Patents by Inventor Masao Tomioka

Masao Tomioka 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: 10773473
    Abstract: The purpose of the present invention is to obtain a fiber-reinforced plastic that is capable of controlling anisotropy, has excellent mechanical characteristics, has little variation, has excellent heat resistance, and has good fluidity during forming. A production method for fiber-reinforced plastic, having: a step in which a material (A) (100) including a prepreg base material is obtained, said prepreg base material having cuts therein and having a thermoplastic resin impregnated in reinforcing fibers (110) arranged in parallel in one direction; a step in which a pressurizing device is used that applies a substantially uniform pressure in a direction (X) orthogonal to the travel direction of the material (A) (100) and the material (A) (100) is caused to travel in the one direction and is pressurized while being heated to a prescribed temperature (T), an angle (.theta.) of ?20-20 .degree.
    Type: Grant
    Filed: December 28, 2017
    Date of Patent: September 15, 2020
    Assignee: Mitsubishi Chemical Corporation
    Inventors: Masao Tomioka, Takeshi Ishikawa, Takayuki Kobayashi
  • Patent number: 10576695
    Abstract: A fiber-reinforced plastic producing method capable of easily producing a fiber-reinforced plastic in which swelling and warpage are less likely to occur and of which excellent mechanical characteristics and isotropy are ensured, and a fiber-reinforced plastic in which swelling and warpage are suppressed from occurring. The fiber-reinforced plastic producing method has a step for obtaining a material (A) including a prepreg base material in which a region (B), where reinforcing fibers pulled and aligned in one direction are impregnated with a matrix resin and a plurality of cuts (b) are formed, and a region (C), where a plurality of cuts (c) are formed, are alternately formed in a direction orthogonal to a fiber axis of the reinforcing fiber, a step for hot-pressing the material (A) while moving the material (A) under specific conditions, and a step for cooling the pressed material (A) to obtain the fiber-reinforced plastic.
    Type: Grant
    Filed: August 4, 2016
    Date of Patent: March 3, 2020
    Assignee: Mitsubishi Chemical Corporation
    Inventors: Masao Tomioka, Takeshi Ishikawa, Takayuki Kobayashi
  • Patent number: 10370506
    Abstract: Provided are a carbon fiber thermoplastic resin prepreg which is a carbon fiber prepreg obtained by impregnating a PAN-based carbon fiber in which the average fiber fineness of a single fiber is 1.0 dtex to 2.4 dtex with a thermoplastic resin, wherein the thermoplastic resin satisfies 20?(FM/FS)?40 (where FM: flexural modulus (MPa) of a resin sheet comprising only the thermoplastic resin, and FS: flexural strength (MPa) of the resin sheet), a method for manufacturing the same, and a carbon fiber composite material employing the carbon fiber prepreg.
    Type: Grant
    Filed: March 29, 2013
    Date of Patent: August 6, 2019
    Assignee: MITSUBISHI CHEMICAL CORPORATION
    Inventors: Masao Tomioka, Takahiro Hayashi, Saki Fujita, Takeshi Ishikawa, Keigo Yoshida, Takuya Teranishi, Atsushi Takahashi, Kenichi Watanabe, Morio Katagiri, Akinobu Sasaki, Masahiro Oosuka, Hiroshi Tategaki, Takayuki Kobayashi
  • Patent number: 10370507
    Abstract: Provided are a carbon fiber thermoplastic resin prepreg which is a carbon fiber prepreg obtained by impregnating a PAN-based carbon fiber in which the average fiber fineness of a single fiber is 1.0 dtex to 2.4 dtex with a thermoplastic resin, wherein the thermoplastic resin satisfies 20?(FM/FS)?40 (where FM: flexural modulus (MPa) of a resin sheet comprising only the thermoplastic resin, and FS: flexural strength (MPa) of the resin sheet), a method for manufacturing the same, and a carbon fiber composite material employing the carbon fiber prepreg.
