amounts of A-C contained satisfy the conditions described in the description. The aqueous dispersion disperses the sizing agent. The carbon fiber bundle contains 0.6-3.0 mass % inclusive of the sizing agent.
    Type: Application
    Filed: August 21, 2012
    Publication date: September 11, 2014
    Applicant: MITSUBISHI RAYON CO., LTD.
    Inventors: Kouki Wakabayashi, Naoki Sugiura, Masahiro Hata, Shigekazu Takeda, Keigo Yoshida, Shuuichi Nakamura
  • Patent number: 8679991
    Abstract: The invention relates to a prepreg containing a reinforcing fiber, a sheet-like reinforcing fiber substrate including the reinforcing fiber, and a matrix resin, wherein the matrix resin is impregnated into the sheet-like reinforcing fiber substrate and also covers one surface of the sheet-like reinforcing fiber substrate, such that the matrix resin impregnation ratio is within a range of 35% to 95%. The invention also relates to a prepreg containing a reinforcing fiber substrate in the form of a sheet and formed from a reinforcing fiber woven fabric, and a matrix resin, wherein at least one surface of the reinforcing fiber substrate displays a sea-and-island-type pattern with resin-impregnated portions (island portions) and fiber portions (sea portions), such that a surface coverage of the matrix resin is within a range of 3% to 80%.
    Type: Grant
    Filed: April 13, 2012
    Date of Patent: March 25, 2014
    Assignee: Mitsubishi Rayon Co., Ltd.
    Inventors: Kazuya Goto, Kazuki Koga, Tadayoshi Saitou, Akihiro Ito, Tsuneo Takano, Kouki Wakabayashi
  • Publication number: 20140057514
    Abstract: This invention relates to a prepreg containing a reinforcing fiber, a reinforcing fiber substrate in the form of a sheet and containing the reinforcing fiber, and a matrix resin, such that the matrix resin is impregnated into the reinforcing fiber substrate and also covers one surface of the reinforcing fiber substrate, and an impregnation ratio of the matrix resin is within a range of 35% to 95%.
    Type: Application
    Filed: November 5, 2013
    Publication date: February 27, 2014
    Applicant: MITSUBISHI RAYON CO., LTD.
    Inventors: Kazuya Goto, Kazuki Koga, Tadayoshi Saitou, Akihiro Ito, Tsuneo Takano, Kouki Wakabayashi
  • Publication number: 20120276795
    Abstract: The invention relates to a prepreg containing a reinforcing fiber, a sheet-like reinforcing fiber substrate including the reinforcing fiber, and a matrix resin, wherein the matrix resin is impregnated into the sheet-like reinforcing fiber substrate and also covers one surface of the sheet-like reinforcing fiber substrate, such that the matrix resin impregnation ratio is within a range of 35% to 95%. The invention also relates to a prepreg containing a reinforcing fiber substrate in the form of a sheet and formed from a reinforcing fiber woven fabric, and a matrix resin, wherein at least one surface of the reinforcing fiber substrate displays a sea-and-island-type pattern with resin-impregnated portions (island portions) and fiber portions (sea portions), such that a surface coverage of the matrix resin is within a range of 3% to 80%.
    Type: Application
    Filed: April 13, 2012
    Publication date: November 1, 2012
    Inventors: Kazuya GOTO, Kazuki KOGA, Tadayoshi SAITOU, Akihiro ITO, Tsuneo TAKANO, Kouki WAKABAYASHI
  • Publication number: 20120088104
    Abstract: Provided is a carbon fiber bundle for obtaining a fiber-reinforced plastic having high mechanical characteristics. An acrylonitrile swollen fiber for a carbon fiber having openings of 10 nm or more in width in the circumference direction of the swollen fiber at a ratio in the range of 0.3 openings/?m2 or more and 2 openings/?m2 or less on the surface of the swollen fiber, and the swollen fiber is not treated with a finishing oil agent. A precursor fiber obtained by treating the swollen fiber with a silicone-based finishing oil agent has a silicon content of 1700 ppm or more and 5000 ppm or less, and the silicon content is 50 ppm or more and 300 ppm or less after the finishing oil agent is washed away with methyl ethyl ketone by using a Soxhlet extraction apparatus for 8 hours. The fiber is preferably an acrylonitrile copolymer containing acrylonitrile in an amount of 96.0 mass % or more and 99.7 mass % or less and an unsaturated hydrocarbon having at least one carboxyl group or ester group in an amount of 0.
    Type: Application
    Filed: June 10, 2010
    Publication date: April 12, 2012
    Applicant: MITSUBISHI RAYON CO., LTD.
