Patents by Inventor Naokichi Imai

Naokichi Imai 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: 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: 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
  • 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: 10472498
    Abstract: A molded article includes 10 to 40% by mass of reinforcing fibers (A); and 60 to 90% by mass of a matrix resin (B) mainly including a polyarylene sulfide, the molded article satisfying conditions (I) to (IV) and having a tensile strength of 240 MPa or more in a main orientation direction of the reinforcing fibers (A) in the molded article: (I) strand tensile strength of the reinforcing fibers (A) is 1.5 to 5.5 OPa; (II) number average fiber length of the reinforcing fibers (A) in the molded article is 0.4 mm or more and less than 0.6 mm; (III) tensile elongation of the matrix resin (B) is 1.5 to 10%; and (IV) interfacial shear strength between the reinforcing fibers (A) and the matrix resin (B) is 20 MPa or more.
    Type: Grant
    Filed: January 17, 2018
    Date of Patent: November 12, 2019
    Assignee: Toray Industries, Inc.
    Inventors: Naokichi Imai, Kentaro Sano, Keisuke Inose
  • Patent number: 10308775
    Abstract: A fiber-reinforced resin composition includes a polyarylene sulfide (A), a carbodiimide compound (B) and carbon fibers (C) in specific blending amounts and in which the carbon fibers (C) are surface-treated with a sizing agent (D), the carbodiimide compound (B) is an aliphatic carbodiimide compound, and the sizing agent (D) is a compound having three or more specific functional groups in one molecule; and a fiber-reinforced composite material includes a thermoplastic resin (A?), an adhesive compound (B?) and reinforcing fibers (C?) and in which the adhesive compound (B?) is a compound having two or more specific structures in one molecule, the thermoplastic resin (A?) is a thermoplastic resin containing an element other than carbon in a repeating unit structure of a main chain, and an abundance ratio Rb of the adhesive compound (B?) is 1.2 or more.
    Type: Grant
    Filed: October 24, 2014
    Date of Patent: June 4, 2019
    Assignee: Toray Industries Inc.
    Inventors: Naokichi Imai, Keisuke Inose, Kentaro Sano, Atsuki Tsuchiya
  • Publication number: 20180362760
    Abstract: Provided is a molding material which includes a composite of 1 to 50 wt % of a continuous reinforcing fiber bundle (A) and 0.1 to 20 wt % of a poly(phenylene ether ether ketone) oligomer (B); and 30 to 98.9 wt % of a thermoplastic resin (C) adhering to the composite, wherein the component (B) has a melting point of not higher than 270° C. Also provided are a method for molding the molding material, a method for producing the molding material, and a method for producing a fiber-reinforced composite material. A molded article having high heat resistance and dynamic properties can be easily produced without impairing the economic efficiency and productivity during the process for producing a molding material. In addition, a fiber-reinforced composite material can be produced with more ease and high productivity.
    Type: Application
    Filed: June 14, 2018
    Publication date: December 20, 2018
    Applicant: Toray Industries, Inc.
    Inventors: Naokichi Imai, Atsuki Tsuchiya, Masato Honma, Kohei Yamashita, Shunsuke Horiuchi, Koji Yamauchi
  • Patent number: 10093802
    Abstract: A molding material includes 5 to 50 parts by mass of reinforcing fibers (A) with a sizing agent (s) deposited thereon, 1 to 20 parts by mass of a component (B) containing a polycarbodiimide compound (B-1) that is liquid at 50° C., and 30 to 94 parts by mass of a thermoplastic resin (C) containing an element other than carbon in the repeating unit structure of the main chain, based on 100 parts by mass of the total of the components (A) to (C), wherein the molding material is a composite in which a composite fiber bundle (D) with the component (A) impregnated with the component (B) is covered with the component (C).
    Type: Grant
    Filed: October 24, 2014
    Date of Patent: October 9, 2018
    Assignee: Toray Industries, Inc.
    Inventors: Kentaro Sano, Keisuke Inose, Naokichi Imai, Atsuki Tsuchiya
  • Publication number: 20180260003
    Abstract: An electronic device housing includes: a bottom cover; a top cover; a partition structure that is disposed in a space divided by the bottom cover and the top cover and has an opening; and a heat generation member. The partition structure is joined to the bottom cover or the top cover to form a hollow structure, and the heat generation member is disposed on a surface of the partition structure on the hollow structure side.