    Type: Grant
    Filed: April 27, 2017
    Date of Patent: August 6, 2019
    Assignee: Mistubishi Chemical Corporation
    Inventors: Masao Tomioka, Takahiro Hayashi, Saki Fujita, Takeshi Ishikawa, Keigo Yoshida, Takuya Teranishi, Atsushi Takahashi, Kenichi Watanabe, Morio Katagiri, Akinobu Sasaki, Masahiro Oosuka, Hiroshi Tategaki, Takayuki Kobayashi
  • Patent number: 10364347
    Abstract: To provide an epoxy-resin composition and prepreg for producing a fiber-reinforced composite material which exhibits excellent curability and has excellent flame retardance and heat resistance, as well as to provide fiber-reinforced composite materials produced using the prepreg and to provide housing for electronic/electrical devices. The epoxy resin composition contains component (A): a phosphorus compound; component (B): an epoxy resin which has at least three epoxy groups in the molecule, and which does not correspond to component (A) nor include component (A); component (C): an epoxy resin curing agent which does not have a urea structure in the molecule; and component (D): a dimethylurea compound represented by formula (a) (in formula (a), “R” is a hydrogen atom or an alkyl group having any number of 1 to 10 carbons).
    Type: Grant
    Filed: March 22, 2012
    Date of Patent: July 30, 2019
    Assignee: Mitsubishi Chemical Corporation
    Inventors: Masao Tomioka, Manabu Kaneko, Miyuki Hagiwara
  • Publication number: 20190001591
    Abstract: A production method for fiber-reinforced plastic, includes: a step in which a material (A) including a prepreg base material is obtained, said prepreg base material having cuts therein and having a thermoplastic resin impregnated in reinforcing fibers arranged in parallel in one direction; a step in which a pressurizing device is used that applies a substantially uniform pressure in a direction (X) orthogonal to the travel direction of the material (A) and the material (A) is caused to travel in the one direction and is pressurized while being heated to a prescribed temperature (T), an angle (?) of ?20° to 20° being formed between the orthogonal direction (X) and a fiber axial direction (Y) for the reinforcing fibers of the prepreg base material; and a step in which the material (A) pressurized by the pressurizing device is cooled and the fiber-reinforced plastic is obtained.
    Type: Application
    Filed: September 5, 2018
    Publication date: January 3, 2019
    Applicant: Mitsubishi Chemical Corporation
    Inventors: Masao TOMIOKA, Takeshi ISHIKAWA, Takayuki KOBAYASHI
  • Publication number: 20180222128
    Abstract: A fiber-reinforced plastic producing method capable of easily producing a fiber-reinforced plastic in which swelling and warpage are less likely to occur and of which excellent mechanical characteristics and isotropy are ensured, and a fiber-reinforced plastic in which swelling and warpage are suppressed from occurring. The fiber-reinforced plastic producing method has a step for obtaining a material (A) including a prepreg base material in which a region (B), where reinforcing fibers pulled and aligned in one direction are impregnated with a matrix resin and a plurality of cuts (b) are formed, and a region (C), where a plurality of cuts (c) are formed, are alternately formed in a direction orthogonal to a fiber axis of the reinforcing fiber, a step for hot-pressing the material (A) while moving the material (A) under specific conditions, and a step for cooling the pressed material (A) to obtain the fiber-reinforced plastic.
    Type: Application
    Filed: August 4, 2016
    Publication date: August 9, 2018
    Applicant: Mitsubishi Chemical Corporation
    Inventors: Masao TOMIOKA, Takeshi ISHIKAWA, Takayuki KOBAYASHI
  • Patent number: 9969146
    Abstract: Provided are a layered substrate that has excellent mechanical properties such as a flexural strength or a flexural modulus applicable to a structural material, the variations in those mechanical properties are small, exhibits excellent formability into a complicated shape, and is able to be molded in a short time, and a method for manufacturing the same. A layered substrate fabricated by layering plural sheets of sheet-shaped prepregs containing a reinforcing fiber oriented in one direction and a thermoplastic matrix resin, wherein the prepreg has a slit penetrating from the front surface to the back surface, each slit is provided so as to intersect with each reinforcing fiber only one time.
