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: 20220324184
    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: Application
    Filed: May 15, 2020
    Publication date: October 13, 2022
    Applicant: Toray Industries, Inc.
    Inventors: Jun Misumi, Masato Honma, Kyoko Shinohara, Noriyuki Hirano
  • Publication number: 20220315762
    Abstract: The present invention has an object of providing a prepreg for producing a laminate suitable as a structural material, and a laminate, which have excellent combustion resistance, compressive strength and interlaminar fractural toughness values, and can be firmly integrated with another structural member by welding. The present invention is a prepreg including structural components: [A] reinforcing fibers, [B] a thermosetting resin, and [C] a thermoplastic resin [C], wherein [B] includes at least one resin selected from a cyanate ester resin having an average cyanate equivalent of 220 or less, a bismaleimide resin having an average maleimide equivalent of 210 or less, and a benzoxazine resin having an average oxazine equivalent of 300 or less, [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: Application
    Filed: May 15, 2020
    Publication date: October 6, 2022
    Applicant: Toray Industries, Inc.
    Inventors: Kyoko Shinohara, Masato Honma, Jun Misumi
  • Publication number: 20220251317
    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 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] an epoxy resin, and [C] a thermoplastic resin, wherein all epoxy resins included in [B] have an average epoxy value of 2.0 meq./g or more and 5.0 meq./g or less, [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: Application
    Filed: May 15, 2020
    Publication date: August 11, 2022
    Applicant: Toray Industries, Inc.
    Inventors: Jun Misumi, Masato Honma, Kyoko Shinohara, Noriyuki Hirano
  • Publication number: 20220227024
    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: Application
    Filed: May 15, 2020
    Publication date: July 21, 2022
    Applicant: Toray Industries, Inc.
    Inventors: Kotaro Shinohara, Yoshiki Takebe, Yoshihumi Nakayama, Masato Honma
  • Patent number: 11389121
    Abstract: An imaging table for a mammography apparatus is formed by a planar body and is to be supported in a cantilever state on a body of the mammography apparatus. At least an X-ray irradiation surface in the planar body has at least one of the following configurations (1) and (2): (1) the X-ray irradiation surface is formed by a carbon fiber composite material including a unidirectional carbon fiber composite material containing carbon fibers and a matrix resin, the carbon fibers being aligned in one direction; and (2) the X-ray irradiation surface is formed by a skin material and a resin sheet, the skin material including a carbon fiber composite material containing continuous fibers and a matrix resin, the resin sheet being disposed on an inner layer side from the skin material.
    Type: Grant
    Filed: March 20, 2019
    Date of Patent: July 19, 2022
    Assignee: Toray Industries, Inc.
    Inventors: Tomohiro Takehara, Mitsushige Hamaguchi, Masato Honma
  • Publication number: 20220212426
    Abstract: A fiber-reinforced plastic substrate is described in which a plurality of resins having different properties are firmly compounded and that includes components [A], [B], and [C]: [A] reinforcing fibers; [B] thermoplastic resin (b); and [C] thermoplastic resin (c), wherein the component [A] is arranged in one direction, in the fiber-reinforced plastic substrate, a resin area including the component [B] and a resin area including the component [C] are present, the resin area including the component [B] is present on a surface of one side of the fiber-reinforced plastic substrate, and a distance Ra(bc) between Hansen solubility parameters of the component [B] and the component [C] satisfies formula (1): Ra(bc)={4(?DB??DC)2+(?PB??PC)2+(?HB??HC)2}1/2?8 wherein Ra(bc), ?DB, ?DC, ?PB, ?PC, ?HB and ?HC are as defined.
    Type: Application
    Filed: May 15, 2020
    Publication date: July 7, 2022
    Applicant: Toray Industries, Inc.
    Inventors: Takashi Fujioka, Naokichi Imai, Masato Honma, Yoshiki Takebe, Kotaro Shinohara
  • Publication number: 20220213284
    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: Application
    Filed: May 15, 2020
    Publication date: July 7, 2022
    Applicant: Toray Industries, Inc.
    Inventors: Jun Misumi, Masato Honma, Kyoko Shinohara
  • Publication number: 20220204710
    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: Application
    Filed: May 15, 2020
    Publication date: June 30, 2022
    Applicant: Toray Industries, Inc.
    Inventors: Yoshihumi Nakayama, Miho Onodera, Masato Honma
  • Patent number: 11312825
    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: Grant
    Filed: December 20, 2017
    Date of Patent: April 26, 2022
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Yoshiki Takebe, Takashi Fujioka, Masato Honma
  • Patent number: 11225037
    Abstract: A production method for a fiber reinforced composite material includes heating a preform formed by laminating a prepreg layer (I) including a reinforcement fiber (A) and a thermosetting resin (B-1) with a resin layer (II) including a thermosetting resin (B-2) and a solid additive (C) to cure the thermosetting resin (B-1) and the thermosetting resin (B-2), the cured resin layer (II?) formed by curing the resin layer (II) having an average thickness of 35 ?m or more and 300 ?m or less.
    Type: Grant
    Filed: October 8, 2015
    Date of Patent: January 18, 2022
    Assignee: Toray Industries, Inc.