    Type: Application
    Filed: September 6, 2016
    Publication date: September 13, 2018
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Masato HONMA, Yoshiki TAKEBE, Naokichi IMAI, Takashi FUJIOKA
  • Publication number: 20180244879
    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: Application
    Filed: February 24, 2016
    Publication date: August 30, 2018
    Inventors: Tomohiro Takehara, Satoshi Seike, Masato Honma, Naokichi Imai, Satomi Hiasa
  • Patent number: 10023737
    Abstract: Provided is a molding material comprising a composite of 1 to 50 wt % of a continuous reinforcing fiber bundle (A) and 0.1 to 20 wt % of a poly (phenylene ether ether ketone) oligomer (B); and 30 to 98.9 wt % of a thermoplastic resin (C) adhering to the composite, wherein the component (B) has a melting point of not higher than 270° C. Also provided are a method for molding the molding material, a method for producing the molding material, and a method for producing a fiber-reinforced composite material. A molded article having high heat resistance and dynamic properties can be easily produced without impairing the economic efficiency and productivity during the process for producing a molding material. In addition, a fiber-reinforced composite material can be produced with more ease and high productivity.
    Type: Grant
    Filed: June 20, 2012
    Date of Patent: July 17, 2018
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Naokichi Imai, Atsuki Tsuchiya, Masato Honma, Kohei Yamashita, Shunsuke Horiuchi, Koji Yamauchi
  • Patent number: 10017613
    Abstract: A carbon fiber-reinforced polyarylene sulfide has both dynamic characteristics and molding cycle characteristics and can be produced with high productivity by preparing a polycarbodiimide-modified polyarylene sulfide using a polyarylene sulfide and a polycarbodiimide as raw materials, then melting the resulting polycarbodiimide-modified polyarylene sulfide, and combining the polycarbodiimide-modified polyarylene sulfide with carbon fibers at a specific ratio to produce a composite.
    Type: Grant
    Filed: October 24, 2014
    Date of Patent: July 10, 2018
    Assignee: Toray Industries, Inc.
    Inventors: Naokichi Imai, Kentaro Sano, Keisuke Inose
  • Publication number: 20180186134
    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: Application
    Filed: June 30, 2016
    Publication date: July 5, 2018
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Naokichi IMAI, Masato HONMA
  • Patent number: 10005905
    Abstract: A molding material is provided including a composite having 1 to 50 wt % of (A) a bundle of continuous reinforcing fibers and 0.1 to 40 wt % of (B) a polyarylene sulfide prepolymer or (B?) a polyarylene sulfide; and 10 to 98.9 wt % of (C) a thermoplastic resin adhered to the composite; wherein the composite further has (D) a zero-valent transition metal compound or (E) a low-valent iron compound in an amount of 0.001 to 20 mol % based on the amount of sulfur atoms contained in the component (B) or (B?). A prepreg and a method of producing a fiber-reinforced molding base material is also provided. By using the molding material according to the present invention which exhibits excellent economic efficiency and productivity, a molded article having excellent mechanical characteristics can be easily produced.
    Type: Grant
    Filed: January 11, 2012
    Date of Patent: June 26, 2018
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Naokichi Imai, Kaori Narimatsu, Masato Honma, Shunsuke Horiuchi, Koji Yamauchi
  • Publication number: 20180142083
    Abstract: A molded article includes 10 to 40% by mass of reinforcing fibers (A); and 60 to 90% by mass of a matrix resin (B) mainly including a polyarylene sulfide, the molded article satisfying conditions (I) to (IV) and having a tensile strength of 240 MPa or more in a main orientation direction of the reinforcing fibers (A) in the molded article: (I) strand tensile strength of the reinforcing fibers (A) is 1.5 to 5.5 OPa; (II) number average fiber length of the reinforcing fibers (A) in the molded article is 0.4 mm or more and less than 0.6 mm; (III) tensile elongation of the matrix resin (B) is 1.5 to 10%; and (IV) interfacial shear strength between the reinforcing fibers (A) and the matrix resin (B) is 20 MPa or more.
    Type: Application
    Filed: January 17, 2018
    Publication date: May 24, 2018
    Inventors: Naokichi Imai, Kentaro Sano, Keisuke Inose
  • Patent number: 9902840
    Abstract: A molded article includes 10 to 40% by mass of reinforcing fibers (A); and 60 to 90% by mass of a matrix resin (B) mainly including a polyarylene sulfide, the molded article satisfying conditions (I) to (IV) and having a tensile strength of 240 MPa or more in a main orientation direction of the reinforcing fibers (A) in the molded article, wherein (I) strand tensile strength of the reinforcing fibers (A) is 1.5 to 5.5 GPa, (II) number average fiber length of the reinforcing fibers (A) is 0.4 to 10 mm, (III) tensile elongation of the matrix resin (B) is 1.5 to 10%, and (IV) interfacial shear strength between the reinforcing fibers (A) and the matrix resin (B) is 20 MPa or more.