    Type: Grant
    Filed: March 10, 2014
    Date of Patent: May 15, 2018
    Assignee: MITSUBISHI CHEMICAL CORPORATION
    Inventors: Takeshi Ishikawa, Masao Tomioka, Masahiro Osuka, Yuuji Fujita, Yukichi Konami, Takahiro Hayashi
  • Publication number: 20180117861
    Abstract: The purpose of the present invention is to obtain a fiber-reinforced plastic that is capable of controlling anisotropy, has excellent mechanical characteristics, has little variation, has excellent heat resistance, and has good fluidity during forming. A production method for fiber-reinforced plastic, having: a step in which a material (A) (100) including a prepreg base material is obtained, said prepreg base material having cuts therein and having a thermoplastic resin impregnated in reinforcing fibers (110) arranged in parallel in one direction; a step in which a pressurizing device is used that applies a substantially uniform pressure in a direction (X) orthogonal to the travel direction of the material (A) (100) and the material (A) (100) is caused to travel in the one direction and is pressurized while being heated to a prescribed temperature (T), an angle (.theta.) of ?20-20 .degree.
    Type: Application
    Filed: December 28, 2017
    Publication date: May 3, 2018
    Applicant: Mitsubishi Chemical Corporation
    Inventors: Masao TOMIOKA, Takeshi Ishikawa, Takayuki Kobayashi
  • Publication number: 20180104869
    Abstract: A molding provided with a sheet-shaped composite material section formed from a fiber-reinforced composite material containing reinforcing fibers and a matrix resin, and protruding ribs formed directly on a first surface of the composite material section and containing a thermoplastic resin, wherein the ribs intersect with each other on the first surface, and the mean width t, mean height H and the proportion occupied on the first surface are within specified ranges. A manufacturing method for the molding including a composite material section-forming step for forming the composite material section, and a rib-forming step for forming the ribs so as to satisfy the above conditions.
    Type: Application
    Filed: March 30, 2016
    Publication date: April 19, 2018
    Applicant: Mitsubishi Chemical Corporation
    Inventors: Akihiro MAEDA, Masao TOMIOKA
  • Publication number: 20180071957
    Abstract: The purpose of the present invention is to obtain a fiber-reinforced composite material molded article having high adhesive strength in a boundary portion between an insert portion comprising a fiber-reinforced resin substrate and an integrally molded portion molded integrally with the insert portion. A fiber-reinforced composite material molded article (1) containing reinforcing fibers and a thermoplastic resin and being provided with a first layer (23), a second layer (22), and a third layer (21) in this order, the thickness of each layer, the ratio of the total volume of reinforcing fibers (x2) having a fiber length of 3 mm to less than 100 mm with respect to the total volume of reinforcing fibers present in the layer, the ratio of the total volume of reinforcing fibers (y2) having a fiber length of 0.02 mm to less than 3 mm with respect to the total volume of reinforcing fibers present in the layer, and the volume content of fibers in each layer being controlled so as to be in specific ranges.
    Type: Application
    Filed: April 15, 2016
    Publication date: March 15, 2018
    Applicant: Mitsubishi Chemical Corporation
    Inventors: Masao TOMIOKA, Takeshi ISHIKAWA, Akinobu SASAKI
  • Publication number: 20170226297
    Abstract: Provided are a carbon fibre thermoplastic resin prepreg which is a carbon fibre prepreg obtained by impregnating a PAN-based carbon fibre in which the average fibre fineness of a single fibre is 1.0 dtex to 2.4 dtex with a thermoplastic resin, wherein the thermoplastic resin satisfies 20<(FM/FS)<40 (where FM: flexural modulus (MPa) of a resin sheet comprising only the thermoplastic resin, and FS: flexural strength (MPa) of the resin sheet), a method for manufacturing the same, and a carbon fibre composite material employing the carbon fibre prepreg.
    Type: Application
    Filed: April 27, 2017
    Publication date: August 10, 2017
    Applicant: Mitsubishi Rayon Co., Ltd.