    Inventors: Tomohiro Takehara, Satoshi Seike, Masato Honma, Satomi Matsuo
  • Patent number: 11141893
    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: Grant
    Filed: August 24, 2018
    Date of Patent: October 12, 2021
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Takafumi Suzuki, Yuichiro Sento, Naokichi Imai, Mitsushige Hamaguchi, Masato Honma
  • Publication number: 20210244118
    Abstract: In order to provide a layered article in which shape deformation is suppressed while exhibiting compression properties that are an index of impact absorption, and further, a layered article that can control feeling when receiving impact on demand, provided is a layered article including a porous structure material containing discontinuous reinforcing fibers (A), resin (B) and voids (C), and a skin layer formed on a surface of the porous structure material, in which the porous structure material has an elastic resilience from 50% compression of 1 MPa or more, and the layered article has a plastic deformation amount of 20 ?m or less in a falling-weight impact test performed on the surface on which the skin layer is formed.
    Type: Application
    Filed: June 4, 2019
    Publication date: August 12, 2021
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Takashi FUJIOKA, Kentaro ADACHI, Masato HONMA
  • Patent number: 11072098
    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: Grant
    Filed: December 20, 2017
    Date of Patent: July 27, 2021
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Takashi Fujioka, Yoshiki Takebe, Masato Honma
  • Patent number: 11034809
    Abstract: A resin supply material used for press molding or vacuum-pressure molding of a fiber-reinforced resin, the resin supply material including a continuous porous material and a thermosetting resin, wherein an average pore cross-sectional area ratio P expressed by formula (I) is 1.1 or more: P=AII/AI??(I) AI: average pore cross-sectional area in region I AII: average pore cross-sectional area in region II Region I: region occupying 10% of total volume of continuous porous material from surface layer on both surfaces thereof Region II: whole region of continuous porous material.
    Type: Grant
    Filed: February 24, 2016
    Date of Patent: June 15, 2021
    Assignee: Toray Industries, Inc.
    Inventors: Tomohiro Takehara, Satoshi Seike, Masato Honma, Naokichi Imai, Satomi Hiasa
  • Publication number: 20210154952
    Abstract: Provided is a molded article that has both a low specific gravity and high rigidity and further has suppressed wrinkles and scrapes, and a manufacturing method for the same.
    Type: Application
    Filed: March 25, 2019
    Publication date: May 27, 2021
    Applicant: Toray Industries, Inc.
    Inventors: Yoshiki Takebe, Kotaro Shinohara, Masato Honma
  • Patent number: 11001011
    Abstract: A method of producing a fiber reinforced composite material satisfies condition 1: a thermosetting resin base material (B) includes a thermosetting resin (a) and a nonwoven fabric-shaped base material (a thermosetting resin base material satisfying the condition 1 is referred to as a thermosetting resin base material (B-1)); and condition 2: the thermosetting resin base material (B) is a base material including the thermosetting resin (a), and a porous sheet-shaped base material (b) or a film-shaped base material (c), the thermosetting resin (a) has a viscosity of 1,000 Pa·s or more at 40° C., and the thermosetting resin (a) has a minimum viscosity of 10 Pa·s or less during heating from 30° C. at a temperature rise rate of 1.5° C./min (a thermosetting resin base material satisfying the condition 2 is referred to as a thermosetting resin base material (B-2)).
    Type: Grant
    Filed: February 14, 2017
    Date of Patent: May 11, 2021
    Assignee: Toray Industries, Inc.
    Inventors: Tomohiro Takehara, Masato Honma, Terry Sakurai Brown, Noriyuki Hirano
  • Patent number: 10994510
    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: Grant
    Filed: December 20, 2017
    Date of Patent: May 4, 2021
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Yoshiki Takebe, Masato Honma
  • Publication number: 20210106293
    Abstract: An imaging table for a mammography apparatus is formed by a planar body and is to be supported in a cantilever state on a body of the mammography apparatus. At least an X-ray irradiation surface in the planar body has at least one of the following configurations (1) and (2): (1) the X-ray irradiation surface is formed by a carbon fiber composite material including a unidirectional carbon fiber composite material containing carbon fibers and a matrix resin, the carbon fibers being aligned in one direction; and (2) the X-ray irradiation surface is formed by a skin material and a resin sheet, the skin material including a carbon fiber composite material containing continuous fibers and a matrix resin, the resin sheet being disposed on an inner layer side from the skin material.
    Type: Application
    Filed: March 20, 2019
    Publication date: April 15, 2021
    Applicant: Toray Industries, Inc.
    Inventors: Tomohiro Takehara, Mitsushige Hamaguchi, Masato Honma
  • Patent number: 10947352
    Abstract: Provided is a mountain-shaped structure material being excellent in stiffness and lightness. The present invention is a structure material including a resin, reinforced fibers and voids. The structure material has a specific bending stiffness represented as Ec1/3·??1 being 2.5 or more where a bending modulus is Ec and a density is ?. The structure material has a mountain shape.
    Type: Grant
    Filed: December 20, 2017
    Date of Patent: March 16, 2021
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Takashi Fujioka, Yoshiki Takebe, Masato Honma
  • Publication number: 20210039291
    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: Application
    Filed: March 28, 2019
    Publication date: February 11, 2021
    Applicant: Toray Industries, Inc.
    Inventors: Yoshiki Takebe, Masato Honma