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: 20200307148
    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: Application
    Filed: December 20, 2017
    Publication date: October 1, 2020
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Yoshiki TAKEBE, Masato HONMA
  • Patent number: 10787549
    Abstract: A structure material includes a resin, reinforced fibers, and voids. The structure material includes a volume content of the resin being within a range of 2.5% by volume or more and 85% by volume or less, a volume content of the reinforced fibers being within a range of 0.5% by volume or more and 55% by volume or less, the voids being contained in the structure material in a rate within a range of 10% by volume or more and 97% by volume or less, a thickness St of the structure material satisfying a conditional expression: St?Lf2·(1?cos(?f)), and a specific bending modulus of the structure material represented as Ec1/3·??1 being within a range of 3 or more and 20 or less, and a bending modulus Ec of the structure material being 3 GPa or more.
    Type: Grant
    Filed: December 9, 2016
    Date of Patent: September 29, 2020
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Yoshiki Takebe, Masato Honma
  • Patent number: 10787548
    Abstract: A structure material includes a resin, reinforced fibers, and voids, a volume content of the resin being within a range of 2.5% by volume or more and 85% by volume or less, a volume content of the reinforced fibers being within a range of 0.5% by volume or more and 55% by volume or less, the voids being contained in the structure material in a rate within a range of 10% by volume or more and 97% by volume or less, a thickness St of the structure material satisfying a conditional expression: St?Lf2·(1?cos(?f)) where a length of the reinforced fibers is Lf and an oriented angle of the reinforced fibers in a sectional direction of the structure material is ?f, and a compression strength in an in-plane direction at 50% compression of the structure material measured in accordance with JIS K7220 being 3 MPa or more.
    Type: Grant
    Filed: December 9, 2016
    Date of Patent: September 29, 2020
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Kotaro Shinohara, Yoshiki Takebe, Masato Honma
  • Patent number: 10751957
    Abstract: A laminate includes reinforcing fibers, thermosetting resin (B) or thermoplastic resin (D), wherein adhesion with other members, particularly in high-temperature atmospheres, is outstanding. The laminate includes: a porous substrate (C) comprising a thermoplastic resin (c), reinforcing fibers (A) and a thermosetting resin (B), or a porous substrate (C) comprising a thermoplastic resin (c), reinforcing fibers (A) and a thermoplastic resin (D); wherein the porous substrate (C) has a gap part continuous in the thickness direction of the laminate, and the melting point or softening point is higher than 180° C., and at least 10% of the surface area of one surface of the porous substrate (C) is exposed on one side of the laminate.
    Type: Grant
    Filed: November 10, 2015
    Date of Patent: August 25, 2020
    Assignee: Toray Industries, Inc.
    Inventors: Takashi Fujioka, Masato Honma
  • Publication number: 20200198193
    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: Application
    Filed: August 24, 2018
    Publication date: June 25, 2020
    Applicant: Toray Industries, Inc.
    Inventors: Takafumi Suzuki, Yuichiro Sento, Naokichi Imai, Mitsushige Hamaguchi, Masato Honma
  • Publication number: 20200198194
    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: Application
    Filed: August 24, 2018
    Publication date: June 25, 2020
    Applicant: Toray Industries, Inc.
    Inventors: Takafumi Suzuki, Yuichiro Sento, Naokichi Imai, Mitsushige Hamaguchi, Masato Honma
  • Publication number: 20200086588
    Abstract: Provided are a processed product obtained by processing a structure having excellent lightness and mechanical characteristics, and a method for manufacturing the processed product that can process with high precision and high productivity. A method for manufacturing a processed product according the present invention is a method comprising processing a structure, the structure containing reinforced fibers, resin, and voids, the structure having a density in a range of 0.01 to 1 g/cm3, the structure having a compression modulus in a range of 0.2 to 20 GPa, and the processing being cutting processing performed by bringing the structure into contact with a processing tool.
    Type: Application
    Filed: December 20, 2017
    Publication date: March 19, 2020
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Kotaro SHINOHARA, Yoshiki TAKEBE, Masato HONMA
  • Publication number: 20200087471
    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: Application
    Filed: December 20, 2017
    Publication date: March 19, 2020
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Yoshiki TAKEBE, Takashi FUJIOKA, Masato HONMA
  • Publication number: 20200086532
    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: Application
    Filed: December 20, 2017
    Publication date: March 19, 2020
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Takashi FUJIOKA, Yoshiki TAKEBE, Masato HONMA
  • Patent number: 10583640
    Abstract: A method for producing a fiber-reinforced composite material is provided. By satisfying particular conditions, this method is capable of suppressing the problem of poor appearance caused by the release film in the production of the fiber-reinforced composite material having a three-dimensional shape by heat-press molding to enable production of the fiber-reinforced composite material having a high quality appearance in high cycle. A method for manufacturing a fiber-reinforced composite material wherein a fiber-reinforced substrate containing a reinforcing fiber (A) and a thermosetting resin (B) is sandwiched between release films (C) to constitute a layered material, and the layered material is pressed in a mold heated to molding temperature to thereby cure the thermosetting resin (B), wherein the method satisfies the following (i), (ii), and (iii) or (i), (ii), and (iv): (i) the fiber-reinforced composite material has at least 1 bent part, (ii) the molding temperature is 130 to 180° C.
