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).
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Patent number: 11926088Abstract: 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: GrantFiled: November 16, 2020Date of Patent: March 12, 2024Assignee: Toray Industries, Inc.Inventors: Naokichi Imai, Kotaro Shinohara, Masato Honma
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Publication number: 20240066758Abstract: 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: ApplicationFiled: December 21, 2021Publication date: February 29, 2024Applicant: Toray Industries, Inc.Inventors: Miho Onodera, Yoshiki Takebe, Yuta Naito, Jun Misumi, Yoshifumi Nakayama, Masato Honma
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Publication number: 20240059031Abstract: 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: ApplicationFiled: March 17, 2022Publication date: February 22, 2024Applicant: Toray Industries, Inc.Inventors: Kentaro Adachi, Masato Honma, Hiroaki Matsutani
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Patent number: 11878478Abstract: 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: GrantFiled: May 15, 2020Date of Patent: January 23, 2024Assignee: TORAY INDUSTRIES, INC.Inventors: Jun Misumi, Masato Honma, Kyoko Shinohara
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Publication number: 20230405967Abstract: 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: ApplicationFiled: November 15, 2021Publication date: December 21, 2023Applicant: Toray Industries, Inc.Inventors: Takashi Fujioka, Masato Honma, Yoshifumi Nakayama
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Publication number: 20230407018Abstract: 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: ApplicationFiled: October 27, 2021Publication date: December 21, 2023Applicant: Toray Industries, Inc.Inventors: Jun Misumi, Kyoko Shinohara, Masato Honma
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Publication number: 20230406997Abstract: 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: ApplicationFiled: October 27, 2021Publication date: December 21, 2023Applicant: Toray Industries, Inc.Inventors: Jun Misumi, Masato Honma, Kyoko Shinohara
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Patent number: 11840612Abstract: 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: GrantFiled: May 15, 2020Date of Patent: December 12, 2023Assignee: TORAY INDUSTRIES, INC.Inventors: Jun Misumi, Masato Honma, Kyoko Shinohara, Noriyuki Hirano
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Patent number: 11799199Abstract: 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: GrantFiled: September 25, 2017Date of Patent: October 24, 2023Assignee: TORAY INDUSTRIES, INC.Inventors: Mitsushige Hamaguchi, Takashi Fujioka, Masato Honma
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Patent number: 11800656Abstract: 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: GrantFiled: September 25, 2017Date of Patent: October 24, 2023Assignee: TORAY INDUSTRIES, INC.Inventors: Mitsushige Hamaguchi, Takashi Fujioka, Masato Honma
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Patent number: 11794385Abstract: 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: GrantFiled: August 24, 2018Date of Patent: October 24, 2023Assignee: TORAY INDUSTRIES, INC.Inventors: Takafumi Suzuki, Yuichiro Sento, Naokichi Imai, Mitsushige Hamaguchi, Masato Honma
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Publication number: 20230302687Abstract: 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: ApplicationFiled: August 30, 2021Publication date: September 28, 2023Applicant: Toray Industries, Inc.Inventors: Kentaro Adachi, Terumasa Tsuda, Kota Kawahara, Masato Honma, Hiroaki Matsutani
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Publication number: 20230294370Abstract: 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: ApplicationFiled: July 21, 2021Publication date: September 21, 2023Applicant: Toray Industries, Inc.Inventors: Terumasa Tsuda, Tomohiro Takehara, Masato Honma
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Publication number: 20230220170Abstract: 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: ApplicationFiled: June 2, 2021Publication date: July 13, 2023Applicant: Toray Industries, Inc.Inventors: Tomohiro Takehara, Masato Honma
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Patent number: 11697274Abstract: 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: GrantFiled: March 28, 2019Date of Patent: July 11, 2023Assignee: Toray Industries, Inc.Inventors: Yoshiki Takebe, Masato Honma
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Publication number: 20230106362Abstract: 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: ApplicationFiled: March 5, 2021Publication date: April 6, 2023Applicant: Toray Industries, Inc.Inventors: Jun Misumi, Masato Honma, Genki Matsubara, Kyoko Shinohara
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Publication number: 20230075860Abstract: 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: ApplicationFiled: November 12, 2020Publication date: March 9, 2023Applicant: Toray Industries, Inc.Inventors: Naokichi Imai, Masato Honma
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Patent number: 11590716Abstract: 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: GrantFiled: March 27, 2019Date of Patent: February 28, 2023Assignee: TORAY INDUSTRIES, INC.Inventors: Kotaro Shinohara, Masato Honma, Yoshiki Takebe
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Patent number: 11589472Abstract: 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: GrantFiled: June 20, 2017Date of Patent: February 21, 2023Assignee: TORAY INDUSTRIES, INC.Inventors: Takashi Fujioka, Masato Honma
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Publication number: 20230040874Abstract: 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: ApplicationFiled: November 16, 2020Publication date: February 9, 2023Applicant: Toray Industries, Inc.Inventors: Naokichi Imai, Kotaro Shinohara, Masato Honma