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: 20250050547
    Abstract: A method is described for producing a fiber-reinforced plastic substrate that simultaneously satisfies three points of joinability, mechanical characteristics, and productivity, the method including the following components [A], [B], and [C], wherein at least the following drawing step, first impregnating step, second impregnating step, and take-up step are continuously and sequentially performed while the component [A] is caused to run: [A] a reinforcing fiber [B] a thermoplastic resin [C] a thermosetting resin 2<drawing step> step of drawing a continuous reinforcing fiber sheet containing the component [A]; <first impregnating step> step of impregnating either the component [B] or the component [C] from one surface of the continuous reinforcing fiber sheet to obtain a fiber-reinforced plastic intermediate in which either the component [B] or the component [C] is disposed on a first surface; <second impregnating step> step of impregnating the other of the component [B] or the component
    Type: Application
    Filed: October 28, 2024
    Publication date: February 13, 2025
    Applicant: Toray Industries, Inc.
    Inventors: Kotaro Shinohara, Yoshiki Takebe, Yoshihumi Nakayama, Masato Honma
  • Publication number: 20240408841
    Abstract: An object of the present invention is to provide a sandwich structure with excellent lightness and mechanical properties, and a member for electronic device housings. A main object of the present invention is to provide a sandwich structure including: a plate-like fiber-reinforced composite material member (core material) having a portion formed into a shape in which wavy corrugations extend unidirectionally or multidirectionally; and two plate-like fiber-reinforced composite material members (skin materials) that are bonded to the core material at tops or bottoms of the corrugation of the core material, while having interspaces between the member and the rest part of the core material, and are bonded to each other or through a part of the core material without wavy corrugations formed therein at a peripheral part of the corrugation formed in the core material, so as to seal the formed corrugation.
    Type: Application
    Filed: October 18, 2022
    Publication date: December 12, 2024
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Kentaro ADACHI, Hidetoshi SAKAI, Masato HONMA
  • Patent number: 12162186
    Abstract: A method is described for producing a fiber-reinforced plastic substrate that simultaneously satisfies three points of joinability, mechanical characteristics, and productivity, the method including the following components [A], [B], and [C], wherein at least the following drawing step, first impregnating step, second impregnating step, and take-up step are continuously and sequentially performed while the component [A] is caused to run: [A] a reinforcing fiber [B] a thermoplastic resin [C] a thermosetting resin <drawing step> step of drawing a continuous reinforcing fiber sheet containing the component [A]; <first impregnating step> step of impregnating either the component [B] or the component [C] from one surface of the continuous reinforcing fiber sheet to obtain a fiber-reinforced plastic intermediate in which either the component [B] or the component [C] is disposed on a first surface; <second impregnating step> step of impregnating the other of the component [B] or the component [
    Type: Grant
    Filed: May 15, 2020
    Date of Patent: December 10, 2024
    Assignee: Toray Industries, Inc.
    Inventors: Kotaro Shinohara, Yoshiki Takebe, Yoshihumi Nakayama, Masato Honma
  • Publication number: 20240400775
    Abstract: A prepreg and a fiber-reinforced resin molded article are provided that have excellent joint strength with other members, appropriately control the resin flow at the time of welding, and show excellent dimensional stability at the time of welding, where the prepreg includes a thermoplastic resin layer containing reinforcing fibers and a thermoplastic resin, in which the thermoplastic resin layer is present on at least one surface of the prepreg, and where the thermoplastic resin layer contains 65.0 to 99.5% by mass of a constituting unit of the thermoplastic resin and 0.5 to 35.0% by mass of a total amount of a constituting unit of a thermosetting resin and a constituting unit of a curing agent with respect to 100% by mass of a total amount of the constituting unit of the thermoplastic resin, the constituting unit of the thermosetting resin, and the constituting unit of the curing agent.
    Type: Application
    Filed: September 29, 2022
    Publication date: December 5, 2024
    Applicant: Toray Industries, Inc.
