Patents by Inventor Nobuhiro Usui

Nobuhiro Usui 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).

  • Patent number: 9187610
    Abstract: Disclosed is a polypropylene resin composition comprising from 50 to 95 wt. % of propylene homopolymer component (A) and from 5 to 50 wt. % of ethylene-?-olefin copolymer component (B1), the polypropylene resin composition having a melt index of not less than 40 g/10 min but less than 500 g/10 min, provided that the percentages by weight are based on the combined weight of the components (A) and (B1), wherein the homopolymer component (A) has an intrinsic viscosity [?]A of from 0.5 to 1.4 dl/g, and wherein the ratio of the intrinsic viscosity [?]B1 of the copolymer component (B1) to the intrinsic viscosity [?]A of the homopolymer component (A), [?]B1/[?]A, is from 0.5 to 3. This composition may be modified by addition of a resin component selected from the group consisting of ethylene homopolymer and aromatic vinyl compound-containing rubber. These components are advantageously used for injection foam molding.
    Type: Grant
    Filed: October 24, 2005
    Date of Patent: November 17, 2015
    Assignee: SUMITOMO CHEMICAL COMPANY, LIMITED
    Inventors: Tetsuya Hisayama, Nobuhiro Usui, Takashi Sanada
  • Publication number: 20110285058
    Abstract: A method for producing a molded article of an organic fiber-reinforced polyolefin resin from a polyolefin resin and an organic fiber having a weight average length of 4 mm or more includes the following steps (1) a preparing step of preparing an organic fiber-reinforced polyolefin resin containing a polyolefin resin and an organic fiber having a weight average length of 4 mm or more, (2) a melting step of melting the organic fiber-reinforced polyolefin resin to obtain a molten organic fiber-reinforced polyolefin resin, (3) a filling step of filling the molten organic fiber-reinforced polyolefin resin into a mold cavity which is formed by a pair of molds capable of being moved relatively toward or away from each other and which defines a changeable cavity clearance between them, and (4) a removing step of cooling the filled molten organic fiber-reinforced polyolefin resin to form a molded article of an organic fiber-reinforced polyolefin resin and removing the molded article of the organic fiber-reinforced pol
    Type: Application
    Filed: May 13, 2011
    Publication date: November 24, 2011
    Applicant: SUMITOMO CHEMICAL COMPANY, LIMITED
    Inventors: Yoshitaka Kobayashi, Yuya Yamamoto, Nobuhiro Usui
  • Publication number: 20110263738
    Abstract: A foamed article comprising a polyolefin resin composition (I) comprising a polyvinyl alcohol fiber (A), a polyolefin resin (B), and an unsaturated carboxylic acid-modified polyolefin resin and/or an unsaturated carboxylic acid derivative-modified polyolefin resin (C); the polyvinyl alcohol fiber (A) being present in an amount of 1 to 70 mass %, the polyolefin resin (B) being present in an amount of 20 to 98.5 mass %, and the modified polyolefin resin (C) being present in an amount of 0.5 to 40 mass % with respect to the total amount of the polyvinyl alcohol fiber (A), the polyolefin resin (B), and the modified polyolefin resin (C); the foamed article having an expansion ratio ranging from 1.3 to 5; the polyvinyl alcohol fiber (A) comprising polyvinyl alcohol filaments (A-I) and a sizing agent (A-II), the sizing agent (A-II) being present in an amount of 0.1 to 10 parts by mass per 100 parts by mass of the polyvinyl alcohol filaments (A-I).
    Type: Application
    Filed: December 18, 2009
    Publication date: October 27, 2011
    Applicants: Kuraray Co., LTD., SUMITOMO CHEMICAL COMPANY, LIMITED
    Inventors: Yuya Yamamoto, Nobuhiro Usui, Kenji Atarashi, Kenji Watanabe
  • Publication number: 20110014454
    Abstract: There are provided a foamed molded article formed of a resin composition comprising a reinforcing fiber and a resin component, wherein the reinforcing fiber comprises a surface-treated fiber (A) comprising a base fiber (A-I) composed of a polyalkylene terephthalate and/or a polyalkylene naphthalene dicarboxylate and from 0.1 to 10 parts by weight, relative to 100 parts by weight of the base fiber (A-I), of a sizing agent (A-II) adhering to the surface of the base fiber (A-1), and the resin component comprises a modified polyolefin resin (B) which is a polyolefin resin modified with an unsaturated carboxylic acid and/or an unsaturated carboxylic acid derivative, wherein the foamed molded article has an expansion ratio of 1.3 to 5, and a method for producing the same.