    Type: Grant
    Filed: October 24, 2014
    Date of Patent: February 27, 2018
    Assignee: Toray Industries, Inc.
    Inventors: Naokichi Imai, Kentaro Sano, Keisuke Inose
  • Publication number: 20160272814
    Abstract: A molding material includes 5 to 50 parts by mass of reinforcing fibers (A) with a sizing agent (s) deposited thereon, 1 to 20 parts by mass of a component (B) containing a polycarbodiimide compound (B-1) that is liquid at 50° C., and 30 to 94 parts by mass of a thermoplastic resin (C) containing an element other than carbon in the repeating unit structure of the main chain, based on 100 parts by mass of the total of the components (A) to (C), wherein the molding material is a composite in which a composite fiber bundle (D) with the component (A) impregnated with the component (B) is covered with the component (C).
    Type: Application
    Filed: October 24, 2014
    Publication date: September 22, 2016
    Inventors: Kentaro Sano, Keisuke Inose, Naokichi Imai, Atsuki Tsuchiya
  • Publication number: 20160264740
    Abstract: A fiber-reinforced resin composition includes a polyarylene sulfide (A), a carbodiimide compound (B) and carbon fibers (C) in specific blending amounts and in which the carbon fibers (C) are surface-treated with a sizing agent (D), the carbodiimide compound (B) is an aliphatic carbodiimide compound, and the sizing agent (D) is a compound having three or more specific functional groups in one molecule; and a fiber-reinforced composite material includes a thermoplastic resin (A?), an adhesive compound (B?) and reinforcing fibers (C?) and in which the adhesive compound (B?) is a compound having two or more specific structures in one molecule, the thermoplastic resin (A?) is a thermoplastic resin containing an element other than carbon in a repeating unit structure of a main chain, and an abundance ratio Rb of the adhesive compound (B?) is 1.2 or more.
    Type: Application
    Filed: October 24, 2014
    Publication date: September 15, 2016
    Inventors: Naokichi Imai, Keisuke Inose, Kentaro Sano, Atsuki Tsuchiya
  • Publication number: 20160257793
    Abstract: A carbon fiber-reinforced polyarylene sulfide has both dynamic characteristics and molding cycle characteristics and can be produced with high productivity by preparing a polycarbodiimide-modified polyarylene sulfide using a polyarylene sulfide and a polycarbodiimide as raw materials, then melting the resulting polycarbodiimide-modified polyarylene sulfide, and combining the polycarbodiimide-modified polyarylene sulfide with carbon fibers at a specific ratio to produce a composite.
    Type: Application
    Filed: October 24, 2014
    Publication date: September 8, 2016
    Inventors: Naokichi Imai, Kentaro Sano, Keisuke Inose
  • Publication number: 20160251498
    Abstract: A molded article includes 10 to 40% by mass of reinforcing fibers (A); and 60 to 90% by mass of a matrix resin (B) mainly including a polyarylene sulfide, the molded article satisfying conditions (I) to (IV) and having a tensile strength of 240 MPa or more in a main orientation direction of the reinforcing fibers (A) in the molded article, wherein (I) strand tensile strength of the reinforcing fibers (A) is 1.5 to 5.5 GPa, (II) number average fiber length of the reinforcing fibers (A) is 0.4 to 10 mm, (III) tensile elongation of the matrix resin (B) is 1.5 to 10%, and (IV) interfacial shear strength between the reinforcing fibers (A) and the matrix resin (B) is 20 MPa or more.
    Type: Application
    Filed: October 24, 2014
    Publication date: September 1, 2016
    Inventors: Naokichi Imai, Kentaro Sano, Keisuke Inose
  • Publication number: 20140155540
    Abstract: Provided is a molding material comprising a composite of 1 to 50 wt % of a continuous reinforcing fiber bundle (A) and 0.1 to 20 wt % of a poly(phenylene ether ether ketone) oligomer (B); and 30 to 98.9 wt % of a thermoplastic resin (C) adhering to the composite, wherein the component (B) has a melting point of not higher than 270° C. Also provided are a method for molding the molding material, a method for producing the molding material, and a method for producing a fiber-reinforced composite material. A molded article having high heat resistance and dynamic properties can be easily produced without impairing the economic efficiency and productivity during the process for producing a molding material. In addition, a fiber-reinforced composite material can be produced with more ease and high productivity.
    Type: Application
    Filed: June 20, 2012
    Publication date: June 5, 2014
    Applicant: Toray Industries, Inc.
    Inventors: Naokichi Imai, Atsuki Tsuchiya, Masato Honma, Kohei Yamashita, Shunsuke Horiuchi, Koji Yamauchi