Patents by Inventor Nobuyuki Arai

Nobuyuki Arai 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: 11286359
    Abstract: A prepreg includes; sizing agent-coated carbon fibers coated with a sizing agent; and a thermosetting resin composition impregnated into the sizing agent-coated carbon fibers. The sizing agent includes an aliphatic epoxy compound (A) and an aromatic compound (B) at least containing an aromatic epoxy compound (B1). The thermosetting resin composition includes a thermosetting resin (D) and a latent hardener (E), and optionally includes an additive (F) other than the thermosetting resin (D) and the latent hardener (E). The (a)/(b) ratio is within a predetermined range where (a) is the height of a component at a binding energy assigned to CHx, C—C, and C?C and (b) is the height of a component at a binding energy assigned to C—O in a C1s core spectrum of the surfaces of the sizing agent-coated carbon fibers analyzed by X-ray photoelectron spectroscopy.
    Type: Grant
    Filed: August 6, 2019
    Date of Patent: March 29, 2022
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Nobuyuki Arai, Tomoko Ichikawa, Hiroshi Taiko, Makoto Endo, Masanobu Kobayashi, Jun Misumi
  • Publication number: 20220033640
    Abstract: An epoxy resin composition is provided which includes a poly-naphthalene-based epoxy resin having two or more epoxy groups per molecule combined with a non-linear multi-phenyl epoxy resin and an additional epoxy resin having an epoxy functionality of 3 or more, as well as a prepreg, and a fiber-reinforced composite material prepared using the epoxy resin composition. More specifically, an epoxy resin composition is provided which contains a combination of particular types of epoxy resins and curatives that, when cured, provides high flexural modulus and that is suitable for preparing a fiber-reinforced composite material capable of withstanding extreme use environments such as low-temperature environments and high-temperature moisture-absorbing environments. In addition, epoxy resin systems are provided which are capable of achieving a high Tg along with good thermal stability for long periods of time at elevated temperatures (e.g., 180° C. or more) when cured at 210° C. for 2 hours.
    Type: Application
    Filed: September 20, 2019
    Publication date: February 3, 2022
    Applicant: Toray Industries, Inc.
    Inventors: Swezin Than Tun, Jonathan Hughes, Nobuyuki Arai
  • Publication number: 20210371612
    Abstract: The void content of a cured fiber-reinforced composite material is advantageously reduced, particularly when the composite material article is large in size or fabricated using an out-of-autoclave procedure, by using prepreg sheets impregnated with a thermosettable resin composition containing thermoplastic particles and modified to have one or more characteristics such as a certain level of average surface roughness. Such characteristics may be imparted to the prepreg sheet by, for example, conditioning the prepreg sheet by subjecting it to vacuum conditions in advance of being consolidated and cured as part of a prepreg stack.
    Type: Application
    Filed: January 30, 2019
    Publication date: December 2, 2021
    Applicant: Toray Industries, Inc.
    Inventors: Andrew Hideo Koyanagi, Alfred P. Haro, Nobuyuki Arai
  • Patent number: 11111345
    Abstract: A prepreg includes; sizing agent-coated carbon fibers coated with a sizing agent; and a thermosetting resin composition impregnated into the sizing agent-coated carbon fibers. The sizing agent includes an aliphatic epoxy compound (A) and an aromatic compound (B) at least containing an aromatic epoxy compound (B1). The thermosetting resin composition includes a thermosetting resin (D) and a latent hardener (E), and optionally includes an additive (F) other than the thermosetting resin (D) and the latent hardener (E). The (a)/(b) ratio is within a predetermined range where (a) is the height of a component at a binding energy assigned to CHx, C—C, and C?C and (b) is the height of a component at a binding energy assigned to C—O in a C1s core spectrum of the surfaces of the sizing agent-coated carbon fibers analyzed by X-ray photoelectron spectroscopy.
    Type: Grant
    Filed: August 4, 2017
    Date of Patent: September 7, 2021
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Nobuyuki Arai, Tomoko Ichikawa, Hiroshi Taiko, Makoto Endo, Masanobu Kobayashi, Jun Misumi
  • Publication number: 20210269635
    Abstract: This invention relates to an epoxy resin composition for fiber-reinforced composite materials, which contains the following constituent components (A), (B), and (C). Component (A) contains at least one poly-naphthalene-based epoxy resin, component (B) contains at least one alicyclic epoxy resin and/or a divinylarene diepoxide resin, and component (C) contains at least one amine curing agent. This epoxy resin composition, containing a specific combination of particular types of epoxy resin and curatives, provides high heat resistance and high flexural modulus under extreme environmental conditions. More particularly, a cured resin prepared by the epoxy resin composition offers well balanced mechanical properties that are suitable for preparing fiber-reinforced composite materials useful in aircraft components, spacecraft components, automobile components, artificial satellites components, industrial components, and the like.
    Type: Application
    Filed: September 20, 2019
    Publication date: September 2, 2021
    Applicant: Toray Industries, Inc.
    Inventors: Swezin Than Tun, Jonathan Hughes, Nobuyuki Arai
  • Patent number: 11042082
    Abstract: There is provided a projection optical system capable of projecting an image formed on an image forming unit on a projection plane, which has an extremely short projection distance and a small size.
    Type: Grant
    Filed: March 21, 2019
    Date of Patent: June 22, 2021
    Assignee: Ricoh Company, Ltd.
