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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Publication number: 20220388204Abstract: 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: ApplicationFiled: November 11, 2020Publication date: December 8, 2022Applicant: TORAY INDUSTRIES, INC.Inventors: Takafumi SUZUKI, Takumi HONDA, Masato HONMA
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Publication number: 20220388289Abstract: 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: ApplicationFiled: November 20, 2020Publication date: December 8, 2022Applicant: Toray Industries, Inc.Inventors: Jun Misumi, Masato Honma, Kyoko Shinohara
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Publication number: 20220324184Abstract: 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: ApplicationFiled: May 15, 2020Publication date: October 13, 2022Applicant: Toray Industries, Inc.Inventors: Jun Misumi, Masato Honma, Kyoko Shinohara, Noriyuki Hirano
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Publication number: 20220315762Abstract: 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: ApplicationFiled: May 15, 2020Publication date: October 6, 2022Applicant: Toray Industries, Inc.Inventors: Kyoko Shinohara, Masato Honma, Jun Misumi
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Publication number: 20220251317Abstract: 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: ApplicationFiled: May 15, 2020Publication date: August 11, 2022Applicant: Toray Industries, Inc.Inventors: Jun Misumi, Masato Honma, Kyoko Shinohara, Noriyuki Hirano
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Publication number: 20220227024Abstract: 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 componentType: ApplicationFiled: May 15, 2020Publication date: July 21, 2022Applicant: Toray Industries, Inc.Inventors: Kotaro Shinohara, Yoshiki Takebe, Yoshihumi Nakayama, Masato Honma
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Patent number: 11389121Abstract: 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: GrantFiled: March 20, 2019Date of Patent: July 19, 2022Assignee: Toray Industries, Inc.Inventors: Tomohiro Takehara, Mitsushige Hamaguchi, Masato Honma
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Publication number: 20220212426Abstract: 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: ApplicationFiled: May 15, 2020Publication date: July 7, 2022Applicant: Toray Industries, Inc.Inventors: Takashi Fujioka, Naokichi Imai, Masato Honma, Yoshiki Takebe, Kotaro Shinohara
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Publication number: 20220213284Abstract: 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: ApplicationFiled: May 15, 2020Publication date: July 7, 2022Applicant: Toray Industries, Inc.Inventors: Jun Misumi, Masato Honma, Kyoko Shinohara
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Publication number: 20220204710Abstract: 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: ApplicationFiled: May 15, 2020Publication date: June 30, 2022Applicant: Toray Industries, Inc.Inventors: Yoshihumi Nakayama, Miho Onodera, Masato Honma
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Patent number: 11312825Abstract: 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: GrantFiled: December 20, 2017Date of Patent: April 26, 2022Assignee: TORAY INDUSTRIES, INC.Inventors: Yoshiki Takebe, Takashi Fujioka, Masato Honma
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Patent number: 11225037Abstract: 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: GrantFiled: October 8, 2015Date of Patent: January 18, 2022Assignee: Toray Industries, Inc.Inventors: Tomohiro Takehara, Satoshi Seike, Masato Honma, Satomi Matsuo
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Patent number: 11141893Abstract: 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: GrantFiled: August 24, 2018Date of Patent: October 12, 2021Assignee: TORAY INDUSTRIES, INC.Inventors: Takafumi Suzuki, Yuichiro Sento, Naokichi Imai, Mitsushige Hamaguchi, Masato Honma
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Publication number: 20210244118Abstract: 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: ApplicationFiled: June 4, 2019Publication date: August 12, 2021Applicant: TORAY INDUSTRIES, INC.Inventors: Takashi FUJIOKA, Kentaro ADACHI, Masato HONMA
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Patent number: 11072098Abstract: 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: GrantFiled: December 20, 2017Date of Patent: July 27, 2021Assignee: TORAY INDUSTRIES, INC.Inventors: Takashi Fujioka, Yoshiki Takebe, Masato Honma
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Patent number: 11034809Abstract: 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: GrantFiled: February 24, 2016Date of Patent: June 15, 2021Assignee: Toray Industries, Inc.Inventors: Tomohiro Takehara, Satoshi Seike, Masato Honma, Naokichi Imai, Satomi Hiasa
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Publication number: 20210154952Abstract: 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: ApplicationFiled: March 25, 2019Publication date: May 27, 2021Applicant: Toray Industries, Inc.Inventors: Yoshiki Takebe, Kotaro Shinohara, Masato Honma
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Patent number: 11001011Abstract: 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: GrantFiled: February 14, 2017Date of Patent: May 11, 2021Assignee: Toray Industries, Inc.Inventors: Tomohiro Takehara, Masato Honma, Terry Sakurai Brown, Noriyuki Hirano
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Patent number: 10994510Abstract: 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: GrantFiled: December 20, 2017Date of Patent: May 4, 2021Assignee: TORAY INDUSTRIES, INC.Inventors: Yoshiki Takebe, Masato Honma
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Publication number: 20210106293Abstract: 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: ApplicationFiled: March 20, 2019Publication date: April 15, 2021Applicant: Toray Industries, Inc.Inventors: Tomohiro Takehara, Mitsushige Hamaguchi, Masato Honma