    Inventors: Masao TOMIOKA, Takahiro Hayashi, Saki Fujita, Takeshi Ishikawa, Keigo Yoshida, Takuya Teranishi, Atsushi Takahashi, Kenichi Watanabe, Morio Katagiri, Akinobu Sasaki, Masahiro Oosuka, Hiroshi Tategaki, Takayuki Kobayashi
  • Publication number: 20170190123
    Abstract: The purpose of the present invention is to obtain a fiber-reinforced plastic that is capable of controlling anisotropy, has excellent mechanical characteristics, has little variation, has excellent heat resistance, and has good fluidity during forming. A production method for fiber-reinforced plastic, having: a step in which a material (A) (100) including a prepreg base material is obtained, said prepreg base material having cuts therein and having a thermoplastic resin impregnated in reinforcing fibers (110) arranged in parallel in one direction; a step in which a pressurizing device is used that applies a substantially uniform pressure in a direction (X) orthogonal to the travel direction of the material (A) (100) and the material (A) (100) is caused to travel in the one direction and is pressurized while being heated to a prescribed temperature (T), an angle (.theta.) of ?20-20.degree.
    Type: Application
    Filed: February 13, 2015
    Publication date: July 6, 2017
    Applicant: MITSUBISHI RAYON CO., LTD.
    Inventors: Masao TOMIOKA, Takeshi ISHIKAWA, Takayuki KOBAYASHI
  • Publication number: 20170157889
    Abstract: Provided is a laminated substrate wherein a sheet-shaped material with a porosity of 50-99% is laminated onto at least one surface of a prepreg substrate which includes a reinforcing fiber and a thermoplastic resin.
    Type: Application
    Filed: December 5, 2014
    Publication date: June 8, 2017
    Applicant: Mitsubishi Rayon Co., Ltd.
    Inventors: Takeshi ISHIKAWA, Hayato OGASAWARA, Masao TOMIOKA
  • Publication number: 20160016382
    Abstract: Provided are a layered substrate that has excellent mechanical properties such as a flexural strength or a flexural modulus applicable to a structural material, the variations in those mechanical properties are small, exhibits excellent formability into a complicated shape, and is able to be molded in a short time, and a method for manufacturing the same. A layered substrate fabricated by layering plural sheets of sheet-shaped prepregs containing a reinforcing fiber oriented in one direction and a thermoplastic matrix resin, wherein the prepreg has a slit penetrating from the front surface to the back surface, each slit is provided so as to intersect with each reinforcing fiber only one time.
    Type: Application
    Filed: March 10, 2014
    Publication date: January 21, 2016
    Applicant: MITSUBISHI RAYON CO., LTD.
    Inventors: Takeshi ISHIKAWA, Masao TOMIOKA, Masahiro OSUKA, Yuuji FUJITA, Yokichi KONAMI, Takahiro HAYASHI
  • Publication number: 20150099832
    Abstract: The present invention relates to an epoxy resin composition which comprises a phosphorus-containing modified epoxy resin (A) consisting of a compound (a) represented by Formula (a); a novolak epoxy resin (B); a hardener (C) for epoxy resins; and a metal hydroxide (D), wherein the content in mass % of the phosphorus-containing modified epoxy resin (A), CA, and the content in mass % of the metal hydroxide (D), CD, relative to the total amount of the epoxy resin composition, satisfy the following Formulas (1), (2), and (3): (1) 2.5CA+CD?45; (2) 6?CA?40; and (3) 3?CD?30. This epoxy resin composition can give a composite material which has excellent flame retardancy even when neither a halogenated flame retardant, nor red phosphorus, nor a phosphoric acid ester is contained therein. According to the invention, it is also possible to provide a prepreg and a fiber-reinforced composite material obtained using the prepreg.
    Type: Application
    Filed: December 15, 2014
    Publication date: April 9, 2015
    Applicant: Mitsubishi Rayon Co., Ltd.
