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).

  • 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: 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
  • 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
  • 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
  • Patent number: 11799199
    Abstract: The present invention aims to provide an electronic device housing that is able to maintain the antenna performance without deteriorating the radio communication performance, excellent in terms of the degree of warpage and dimensional accuracy, and mass productivity. The electronic device housing includes a fiber reinforcing member (a) and a fiber reinforcing member (b), wherein the fiber reinforcing member (a) contains a resin (a1) and a fiber (a2), the fiber (a2) being in the form of discontinuous fibers; the fiber reinforcing member (b) contains a resin (b1) and a fiber (b2), the fiber (b2) being in the form of continuous fibers; the projected area of the fiber reinforcing member (a) accounts for 60% or more of the total projected area, which accounts for 100%, of the housing projected onto the plane of the top face; and requirements (i) and/or (ii) given below are met: (i) the resin (a1) is a thermoplastic resin having a melting point of more than 265° C.
    Type: Grant
    Filed: September 25, 2017
    Date of Patent: October 24, 2023
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Mitsushige Hamaguchi, Takashi Fujioka, Masato Honma
  • Patent number: 11800656
    Abstract: The invention aims to provide an electronic device housing that can maintain the antenna performance without deteriorating the radio communication performance, ensures uniform characteristics as one molded electronic device housing in spite of consisting of a plurality of members, and show excellent features in terms of the degree of warpage and dimensional accuracy as well as small deformation in high temperature environments and high mass productivity.
    Type: Grant
    Filed: September 25, 2017
    Date of Patent: October 24, 2023
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Mitsushige Hamaguchi, Takashi Fujioka, Masato Honma
  • Patent number: 11794385
    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: Grant
    Filed: August 24, 2018
    Date of Patent: October 24, 2023
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Takafumi Suzuki, Yuichiro Sento, Naokichi Imai, Mitsushige Hamaguchi, Masato Honma
  • Publication number: 20230302687
    Abstract: A fiber-reinforced plastic capable of coping with a more complicated shape while maintaining lightweight properties and mechanical properties is provided, where a thermoplastic prepreg is obtained by impregnating a discontinuous reinforcing fiber web impregnated with a thermoplastic resin, the thermoplastic prepreg satisfying at least one of the following features (A) or (B): feature (A): a plurality of incisions cutting at least a part of discontinuous reinforcing fibers constituting the discontinuous reinforcing fiber web; and feature (B): a fiber length variation region in which a coefficient of variation in fiber length of the discontinuous reinforcing fibers constituting the discontinuous reinforcing fiber web is 40% or more.
    Type: Application
    Filed: August 30, 2021
    Publication date: September 28, 2023
    Applicant: Toray Industries, Inc.
    Inventors: Kentaro Adachi, Terumasa Tsuda, Kota Kawahara, Masato Honma, Hiroaki Matsutani
  • Publication number: 20230294370
    Abstract: The present invention pertains to a fiber-reinforced plastic that has, as at least one of the surface layers in the thickness direction thereof, a layer containing reinforced fibers and a matrix in which a thermosetting resin and a thermoplastic resin are integrated. The reinforced fibers form discontinuous reinforced fiber bundles randomly stacked or discontinuous reinforced fiber bundles arranged in one direction. A portion of the discontinuous reinforced fiber bundles is in contact with both of the thermosetting resin and the thermoplastic resin. The thermoplastic resin is exposed in at least a portion of the surface of the surface layer.
    Type: Application
    Filed: July 21, 2021
    Publication date: September 21, 2023
    Applicant: Toray Industries, Inc.
    Inventors: Terumasa Tsuda, Tomohiro Takehara, Masato Honma
  • Publication number: 20230220170
    Abstract: The present invention relates to a fiber-reinforced plastic, including: a reinforcing fiber group containing reinforcing fibers; a thermosetting resin layer containing a first thermosetting resin; and a thermoplastic resin layer, in which the thermoplastic resin layer is provided as a surface layer of the fiber-reinforced plastic, an interface between the thermoplastic resin layer and the thermosetting resin layer is positioned inside the reinforcing fiber group, and the thermoplastic resin layer contains a dispersed phase of a second thermosetting resin.
    Type: Application
    Filed: June 2, 2021
    Publication date: July 13, 2023
    Applicant: Toray Industries, Inc.
    Inventors: Tomohiro Takehara, Masato Honma
  • Patent number: 11697274
    Abstract: A molded product having both small specific gravity and high stiffness and also suffering few sink marks is described along with a method for the production thereof, where the molded product includes a porous body (A) integrated with an injection molded body (B), the porous body (A) having an apparent density of 0.05 to 0.8 g/cm3, the average thickness (tA) of the porous body (A) and the average thickness (tB) of the injection molded body (B) satisfying the relation tA?3×tB, and the injection molded body (B) covering at least one face of the porous body (A).
    Type: Grant
    Filed: March 28, 2019
    Date of Patent: July 11, 2023
    Assignee: Toray Industries, Inc.
    Inventors: Yoshiki Takebe, Masato Honma
  • Publication number: 20230106362
    Abstract: The present invention provides a fiber-reinforced resin which has excellent tensile shear joining strength and is able to be integrated with another structural member with high productivity by means of thermal welding, thereby being suitable as a structural material. The present invention is a fiber-reinforced resin which contains constituents (A), (B) and (C), while having a multilayer structure that is composed of a thermosetting resin layer that is formed of (B) a thermosetting resin, a thermoplastic resin layer that is formed of (C) a thermoplastic resin, and a mixed layer that is present between the thermoplastic resin layer and the thermosetting resin layer, while being obtained by mixing the thermoplastic resin (C) and the thermosetting resin (B), in such a manner that the thermoplastic resin layer is present in the surface. With respect to this fiber-reinforced resin, at least some of (A) reinforcing fibers are present in the mixed layer.
    Type: Application
    Filed: March 5, 2021
    Publication date: April 6, 2023
    Applicant: Toray Industries, Inc.
    Inventors: Jun Misumi, Masato Honma, Genki Matsubara, Kyoko Shinohara
  • Publication number: 20230075860
    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: Application
    Filed: November 12, 2020
    Publication date: March 9, 2023
    Applicant: Toray Industries, Inc.
    Inventors: Naokichi Imai, Masato Honma
  • Patent number: 11590716
    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: Grant
    Filed: March 27, 2019
    Date of Patent: February 28, 2023
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Kotaro Shinohara, Masato Honma, Yoshiki Takebe
  • Patent number: 11589472
    Abstract: A case which is configured of a cover comprising an electronic device, and which is characterized in that the electronic device is inserted into the cover. A case which is configured of a cover comprising an electronic device, and which has an improved storage capacity, while maintaining the stiffness required for a case.
    Type: Grant
    Filed: June 20, 2017
    Date of Patent: February 21, 2023
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Takashi Fujioka, Masato Honma
  • Publication number: 20230040874
    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: Application
    Filed: November 16, 2020
    Publication date: February 9, 2023
    Applicant: Toray Industries, Inc.
    Inventors: Naokichi Imai, Kotaro Shinohara, Masato Honma