    Inventors: Hiroshi Kobayashi, Masato Honma, Kotaro Shinohara, Hideki Hanabusa
  • Publication number: 20240359450
    Abstract: A composite prepreg and a fiber-reinforced plastic molded body are described that are excellent in secondary weldability with another member and exhibit excellent handleability and reinforcing characteristics, where the composite prepreg in which reinforcing fibers are impregnated with a thermoplastic resin and a thermosetting resin, and a thermoplastic resin layer and a thermosetting resin layer that form an interface and joined to each other are formed, wherein the thermoplastic resin layer is present on at least one surface of the composite prepreg, and the thermoplastic resin layer contains continuous reinforcing fibers.
    Type: Application
    Filed: July 8, 2024
    Publication date: October 31, 2024
    Applicant: Toray Industries, Inc.
    Inventors: Kotaro Shinohara, Masato Honma
  • Patent number: 12076943
    Abstract: An object of the present invention is to obtain a fiber-reinforced composite material achieving both lightweight properties and mechanical properties at a high level. The present invention is a fiber-reinforced composite material including: a resin (A); and a reinforcing fiber (B), and including: a fiber-reinforced structure portion including an in-plane orientation portion having an average fiber orientation angle of the reinforcing fiber (B) of 0° or more and 45° or less and an out-of-plane orientation portion having an average fiber orientation angle of the reinforcing fiber (B) of more than 45° and 90° or less; and a cavity portion defined by the in-plane orientation portion and the out-of-plane orientation portion of the fiber-reinforced structure portion.
    Type: Grant
    Filed: November 16, 2020
    Date of Patent: September 3, 2024
    Assignee: Toray Industries, Inc.
    Inventors: Naokichi Imai, Kotaro Shinohara, Masato Honma
  • Publication number: 20240288018
    Abstract: The present invention aims to provide a joint structure, a joined assembly, and a set of members in which high joining strength is developed by fitting. It provides a joint structure including a first joint part formed in a first member and a second joint part formed in a second member that are fitted and fixed together wherein at least either of the first member and the second member is made of a fiber reinforced plastic material that contains reinforcing fibers with an average fiber length of 1 mm or more; the first joint part has a recessed shape in at least one cross-section of the joint structure while the second joint part has a shape that fits into the recessed shape of the first joint part in that cross-section; and there exists a pressing force between the first joint part and the second joint part so that the first member and the second member are fitted and fixed together.
    Type: Application
    Filed: June 16, 2022
    Publication date: August 29, 2024
    Applicant: TORAY Industries, Inc.
    Inventors: Kota KAWAHARA, Hiroaki MATSUTANI, Masato HONMA
  • Patent number: 12049548
    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 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, wherein [A] has a surface free energy, measured by a Wilhelmy method, of 10 to 50 mJ/m2, [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: Grant
    Filed: May 15, 2020
    Date of Patent: July 30, 2024
    Assignee: Toray Industries, Inc.
    Inventors: Yoshihumi Nakayama, Miho Onodera, Masato Honma
  • Patent number: 12030291
    Abstract: An object of the present invention is to obtain a fiber-reinforced composite material achieving both lightweight properties and mechanical properties at a high level. The present invention provides a fiber-reinforced composite material including a resin (A) and a reinforcing fiber (B), and having: a porous structure portion having micropores with an average pore diameter of 500 ?m or less as measured by a mercury intrusion method; and a coarse cavity portion defined by the porous structure portion and having a maximum length of more than 500 ?m as a cross-sectional opening portion.
    Type: Grant
    Filed: November 16, 2020
    Date of Patent: July 9, 2024
    Assignee: Toray Industries, Inc.
    Inventors: Naokichi Imai, Kotaro Shinohara, Masato Honma
  • Patent number: 12024606
    Abstract: Provided is a composite prepreg including a region (A) containing a thermosetting resin (a) and a reinforcing fiber and a region (B) containing a thermosetting resin (b) and a reinforcing fiber, the composite prepreg satisfying conditions (i) and (ii) or satisfying conditions (ii) and (iii): (i) The thermosetting resin (b) is a resin having a gel time Tb longer than a gel time Ta of the thermosetting resin (a), and in at least a part of a temperature range of 40° C. or more and 180° C. or less, satisfy Ta/Tb?0.8; (ii) A ratio of the region (A) on a surface of the composite prepreg is 20 to 80%; and (iii) The thermosetting resin (b) is a resin having a higher heat generation starting temperature Eb than a heat generation starting temperature Ea of the thermosetting resin (a), and in a differential scanning calorimetry chart obtained by measuring at 5° C./min with 40° C. as a starting temperature, satisfy Eb?Ea?30.
