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: 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
  • Publication number: 20230036115
    Abstract: A prepreg and an integrally molded article are described, the prepreg including a thermoplastic resin existing on one face of a layer in which reinforcing fibers are impregnated with a thermosetting resin, wherein the prepreg exhibits, in injection molding or press molding, thermal weldability with a member containing a thermoplastic resin, and wherein the thermosetting resin has a specific peak on a loss tangent (tan ?) curve obtained by dynamic mechanical analysis (DMA), so that the prepreg exhibits suitable flexibility and adhesiveness, excellent 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.
    Type: Application
    Filed: November 6, 2020
    Publication date: February 2, 2023
    Applicant: Toray Industries, Inc.
    Inventors: Miho Onodera, Yoshiki Takebe, Daisuke Konishi, Yuta Naito, Yoshifumi Nakayama, Masato Honma
  • Publication number: 20230017689
    Abstract: A prepreg includes composition elements [A], [B], and [C] described below, [A] a reinforcing fiber, [B] a thermosetting resin, and [C] a thermoplastic resin. [C] is present on a surface of the prepreg, [B] contains a first curing agent [b1] and a second curing agent [b2], and the reinforcing fiber of [A] that crosses over a boundary surface between a resin region containing [B] and a resin region containing [C] and that is in contact with both resin regions is present.
    Type: Application
    Filed: November 20, 2020
    Publication date: January 19, 2023
    Applicant: Toray Industries, Inc.
    Inventors: Jun Misumi, Masato Honma, Kyoko Shinohara, Koji Furukawa, Atsuhito Arai
  • Publication number: 20230001651
    Abstract: A prepreg includes composition elements [A], [B], and [C] described below, [A] a reinforcing fiber, [B] a thermosetting resin, and [C] a thermoplastic resin. [B] contains a thermoplastic resin having an aromatic ring with an amount of 10% or more by mass, a resin region containing [B] is present on one surface of the prepreg, a resin region containing [C] is present on another surface of the prepreg, and [A] that crosses over a boundary surface between the resin region containing [B] and the resin region containing [C] and that is in contact with both resin regions is present.
    Type: Application
    Filed: November 20, 2020
    Publication date: January 5, 2023
    Applicant: Toray Industries, Inc.
    Inventors: Kyoko Shinohara, Masato Honma, Jun Misumi
  • Publication number: 20220410502
    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: Application
    Filed: November 16, 2020
    Publication date: December 29, 2022
    Applicant: Toray Industries, Inc.
    Inventors: Naokichi Imai, Kotaro Shinohara, Masato Honma
  • Publication number: 20220410465
    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: Application
    Filed: November 16, 2020
    Publication date: December 29, 2022
    Applicant: Toray Industries, Inc.
    Inventors: Naokichi Imai, Kotaro Shinohara, Masato Honma
  • Patent number: 11534117
    Abstract: An imaging table to be supported in a cantilever state on an X-ray imaging apparatus, includes a planar body including an opening portion in a surface to be connected to the apparatus, and a coupling member to be connected to the apparatus. The planar body includes a first member forming a top surface including an X-ray irradiation surface, and a second member forming a bottom surface opposed to the X-ray irradiation surface and a standing wall portion erectly provided on an outer circumference of the bottom surface. The second member is bonded to the first member in the standing wall portion. The first member and the coupling member are bonded to each other. The first member has an aluminum-equivalent X-ray transmission dose of 0.5 mmAL or less at any point in the X-ray irradiation surface.
    Type: Grant
    Filed: March 20, 2019
    Date of Patent: December 27, 2022
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Tomohiro Takehara, Mitsushige Hamaguchi, Masato Honma
  • Publication number: 20220404106
    Abstract: The purpose of the present invention is to provide a sandwich structure that has both excellent heat dissipation properties and excellent mechanical properties. In order to achieve this purpose, the sandwich structure of the present invention has the following structure. The sandwich structure includes a core member (I), and a fiber reinforced member (II) disposed on both sides of the core member (I), wherein the core member (I) includes a sheet-shaped heat conductive member (III) having an in-plane thermal conductivity of 300 W/m.K or more.
    Type: Application
    Filed: November 11, 2020
    Publication date: December 22, 2022
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Takafumi SUZUKI, Takumi HONDA, Masato HONMA
  • Publication number: 20220402258
    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: November 12, 2020
    Publication date: December 22, 2022
    Applicant: Toray Industries, Inc.
    Inventors: Kotaro Shinohara, Masato Honma
  • Publication number: 20220388289
    Abstract: A prepreg includes [A], [B], and [C] described below. The [B] further comprises [B?]; a ratio of a mole number of an active hydrogen contained in [B?] to a mole number of an epoxy group in an epoxy resin contained in [B] is in a range of 0.6 to 1.1 both inclusive; [C] is present on a surface of the prepreg; and [A] that crosses over a boundary surface between a resin region containing [B] and a resin region containing [C] and that is in contact with both resin regions is present: [A] a reinforcing fiber; [B] an epoxy resin composition; an amine compound; and [C] a thermoplastic resin composition.
    Type: Application
    Filed: November 20, 2020
    Publication date: December 8, 2022
    Applicant: Toray Industries, Inc.
    Inventors: Jun Misumi, Masato Honma, Kyoko Shinohara
  • Publication number: 20220388204
    Abstract: The purpose of the present invention is to provide a thermal conductor achieving both excellent light weight and excellent rigidity and also having excellent heat dissipation property. In order to achieve the above object, the thermal conductor according to the present invention has the following configuration. That is, a thermal conductor in which a sheet-shaped thermal conductive material (II) having an in-plane thermal conductivity of 300 W/m·K or more is contained in a porous structure (I) configured of reinforcing fibers and a resin.
    Type: Application
    Filed: November 11, 2020
    Publication date: December 8, 2022
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Takafumi SUZUKI, Takumi HONDA, Masato HONMA
  • 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