    Type: Application
    Filed: March 27, 2009
    Publication date: January 20, 2011
    Applicant: SUMITOMO CHEMICAL COMPANY, LIMITED
    Inventors: Yuya Yamamoto, Nobuhiro Usui, Kenji Atarashi, Kenji Watanabe
  • Publication number: 20080264544
    Abstract: Disclosed is a foamed resin molding with a functional component obtained by supplying a molten resin locally to the backside of a foamed resin molding made of a preliminarily-shaped foamed laminate sheet having a foamed base layer made of a foamed resin sheet, the foamed base layer having on at least one side thereof a skin layer laminated, and shaping the molten resin into a functional component and simultaneously integrating the functional component to the foamed resin molding by welding, wherein the following inequality is satisfied: 1<X<3{(t1/E)+t2} where t1 is a thickness of the foamed base layer in the portion where the functional component is integrated, E is an expansion ratio of the foamed base layer, t2 is a thickness of the skin layer, and X is a width of the welded portion of the functional component to the foamed base layer.
    Type: Application
    Filed: April 15, 2008
    Publication date: October 30, 2008
    Applicant: Sumitomo Chemical Company, Limited
    Inventor: Nobuhiro Usui
  • Patent number: 7442436
    Abstract: The present invention provides a thermoplastic resin-molded article comprising a thermoplastic resin functional member fused partially to a foamed sheet made of thermoplastic resin shaped in a predetermined form, as well as a process for producing the same. The thermoplastic molded article is preferably used mainly as an interior part in automobiles. According to the present invention, thermoplastic resin molded articles having less variability of the drawing strength of thermoplastic resin functional members from thermoplastic resin foamed sheets can be provided, and these used in interior parts in automobiles. Such molded articles made of thermoplastic resin can be produced efficiently according to the process of the present invention.
    Type: Grant
    Filed: April 4, 2003
    Date of Patent: October 28, 2008
    Assignee: Sumitomo Chemical Company, Limited
    Inventors: Satoshi Hanada, Nobuhiro Usui
  • Patent number: 7235206
    Abstract: An inventive mold is adapted to adhere skin materials having a boundary portion and a resin to each other, and is provided with a resin blocking member which is so embedded as to extend substantially along the boundary portion of the skin materials placed in the mold, and a movable member for projecting the resin blocking member from a molding surface. If such a mold is used, a flow of the resin supplied into the mold can be controlled by projecting the resin blocking member to thereby control an arrival timing of the resin at the boundary portion. Thus, displacement of the boundary portion and wrinkling can be securely prevented from occurring.
    Type: Grant
    Filed: December 2, 2004
    Date of Patent: June 26, 2007
    Assignee: Sumitomo Chemcial Company, Limited
    Inventors: Yoshitaka Kobayashi, Nobuhiro Usui
  • Publication number: 20060261507
    Abstract: Disclosed is a method for producing a foamed article by injecting a molten polypropylene resin containing a foaming agent between cavity surfaces of a pair of a female and male molds having the cavity surfaces, wherein the molten polypropylene resin is injected between the cavity surfaces at an injection rate of from 200 cc/sec to 1200 cc/sec and a quotient of the longest flow distance of the molten resin between the cavity surfaces during a molding process divided by an injection time is 200 mm/sec or less.
    Type: Application
    Filed: October 25, 2005
    Publication date: November 23, 2006
    Applicant: Sumitomo Chemical Company, Limited
    Inventors: Yoshitaka Kobayashi, Nobuhiro Usui
  • Publication number: 20060089417
    Abstract: Disclosed is a polypropylene resin composition comprising from 50 to 95 wt. % of propylene homopolymer component (A) and from 5 to 50 wt. % of ethylene-?-olefin copolymer component (B1), the polypropylene resin composition having a melt index of not less than 40 g/10 min but less than 500 g/10 min, provided that the percentages by weight are based on the combined weight of the components (A) and (B1), wherein the homopolymer component (A) has an intrinsic viscosity [?]A of from 0.5 to 1.4 dl/g, and wherein the ratio of the intrinsic viscosity [?]B1 of the copolymer component (B1) to the intrinsic viscosity [?]A of the homopolymer component (A), [?]B1/[?]A, is from 0.5 to 3. This composition may be modified by addition of a resin component selected from the group consisting of ethylene homopolymer and aromatic vinyl compound-containing rubber. These components are advantageously used for injection foam molding.
