Patents by Inventor Masato Honma

Masato Honma 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: 20210016474
    Abstract: A method is described for manufacturing a molded product having a recessed/protruding part from a molded substrate (A) including reinforcing fibers and a matrix resin by press molding, the method comprising: a step (I) of placing the molded substrate (A) between molds including an upper mold and a lower mold and deforming the molded substrate (A) in an in-plane direction by heating and pressing the molds; and a step (II) of deforming the molded substrate (A) in an out-of-plane direction by depressurizing the molds subsequent to the step (I), wherein a deformation rate ratio T represented by the following formula (1) is within a range of 0.1 to 1: T=X/Z ??(1) where X and Z are as defined.
    Type: Application
    Filed: March 27, 2019
    Publication date: January 21, 2021
    Applicant: Toray Industries, Inc.
    Inventors: Kotaro Shinohara, Masato Honma, Yoshiki Takebe
  • Publication number: 20210016549
    Abstract: A molded article includes a continuous porous body provided with a thin film layer, the continuous porous body having a void that is continuous in a thickness direction of the continuous porous body, the thin film layer including a solid additive and a resin. A permeation rate of water from a surface of the molded article on a side of the thin film layer is 10% or less.
    Type: Application
    Filed: March 28, 2019
    Publication date: January 21, 2021
    Applicant: Toray Industries, Inc.
    Inventors: Takashi Fujioka, Kotaro Shinohara, Masato Honma
  • Publication number: 20210009783
    Abstract: Provided is a method for producing a molded article having a thin film layer (B) formed on a surface of a porous body (A). The method includes a process (I) and a process (II) described below in this order: process (I): forming the thin film layer (B) on a surface of a precursor (a) of the porous body (A) to obtain a preform, and process (II): expanding and molding the precursor (a) to the porous body (A).
    Type: Application
    Filed: March 28, 2019
    Publication date: January 14, 2021
    Applicant: Toray Industries, Inc.
    Inventors: Takashi Fujioka, Kotaro Shinohara, Masato Honma
  • Publication number: 20210001536
    Abstract: Provided is a method for producing a molded article obtained by integrating a decoration layer onto a surface of a porous body including a reinforcing fiber. The method includes: a preheating process at which the decoration layer is preheated; and a shaping and integrating process at which the porous body is pressed to the decoration layer or the decoration layer is pressed to the porous body to shape the decoration layer, and the porous body and the decoration layer are integrated to each other.
    Type: Application
    Filed: March 28, 2019
    Publication date: January 7, 2021
    Applicant: Toray Industries, Inc.
    Inventors: Takashi Fujioka, Kotaro Shinohara, Masato Honma
  • Patent number: 10882224
    Abstract: A method for manufacturing a structure material is a method for manufacturing a structure material that includes a thermoplastic resin, reinforced fibers, and voids. The method includes: a first process for arranging a structure precursor comprising the thermoplastic resin and the reinforced fibers in a mold with a surface temperature of 80° C. or less; a second process for raising the surface temperature of the mold up to a temperature at which a storage elastic modulus (G?) of the structure precursor is less than 1.2×108 Pa; a third process for lowering the surface temperature of the mold down to a temperature at which the storage elastic modulus (G?) of the structure precursor is 1.2×108 Pa or more; and a fourth process for removing a structure material obtained after end of the third process from the mold.
    Type: Grant
    Filed: December 9, 2016
    Date of Patent: January 5, 2021
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Takashi Fujioka, Yoshiki Takebe, Masato Honma
  • Patent number: 10822463
    Abstract: A resin supply material is used for molding a fiber-reinforced resin and includes a continuous porous material and a resin. The continuous porous material has a bending resistance Grt of 10 mN·cm or more at 23° C., and a bending resistance ratio Gr of 0.7 or less, the bending resistance ratio Gr being expressed by the formula: Gr=Gmt/Grt Gmt: bending resistance of continuous porous material at 70° C.