    Inventors: Masao Tomioka, Manabu Kaneko, Kazutami Mitani
  • Publication number: 20150044470
    Abstract: Provided are a carbon fibre thermoplastic resin prepreg which is a carbon fibre prepreg obtained by impregnating a PAN-based carbon fibre in which the average fibre fineness of a single fibre is 1.0 dtex to 2.4 dtex with a thermoplastic resin, wherein the thermoplastic resin satisfies 20?(FM/FS)?40 (where FM: flexural modulus (MPa) of a resin sheet comprising only the thermoplastic resin, and FS: flexural strength (MPa) of the resin sheet), a method for manufacturing the same, and a carbon fibre composite material employing the carbon fibre prepreg.
    Type: Application
    Filed: March 29, 2013
    Publication date: February 12, 2015
    Applicant: Mitsubishi Rayon Co., Ltd.
    Inventors: Masao Tomioka, Takahiro Hayashi, Saki Fujita, Takeshi Ishikawa, Keigo Yoshida, Takuya Teranishi, Atsushi Takahashi, Kenichi Watanabe, Morio Katagiri, Akinobu Sasaki, Masahiro Oosuka, Hiroshi Tategaki, Takayuki Kobayashi
  • Publication number: 20140010979
    Abstract: To provide an epoxy-resin composition and prepreg for producing a fiber-reinforced composite material which exhibits excellent curability and has excellent flame retardance and heat resistance, as well as to provide fiber-reinforced composite materials produced using the prepreg and to provide housing for electronic/electrical devices. The epoxy resin composition contains component (A): a phosphorus compound; component (B): an epoxy resin which has at least three epoxy groups in the molecule, and which does not correspond to component (A) nor include component (A); component (C): an epoxy resin curing agent which does not have a urea structure in the molecule; and component (D): a dimethylurea compound represented by formula (a) (in formula (a), “R” is a hydrogen atom or an alkyl group having any number of 1 to 10 carbons).
    Type: Application
    Filed: March 22, 2012
    Publication date: January 9, 2014
    Applicant: Mitsubishi Rayon Co., Ltd.
    Inventors: Masao Tomioka, Manabu Kaneko, Miyuki Hagiwara
  • Publication number: 20130338266
    Abstract: The present invention relates to an epoxy resin composition which comprises a phosphorus-containing modified epoxy resin (A) consisting of a compound (a) represented by Formula (a); a novolak epoxy resin (B); a hardener (C) for epoxy resins; and a metal hydroxide (D), wherein the content in mass % of the phosphorus-containing modified epoxy resin (A), CA, and the content in mass % of the metal hydroxide (D), CD, relative to the total amount of the epoxy resin composition, satisfy the following Formulas (1), (2), and (3): (1) 2.5CA+CD?5; (2) 6?CA?40; and (3) 3?CD?30. This epoxy resin composition can give a composite material which has excellent flame retardancy even when neither a halogenated flame retardant, nor red phosphorus, nor a phosphoric acid ester is contained therein. According to the invention, it is also possible to provide a prepreg and a fiber-reinforced composite material obtained using the prepreg.
    Type: Application
    Filed: February 16, 2012
    Publication date: December 19, 2013
    Applicant: MITSUBISHI RAYON CO., LTD.
    Inventors: Masao Tomioka, Manabu Kaneko, Kazutami Mitani
  • Publication number: 20120071585
    Abstract: Provided is an epoxy resin composition having superior flame resistance without containing a halogen-based flame retardant, red phosphorous or phosphate ester, and a prepreg and a fiber-reinforced composite material that use the epoxy resin composition. The epoxy resin composition has as essential components thereof (A) a phosphorous-containing epoxy resin composed of a compound (a) represented by the following formula (a), (C) a novolak-type epoxy resin, and (D) an epoxy resin curing agent. A prepreg containing the epoxy resin composition and a fiber-reinforced composite material obtained by curing the prepreg are also provided.
    Type: Application
    Filed: June 1, 2010
    Publication date: March 22, 2012
    Applicant: Mitsubishi Rayon Co., Ltd.
    Inventors: Atsushi Nohara, Manabu Kaneko, Masao Tomioka