    Type: Application
    Filed: October 24, 2005
    Publication date: April 27, 2006
    Inventors: Tetsuya Hisayama, Nobuhiro Usui, Takashi Sanada
  • Patent number: 7014907
    Abstract: Disclosed is a multilayer molded article comprising a thermoplastic resin substrate and at least two kinds of skin materials laminated on a surface of the substrate, the at least two kinds of skin materials including a pair of skin materials adjacent to each other wherein the pair of skin materials are folded toward the substrate to have folded edges which separate the substrate at least partly to define two portions, wherein the separated portions of the substrate are combined together via a plurality of ribs of the thermoplastic resin molded integrally with the substrate, the ribs enclosing therein a part of the folded edges of the pair of skin materials.
    Type: Grant
    Filed: August 21, 2002
    Date of Patent: March 21, 2006
    Assignee: Sumitomo Chemical Company, Limited
    Inventors: Yoshitaka Kobayashi, Nobuhiro Usui
  • Publication number: 20050093203
    Abstract: An inventive mold is adapted to adhere skin materials having a boundary portion and a resin to each other, and is provided with a resin blocking member which is so embedded as to extend substantially along the boundary portion of the skin materials placed in the mold, and a movable member for projecting the resin blocking member from a molding surface. If such a mold is used, a flow of the resin supplied into the mold can be controlled by projecting the resin blocking member to thereby control an arrival timing of the resin at the boundary portion. Thus, displacement of the boundary portion and wrinkling can be securely prevented from occurring.
    Type: Application
    Filed: December 2, 2004
    Publication date: May 5, 2005
    Applicant: Sumitomo Chemical Company, Limited
    Inventors: Yoshitaka Kobayashi, Nobuhiro Usui
  • Publication number: 20050017391
    Abstract: Disclosed is a method for producing a thermoplastic resin molded article, the method comprising: providing a mold comprising paired female and male dies each having a cavity surface, the cavity surfaces being opposite each other, supplying a predetermined amount of thermoplastic resin in a molten state between the cavity surfaces, making the female and male dies approach relatively each other until a cavity having predetermined dimensions is formed by the cavity surfaces, wherein the relative approach of the female and male dies is started during or after the supply of the thermoplastic resin and is finished after the supply of the thermoplastic resin, and compressing the thermoplastic resin in the cavity via the female and male dies to fill a predetermined region of the cavity with the thermoplastic resin, wherein the mold closure speed is specially controlled.
    Type: Application
    Filed: July 19, 2004
    Publication date: January 27, 2005
    Applicant: Sumitomo Chemical Company, Limited
    Inventors: Yoshitaka Kobayashi, Nobuhiro Usui
  • Patent number: 6846169
    Abstract: An inventive mold is adapted to adhere skin materials having a boundary portion and a resin to each other, and is provided with a resin blocking member which is so embedded as to extend substantially along the boundary portion of the skin materials placed in the mold, and a movable member for projecting the resin blocking member from a molding surface. If such a mold is used, a flow of the resin supplied into the mold can be controlled by projecting the resin blocking member to thereby control an arrival timing of the resin at the boundary portion. Thus, displacement of the boundary portion and wrinkling can be securely prevented from occurring.
    Type: Grant
    Filed: March 28, 2002
    Date of Patent: January 25, 2005
    Assignee: Sumitomo Chemical Company, Ltd.
    Inventors: Yoshitaka Kobayashi, Nobuhiro Usui
  • Patent number: 6790020
    Abstract: Disclosed is a system in which carbon dioxide is supplied to a pressure chamber of a molten resin preparing apparatus which has established a certain temperature environment to diffuse the carbon dioxide in a material synthetic resin in a molten state. After turning the material synthetic resin into a gas-dissolving-resin in the pressure chamber, the gas-dissolving-resin is supplied to a mold space of a molding apparatus for compression molding. The pressure inside the mold space is quickly lowered by raising an upper mold of the molding apparatus quickly, whereby a foamed article is produced from the gas-dissolving-resin in the mold space.