    Type: Grant
    Filed: February 24, 2016
    Date of Patent: November 3, 2020
    Assignee: Toray Industries, Inc.
    Inventors: Tomohiro Takehara, Satoshi Seike, Masato Honma, Takashi Fujioka, Satomi Hiasa
  • Patent number: 10800894
    Abstract: A resin supply material used for press molding or vacuum-pressure molding of a fiber-reinforced resin includes a reinforcing fiber base material and a thermosetting resin, wherein a tensile rupture strain of the reinforcing fiber base material is 1% or more at temperature T, and/or a tensile strength of the reinforcing fiber base material is 0.5 MPa or more at the temperature T, wherein Temperature T is a temperature at which the viscosity of the thermosetting resin is minimum in heating of the thermosetting resin at a temperature elevation rate of 1.5° C./minute from 40° C.
    Type: Grant
    Filed: February 24, 2016
    Date of Patent: October 13, 2020
    Assignee: Toray Industries, Inc.
    Inventors: Tomohiro Takehara, Satoshi Seike, Masato Honma, Satomi Hiasa
  • Publication number: 20200307148
    Abstract: A composite structure includes a structure that contains first reinforced fibers and first resin and a laminate that is disposed on at least one surface of the structure and has a plurality of layers containing second reinforced fibers and second resin, with the structure and the laminate integrated, the first reinforced fibers being discontinuous fibers and having a thickness-wise average fiber orientation angle in a range of 5 to 60°, the second reinforced fibers being discontinuous fibers and having a thickness-wise average fiber orientation angle in a range of 0 to 5°, the structure having a density in a range of 0.01 to 1 g/cm3, the laminate having a variation in volume content of the second reinforced fibers in a range of 0 to 10%, and the composite structure having a protruding portion on a laminate's surface opposite from a laminate's surface in contact with the structure.
    Type: Application
    Filed: December 20, 2017
    Publication date: October 1, 2020
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Yoshiki TAKEBE, Masato HONMA
  • Patent number: 10787549
    Abstract: A structure material includes a resin, reinforced fibers, and voids. The structure material includes a volume content of the resin being within a range of 2.5% by volume or more and 85% by volume or less, a volume content of the reinforced fibers being within a range of 0.5% by volume or more and 55% by volume or less, the voids being contained in the structure material in a rate within a range of 10% by volume or more and 97% by volume or less, a thickness St of the structure material satisfying a conditional expression: St?Lf2·(1?cos(?f)), and a specific bending modulus of the structure material represented as Ec1/3·??1 being within a range of 3 or more and 20 or less, and a bending modulus Ec of the structure material being 3 GPa or more.
    Type: Grant
    Filed: December 9, 2016
    Date of Patent: September 29, 2020
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Yoshiki Takebe, Masato Honma
  • Patent number: 10787548
    Abstract: A structure material includes a resin, reinforced fibers, and voids, a volume content of the resin being within a range of 2.5% by volume or more and 85% by volume or less, a volume content of the reinforced fibers being within a range of 0.5% by volume or more and 55% by volume or less, the voids being contained in the structure material in a rate within a range of 10% by volume or more and 97% by volume or less, a thickness St of the structure material satisfying a conditional expression: St?Lf2·(1?cos(?f)) where a length of the reinforced fibers is Lf and an oriented angle of the reinforced fibers in a sectional direction of the structure material is ?f, and a compression strength in an in-plane direction at 50% compression of the structure material measured in accordance with JIS K7220 being 3 MPa or more.