    Inventors: Hiroshi Hashimoto, Naoki Sugiura, Yasuyuki Fujii, Hiroko Matsumura, Takahiro Okuya, Isao Ooki, Masahiro Hata, Kouki Wakabayashi, Akiyoshi Kogame, Kazunori Sumiya, Akito Hatayama
  • Publication number: 20120088103
    Abstract: Provided is a carbon fiber bundle for obtaining a fiber-reinforced resin having high mechanical characteristics. A carbon fiber bundle formed of single carbon fibers, each of which has no uneven surface structure of 0.6 ?m or more in length extending in the longitudinal direction of the single fiber; which has an uneven structure having a difference in height (Rp?v) of 5 to 25 nm between the highest portion and the lowest portion of the surface of the single fiber and having an average roughness Ra of 2 to 6 nm; and which has a ratio of the major axis to the minor axis (major axis/minor axis) of a cross-section of the single fiber of 1.00 to 1.01, wherein a mass of the single fiber per unit length falls within the range of 0.030 to 0.042 mg/m; a strand strength is 5900 MPa or more; a strand elastic modulus measured by the ASTM method is 250 to 380 GPa; and a knot tenacity is 900 N/mm2 or more.
    Type: Application
    Filed: June 10, 2010
    Publication date: April 12, 2012
    Applicant: MITSUBISHI RAYON CO., LTD
    Inventors: Naoki Sugiura, Takahiro Okuya, Hiroshi Hashimoto, Isao Ooki, Hiroko Matsumura, Masahiro Hata, Kouki Wakabayashi, Akito Hatayama
  • Publication number: 20110151206
    Abstract: An FRP is produced using a prepreg comprising reinforcing fiber, a sheet-like reinforcing fiber substrate containing reinforcing fiber, and a matrix resin, wherein the matrix resin is impregnated into the sheet-like reinforcing fiber substrate and also covers one surface of the sheet-like reinforcing fiber substrate, and the matrix resin impregnation ratio is within a range of 35% to 95%; a prepreg comprising reinforcing fiber, a sheet-like reinforcing fiber substrate containing reinforcing fiber, and a matrix resin, wherein the matrix resin exists on both surfaces of the sheet-like reinforcing fiber substrate, and the portion inside the sheet-like reinforcing fiber substrate into which the matrix resin has not been impregnated is continuous; or a prepreg comprising reinforcing fiber, a sheet-like reinforcing fiber substrate containing reinforcing fiber, and a matrix resin, wherein at least one surface exhibits a sea-and-island-type pattern comprising resin-impregnated portions (island portions) where the mat
    Type: Application
    Filed: March 1, 2011
    Publication date: June 23, 2011
    Inventors: Kazuya Goto, Kazuki Koga, Tadayoshi Saitou, Akihiro Ito, Tsuneo Takano, Kouki Wakabayashi
  • Publication number: 20090123717
    Abstract: An FRP is produced using a prepreg comprising reinforcing fiber, a sheet-like reinforcing fiber substrate containing reinforcing fiber, and a matrix resin, wherein the matrix resin is impregnated into the sheet-like reinforcing fiber substrate and also covers one surface of the sheet-like reinforcing fiber substrate, and the matrix resin impregnation ratio is within a range of 35% to 95%; a prepreg comprising reinforcing fiber, a sheet-like reinforcing fiber substrate containing reinforcing fiber, and a matrix resin, wherein the matrix resin exists on both surfaces of the sheet-like reinforcing fiber substrate, and the portion inside the sheet-like reinforcing fiber substrate into which the matrix resin has not been impregnated is continuous; or a prepreg comprising reinforcing fiber, a sheet-like reinforcing fiber substrate containing reinforcing fiber, and a matrix resin, wherein at least one surface exhibits a sea-and-island-type pattern comprising resin-impregnated portions (island portions) where the mat
    Type: Application
    Filed: October 2, 2008
    Publication date: May 14, 2009
    Applicant: Mitsubishi Rayon co., Ltd.
    Inventors: Kazuya Goto, Kazuki Koga, Tadayoshi Saitou, Akihiro Ito, Tsuneo Takano, Kouki Wakabayashi
  • Publication number: 20060035548
    Abstract: An FRP is produced using a prepreg comprising reinforcing fiber, a sheet-like reinforcing fiber substrate containing reinforcing fiber, and a matrix resin, wherein the matrix resin is impregnated into the sheet-like reinforcing fiber substrate and also covers one surface of the sheet-like reinforcing fiber substrate, and the matrix resin impregnation ratio is within a range of 35% to 95%; a prepreg comprising reinforcing fiber, a sheet-like reinforcing fiber substrate containing reinforcing fiber, and a matrix resin, wherein the matrix resin exists on both surfaces of the sheet-like reinforcing fiber substrate, and the portion inside the sheet-like reinforcing fiber substrate into which the matrix resin has not been impregnated is continuous; or a prepreg comprising reinforcing fiber, a sheet-like reinforcing fiber substrate containing reinforcing fiber, and a matrix resin, wherein at least one surface exhibits a sea-and-island-type pattern comprising resin-impregnated portions (island portions) where the mat
    Type: Application
    Filed: July 18, 2003
    Publication date: February 16, 2006
    Applicant: Mitsubishi Rayon Co., Ltd.
    Inventors: Kazuya Goto, Kazuki Koga, Tadayoshi Saitou, Akihiro Ito, Tsuneo Takano, Kouki Wakabayashi