    Type: Grant
    Filed: December 11, 2001
    Date of Patent: September 14, 2004
    Assignee: Sumitomo Chemical Company, Limited
    Inventors: Takeo Kitayama, Nobuhiro Usui
  • Patent number: 6713139
    Abstract: The present invention provides a hollow foamed polyolefin-based resin container comprising an inner layer and an outer layer, at least one of the inner and outer layers being formed of a foamed polyolefin-based resin sheet, wherein at least a side wall part of the container has a hollow portion between the inner and outer layer and a process for produciong the same, and the like. The hollow foamed polyolefin-based resin container can be used as containers for retorted food products and other containers.
    Type: Grant
    Filed: September 27, 2002
    Date of Patent: March 30, 2004
    Assignee: Sumitomo Chemical Company, Limited
    Inventors: Nobuhiro Usui, Takeo Kitayama
  • Patent number: 6685875
    Abstract: The present invention relates to foamed thermoplastic resin moldings which can be used, for example, as food product containers which can contain retort food products, etc., household electrical appliance parts and automotive interior parts, and to a process for producing the same, said foamed thermoplastic resin molding prepared by shaping a foamed thermoplastic resin sheet, the molding comprising a general part and a thick part wherein these parts differ from each other in thickness wherein the mean expansion ratio of the thick part is not less than 1.2 times the mean expansion ratio of the general part and wherein the maximum thickness of the thick part is not less than 1.5 times the thickness of the general part.
    Type: Grant
    Filed: April 30, 2001
    Date of Patent: February 3, 2004
    Assignee: Sumitomo Chemical Company, Ltd.
    Inventors: Nobuhiro Usui, Takeo Kitayama
  • Patent number: 6660195
    Abstract: The present invention relates to a process for producing a skin material-laminated foamed thermoplastic resin molding and to foamed thermoplastic resin moldings, said process comprising a skin material and a thermoplastic resin foam integrally laminated with the skin material, wherein the process uses a mold comprising a male and female mold members which are mutually slidable and whose cavity clearance (t) is adjustable, the process comprising the following steps (1)-(5): (1) skin material supply step, (2) resin injection step, (3) compression step, (4) foaming step and (5) cooling and releasing step, and said moldings that are a panel-shaped foamed thermoplastic resin molding comprising a substrate and a projection standing on the substrate wherein the projection has a mean expansion ratio of not greater than 1.1 times and the substrate has a mean expansion ratio of not less than 1.3 times.
    Type: Grant
    Filed: March 1, 2001
    Date of Patent: December 9, 2003
    Assignee: Sumitomo Chemical Company, Limited
    Inventors: Nobuhiro Usui, Takeo Kitayama
  • Publication number: 20030203185
    Abstract: The present invention provides a thermoplastic resin-molded article comprising a thermoplastic resin functional member fused partially to a foamed sheet made of thermoplastic resin shaped in a predetermined form, as well as a process for producing the same. The thermoplastic molded article is preferably used mainly as an interior part in automobiles.
    Type: Application
    Filed: April 4, 2003
    Publication date: October 30, 2003
    Applicant: Sumitomo Chemical Company, Limited
    Inventors: Satoshi Hanada, Nobuhiro Usui
  • Patent number: 6616879
    Abstract: The present invention provides a method for producing a multilayer molded article comprising a step of supplying a skin material having at least a foam layer between a pair of a male mold half and a female mold half, supplying a molten thermoplastic resin between the skin material and the molding surface of one of the male mold half and the female mold half, a step of laminating the skin material onto at least a part of the surface of a substrate made from the thermoplastic resin and a step of forming a recess in the skin material laminating region, wherein the thickness, t (mm), of the foam layer in the skin material before molding is 0.6 R or less wherein R represents the minimum radius (mm) of the recess on the skin material laminating side of the substrate in the skin material laminating region of the multilayer molded article.
    Type: Grant
    Filed: June 5, 2000
    Date of Patent: September 9, 2003
    Assignee: Sumitomo Chemical Company, Limited
    Inventors: Yoshitaka Kobayashi, Nobuhiro Usui, Takeo Kitayama
  • Publication number: 20030165672
    Abstract: Disclosed is a foamed resin molding with a functional component obtained by
    Type: Application
    Filed: February 4, 2003
    Publication date: September 4, 2003
    Applicant: Sumitomo Chemical Company, Limited
    Inventor: Nobuhiro Usui