    Type: Grant
    Filed: December 9, 2016
    Date of Patent: September 29, 2020
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Kotaro Shinohara, Yoshiki Takebe, Masato Honma
  • Patent number: 10751957
    Abstract: A laminate includes reinforcing fibers, thermosetting resin (B) or thermoplastic resin (D), wherein adhesion with other members, particularly in high-temperature atmospheres, is outstanding. The laminate includes: a porous substrate (C) comprising a thermoplastic resin (c), reinforcing fibers (A) and a thermosetting resin (B), or a porous substrate (C) comprising a thermoplastic resin (c), reinforcing fibers (A) and a thermoplastic resin (D); wherein the porous substrate (C) has a gap part continuous in the thickness direction of the laminate, and the melting point or softening point is higher than 180° C., and at least 10% of the surface area of one surface of the porous substrate (C) is exposed on one side of the laminate.
    Type: Grant
    Filed: November 10, 2015
    Date of Patent: August 25, 2020
    Assignee: Toray Industries, Inc.
    Inventors: Takashi Fujioka, Masato Honma
  • Publication number: 20200198194
    Abstract: In order to solve reduction in strength and rigidity at a weldline which is a problem of an injection molding body, and enable free design such as thin wall molding or complex shape molding of the injection molding body, there is provided an integrally molded body in which a substrate for reinforcement (a) having a discontinuous fiber (a1) and a resin (a2) and an injection molding body (b) having a discontinuous fiber (b1) and a resin (b2) are integrated, in which the substrate for reinforcement (a) has a difference in an orientation angle of the discontinuous fiber (a1) in each of regions obtained by dividing a major axis direction of the substrate for reinforcement (a) into 10 equal parts of within 10°, and the substrate for reinforcement (a) covers a part or all of a weldline of the injection molding body (b) to be integrated with the injection molding body (b).
    Type: Application
    Filed: August 24, 2018
    Publication date: June 25, 2020
    Applicant: Toray Industries, Inc.
    Inventors: Takafumi Suzuki, Yuichiro Sento, Naokichi Imai, Mitsushige Hamaguchi, Masato Honma
  • Publication number: 20200198193
    Abstract: The following configuration is adopted for the purpose of solving reduction in strength and rigidity at a weldline which is a problem of an injection molding body, and enabling free design such as thin wall molding or complex shape molding of the injection molding body. That is, there is provided an integrally molded body in which a substrate for reinforcement (a) having a discontinuous fiber (a1) and a resin (a2) and an injection molding body (b) having a discontinuous fiber (b1) and a resin (b2) are integrated, the substrate for reinforcement (a) covering a part or all of a weldline of the injection molding body (b) to be integrated with the injection molding body (b), the ratio of thickness Ta of the substrate for reinforcement (a) to thickness T of a weldline part of the integrally molded body satisfying relational expression: in a case of Ea?Ebw, Ta/T?((Ebw??(Ea·Ebw))/(Ebw?Ea)) in a case of Ea=Ebw, Ta/T?0.
    Type: Application
    Filed: August 24, 2018
    Publication date: June 25, 2020
    Applicant: Toray Industries, Inc.
    Inventors: Takafumi Suzuki, Yuichiro Sento, Naokichi Imai, Mitsushige Hamaguchi, Masato Honma
  • Publication number: 20200157605
    Abstract: To analyze the concentration of an analyte in a sample, the number of molecules or particles or concentration of the analyte is determined using a table associating at least one piece of information about a plurality of reaction fields generated by splitting a liquid containing the sample, the at least one piece of information being selected from the group consisting of information about the number of positive reaction fields and information about the number of negative reaction fields, with the number of molecules or particles or concentration of the analyte in the sample or in at least some of the plurality of reaction fields.
    Type: Application
    Filed: January 24, 2020
    Publication date: May 21, 2020
    Inventors: Tsutomu Honma, Atsushi Takahashi, Masato Minami, Tetsuya Yano, Yuki Sato
  • Publication number: 20200150135
    Abstract: To analyze the concentration of an analyte in a sample, the size distribution of a plurality of reaction fields generated by splitting a liquid containing the sample is divided into a plurality of classes. A class used for concentration determination is set based on the number or proportion of the positive reaction fields or the number or proportion of the negative reaction fields in each class. The concentration of the analyte is determined based on data for the set class.