    Type: Grant
    Filed: November 12, 2020
    Date of Patent: July 2, 2024
    Assignee: Toray Industries, Inc.
    Inventors: Naokichi Imai, Masato Honma
  • Patent number: 11993687
    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: Grant
    Filed: March 28, 2019
    Date of Patent: May 28, 2024
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Takashi Fujioka, Kotaro Shinohara, Masato Honma
  • Publication number: 20240149550
    Abstract: The purpose of the present invention is to provide a sandwich structure that achieves both excellent heat radiation and excellent mechanical characteristics. To this end, the sandwich structure according to the present invention has the following configuration. That is, the sandwich structure has a core material (I) and fiber-reinforced materials (II) arranged on both surfaces of the core material (I), wherein at least one of the fiber-reinforced materials (II) includes a sheet-shaped heat conduction material (III) having an in-plane heat conduction ratio of 300 W/m·K or more.
    Type: Application
    Filed: November 11, 2020
    Publication date: May 9, 2024
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Takafumi SUZUKI, Takumi HONDA, Masato HONMA
  • Patent number: 11926088
    Abstract: An object of the present invention is to provide a fiber-reinforced composite material achieving both lightweight properties and mechanical properties, a laminate thereof, and a prepreg capable of easily molding a sandwich structure thereof. The present invention is a prepreg comprising a reinforced fiber substrate (B) impregnated with a resin (A), wherein the reinforced fiber substrate (B) exists in a folded state having a plurality of folds with a fold angle of 0° or more and less than 90° in the prepreg.
    Type: Grant
    Filed: November 16, 2020
    Date of Patent: March 12, 2024
    Assignee: Toray Industries, Inc.
    Inventors: Naokichi Imai, Kotaro Shinohara, Masato Honma
  • 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
  • Publication number: 20240059031
    Abstract: A prepreg laminate is described that is a fiber-reinforced plastic material having high rigidity, lightweight properties and excellent moldability, where the prepreg laminate is obtained by a prepreg (A), in which non-continuous reinforcing fibers are impregnated with a thermosetting resin or thermoplastic resin, and a prepreg (B), in which non-continuous reinforcing fibers are impregnated with a thermoplastic resin, being laminated adjacent to each other, and by the prepreg (A) being disposed on at least one surface, at least some combinations of the prepreg (A) and the prepreg (B) adjacent to each other forming an overlap region that satisfies at least one of the requirements (1) and (2) as defined.
    Type: Application
    Filed: March 17, 2022
    Publication date: February 22, 2024
    Applicant: Toray Industries, Inc.
    Inventors: Kentaro Adachi, Masato Honma, Hiroaki Matsutani
  • 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: 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
  • Publication number: 20230405967
    Abstract: A fiber-reinforced resin substrate is described in which a plurality of resins having differing properties are strongly composited, wherein the fiber-reinforced resin substrate is obtained by impregnating a thermoplastic resin (A) and a thermoplastic resin (B) into continuous reinforcement fibers, wherein a thermoplastic resin (A) layer, which comprises the thermoplastic resin (A) and is exposed at one surface, and a thermoplastic resin (B) layer, which comprises the thermoplastic resin (B) and is exposed at the other surface, form a boundary region, where at least some of the continuous reinforcement fibers exist in a manner spanning across the boundary region and both the thermoplastic resin (A) and the thermoplastic resin (B) are crystalline resins having a melting point of not less than 200° C.
    Type: Application
    Filed: November 15, 2021
    Publication date: December 21, 2023
    Applicant: Toray Industries, Inc.
    Inventors: Takashi Fujioka, Masato Honma, Yoshifumi Nakayama
  • 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
  • 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