    Type: Grant
    Filed: June 30, 2016
    Date of Patent: March 10, 2020
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Naokichi Imai, Masato Honma
  • Patent number: 10571963
    Abstract: A housing includes: a top cover; a bottom cover having a rising wall member erected toward the top cover and joined to the top cover at a rim; and a reinforcing structure which is disposed in a space divided by the top cover and the bottom cover, and has an opening, the reinforcing structure being joined to the bottom cover. The bottom cover is formed of a material having a thickness of 0.1 mm or more and 0.8 mm or less and an elastic modulus of 20 GPa or more and 120 GPa or less.
    Type: Grant
    Filed: September 6, 2016
    Date of Patent: February 25, 2020
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Masato Honma, Takashi Fujioka
  • Publication number: 20190382543
    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: Application
    Filed: December 20, 2017
    Publication date: December 19, 2019
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Takashi FUJIOKA, Yoshiki TAKEBE, Masato HONMA
  • Patent number: 10509443
    Abstract: A housing includes: a bottom cover; a top cover; and a reinforcing structure that is disposed in a space divided by the bottom cover and the top cover and has a flat portion, a rising wall member erected on a rim of the flat portion, and a joining portion extending from a rim of the rising wall member, or a curved portion, and a joining portion extending from a rim of the curved portion, the joining portion of the reinforcing structure being joined to the bottom cover or the top cover. The area of the joining portion is within a range of 10 cm2 or more and 100 cm2 or less, and the maximum value of the height of the reinforcing structure is within a range of 3 mm or more and 30 mm or less.
    Type: Grant
    Filed: September 6, 2016
    Date of Patent: December 17, 2019
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Masato Honma, Takashi Fujioka
  • Publication number: 20190313542
    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: Application
    Filed: June 20, 2017
    Publication date: October 10, 2019
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Takashi FUJIOKA, Masato HONMA
  • Publication number: 20190299495
    Abstract: A method for manufacturing a structure material is a method for manufacturing a structure material that includes a thermoplastic resin, reinforced fibers, and voids. The method includes: a first process for arranging a structure precursor comprising the thermoplastic resin and the reinforced fibers in a mold with a surface temperature of 80° C. or less; a second process for raising the surface temperature of the mold up to a temperature at which a storage elastic modulus (G?) of the structure precursor is less than 1.2×108 Pa; a third process for lowering the surface temperature of the mold down to a temperature at which the storage elastic modulus (G?) of the structure precursor is 1.2×108 Pa or more; and a fourth process for removing a structure material obtained after end of the third process from the mold.
    Type: Application
    Filed: December 9, 2016
    Publication date: October 3, 2019
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Takashi FUJIOKA, Yoshiki TAKEBE, Masato HONMA
  • Publication number: 20190237862
    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: Application
    Filed: September 25, 2017
    Publication date: August 1, 2019
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Mitsushige HAMAGUCHI, Takashi FUJIOKA, Masato HONMA
  • Publication number: 20190208654
    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: Application
    Filed: September 25, 2017
    Publication date: July 4, 2019
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Mitsushige HAMAGUCHI, Takashi FUJIOKA, Masato HONMA
  • Publication number: 20190054706
    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: Application
    Filed: February 14, 2017
    Publication date: February 21, 2019
    Inventors: Tomohiro Takehara, Masato Honma, Terry Sakurai Brown, Noriyuki Hirano
  • Publication number: 20190002655
    Abstract: A structure material includes a resin, reinforced fibers, and voids. The structure material includes a volume content of the resin being within a range of 2.5% by volume or more and 85% by volume or less, a volume content of the reinforced fibers being within a range of 0.5% by volume or more and 55% by volume or less, the voids being contained in the structure material in a rate within a range of 10% by volume or more and 97% by volume or less, a thickness St of the structure material satisfying a conditional expression: St?Lf2·(1?cos(?f)), and a specific bending modulus of the structure material represented as Ec1/3·??1 being within a range of 3 or more and 20 or less, and a bending modulus Ec of the structure material being 3 GPa or more.
    Type: Application
    Filed: December 9, 2016
    Publication date: January 3, 2019
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Yoshiki TAKEBE, Masato HONMA
  • Publication number: 20190002654
    Abstract: A structure material includes a resin, reinforced fibers, and voids, a volume content of the resin being within a range of 2.5% by volume or more and 85% by volume or less, a volume content of the reinforced fibers being within a range of 0.5% by volume or more and 55% by volume or less, the voids being contained in the structure material in a rate within a range of 10% by volume or more and 97% by volume or less, a thickness St of the structure material satisfying a conditional expression: St?Lf2·(1?cos(?f)) where a length of the reinforced fibers is Lf and an oriented angle of the reinforced fibers in a sectional direction of the structure material is ?f, and a compression strength in an in-plane direction at 50% compression of the structure material measured in accordance with JIS K7220 being 3 MPa or more.
    Type: Application
    Filed: December 9, 2016
    Publication date: January 3, 2019
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Kotaro SHINOHARA, Yoshiki TAKEBE, Masato HONMA