    Type: Application
    Filed: January 2, 2020
    Publication date: May 14, 2020
    Inventors: Tsutomu Honma, Atsushi Takahashi, Masato Minami, Tetsuya Yano
  • Publication number: 20200086588
    Abstract: Provided are a processed product obtained by processing a structure having excellent lightness and mechanical characteristics, and a method for manufacturing the processed product that can process with high precision and high productivity. A method for manufacturing a processed product according the present invention is a method comprising processing a structure, the structure containing reinforced fibers, resin, and voids, the structure having a density in a range of 0.01 to 1 g/cm3, the structure having a compression modulus in a range of 0.2 to 20 GPa, and the processing being cutting processing performed by bringing the structure into contact with a processing tool.
    Type: Application
    Filed: December 20, 2017
    Publication date: March 19, 2020
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Kotaro SHINOHARA, Yoshiki TAKEBE, Masato HONMA
  • Publication number: 20200086532
    Abstract: A method for manufacturing a composite structure in which a first member and a structure material as a second member are integrated, the method including: an arrangement step of arranging a structure precursor including a resin and reinforced fibers in a mold made of the first member; a heating step of heating the structure precursor to equal to or higher than a temperature at which a storage elastic modulus (G?) of the structure precursor is less than 1.2×108 Pa; a shaping step of expanding the structure precursor by heating to form a structure material as a second member, and bringing the structure material into close contact with the first member to obtain a composite structure; and a cooling step of cooling the composite structure.
    Type: Application
    Filed: December 20, 2017
    Publication date: March 19, 2020
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Takashi FUJIOKA, Yoshiki TAKEBE, Masato HONMA
  • Publication number: 20200087471
    Abstract: Provided is a structure having excellent flexibility represented by elastic restoring from compression or tensile elongation at break, and excellent lightness. A structure according to the present invention includes reinforced fibers, first plastic, and second plastic that exhibits rubber elasticity at room temperature, the reinforced fibers being discontinuous fibers, and the first plastic and/or the second plastic coating a crossing point between the reinforced fibers in contact with each other.
    Type: Application
    Filed: December 20, 2017
    Publication date: March 19, 2020
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Yoshiki TAKEBE, Takashi FUJIOKA, Masato HONMA
  • Patent number: 10583640
    Abstract: A method for producing a fiber-reinforced composite material is provided. By satisfying particular conditions, this method is capable of suppressing the problem of poor appearance caused by the release film in the production of the fiber-reinforced composite material having a three-dimensional shape by heat-press molding to enable production of the fiber-reinforced composite material having a high quality appearance in high cycle. A method for manufacturing a fiber-reinforced composite material wherein a fiber-reinforced substrate containing a reinforcing fiber (A) and a thermosetting resin (B) is sandwiched between release films (C) to constitute a layered material, and the layered material is pressed in a mold heated to molding temperature to thereby cure the thermosetting resin (B), wherein the method satisfies the following (i), (ii), and (iii) or (i), (ii), and (iv): (i) the fiber-reinforced composite material has at least 1 bent part, (ii) the molding temperature is 130 to 180° C.
    Type: Grant
    Filed: June 30, 2016
    Date of Patent: March 10, 2020
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Naokichi Imai, Masato Honma
  • Patent number: 10571963
    Abstract: A housing includes: a top cover; a bottom cover having a rising wall member erected toward the top cover and joined to the top cover at a rim; and a reinforcing structure which is disposed in a space divided by the top cover and the bottom cover, and has an opening, the reinforcing structure being joined to the bottom cover. The bottom cover is formed of a material having a thickness of 0.1 mm or more and 0.8 mm or less and an elastic modulus of 20 GPa or more and 120 GPa or less.
    Type: Grant
    Filed: September 6, 2016
    Date of Patent: February 25, 2020
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Masato Honma, Takashi Fujioka