    Inventors: Yohei Takano, Hibiki Tatsuno, Nobuyuki Arai, Hirotoshi Nakayama
  • Patent number: 11028244
    Abstract: A permeable laminate body containing at least one partially impregnated prepreg which includes at least component (A) containing a matrix of reinforcing fiber, component (B) containing a thermosetting resin, and, optionally, component (C) containing a particle or a fiber of a thermoplastic resin exhibits long out time processability with good storage stability, achieving when molded and cured a fiber reinforced composite having a low void ratio and providing excellent mechanical performance.
    Type: Grant
    Filed: December 14, 2016
    Date of Patent: June 8, 2021
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Alfred P. Haro, Nobuyuki Arai
  • Publication number: 20210024712
    Abstract: A laminate body is provided which contains a thin prepreg having a component (A) containing a matrix of reinforcing fiber, a component (B) containing a thermosetting resin, and a component (C) containing particles of a thermoplastic resin. When molded and cured out of autoclave, the laminate body achieves a fiber-reinforced composite having a low void ratio and providing excellent mechanical performance.
    Type: Application
    Filed: March 26, 2019
    Publication date: January 28, 2021
    Applicant: Toray Industries, Inc.
    Inventors: Alfred P. Haro, Nobuyuki Arai, Andrew Hideo Koyanagi
  • Publication number: 20210024748
    Abstract: A benzoxazine resin composition for a fiber-reinforced composite material is provided which contains at least a component [A] having a peak reaction temperature and a component [B] having a peak reaction temperatures that may be within 50° C. of each other. Component [A] includes at least one multifunctional benzoxazine resin. Component [B] includes at least one cycloaliphatic epoxy resin represented by Formula (I): This benzoxazine resin composition is useful in the molding of fiber-reinforced composite materials. More particularly, it is possible to offer a benzoxazine resin composition for a fiber-reinforced composite material where the cured material obtained by heating having superior performance in extreme use environments, such as high temperature and high moisture.
    Type: Application
    Filed: March 19, 2019
    Publication date: January 28, 2021
    Applicant: Toray Industries, Inc.
    Inventors: Benjamin Lehman, Benjamin Rutz, Nobuyuki Arai
  • Patent number: 10829633
    Abstract: An epoxy resin composition for a fiber-reinforced composite material, containing at least components [A], [B], [C], [D], and [E], wherein the epoxy resin composition when cured has a glass transition temperature greater than 220° C. and a storage modulus, as defined by a specific method, less than 35 MPa, as determined from an elastic shear modulus measured at a temperature of at least 35° C. higher than the glass transition temperature, wherein the components [A], [B], [C], [D], and [E] are: [A] at least one naphthalene-based epoxy resin having an EEW between 190 and 260 g/mol; [B] at least one epoxy resin having a functionality of three or more; [C] at least one amine curing agent; [D] at least one latent acid catalyst; and [E] at least one cycloaliphatic epoxy resin. This epoxy resin composition is useful in the molding of fiber-reinforced composite materials.
    Type: Grant
    Filed: October 19, 2017
    Date of Patent: November 10, 2020
    Assignee: Toray Industries, Inc.
    Inventors: Benjamin Lehman, Jonathan Hughes, Swezin Than Tun, Nobuyuki Arai
  • Patent number: 10808091
    Abstract: An intermediate base material has high handleability and shape conformity to complicated shapes and serves to perform high-yield production, even by low pressure molding, of fiber reinforced plastic material that do not suffer from significant generation of molding defects, such as creases and voids, that can cause a decrease in strength and that has good mechanical characteristics, decreased variations therein, and high dimensional stability. The prepreg includes a layer containing reinforcement fibers impregnated with a resin composition and the impregnation rate with the resin composition in the prepreg is in a predetermined range. It is characterized by being an incised prepreg having a plurality of incisions, being at least partly formed of reinforcement fibers with a predetermined fiber length, and having a reinforcement fiber content by volume Vf in a predetermined range.
    Type: Grant
    Filed: September 14, 2015
    Date of Patent: October 20, 2020
    Assignee: Toray Industries, Inc.
    Inventors: Ichiro Taketa, Yuzo Fujita, Nobuyuki Arai, Narumichi Sato
  • Patent number: 10611057
    Abstract: A process is capable of producing a high-quality fiber-reinforced plastic with good yield in a short molding cycle time despite being atmospheric pressure molding. The process characterized uses local contact heating to give different temperature conditions to produce a fiber-reinforced plastic by atmospheric pressure molding from a fiber-reinforced material which contains a reinforcing fiber impregnated with a thermosetting resin composition.
    Type: Grant
    Filed: September 14, 2015
    Date of Patent: April 7, 2020
    Assignee: Toray Industries, Inc.
    Inventors: Ichiro Taketa, Hiroaki Matsutani, Nobuyuki Arai, Narumichi Sato
  • Publication number: 20200048453
    Abstract: An epoxy resin composition for a fiber-reinforced composite material, containing at least components [A], [B], [C], [D], and [E], wherein the epoxy resin composition when cured has a glass transition temperature greater than 220° C. and a storage modulus, as defined by a specific method, less than 35 MPa, as determined from an elastic shear modulus measured at a temperature of at least 35° C. higher than the glass transition temperature, wherein the components [A], [B], [C], [D], and [E] are: [A] at least one naphthalene-based epoxy resin having an EEW between 190 and 260 g/mol; [B] at least one epoxy resin having a functionality of three or more; [C] at least one amine curing agent; [D] at least one latent acid catalyst; and [E] at least one cycloaliphatic epoxy resin. This epoxy resin composition is useful in the molding of fiber-reinforced composite materials.
    Type: Application
    Filed: October 19, 2017
    Publication date: February 13, 2020
    Applicant: Toray Industries, Inc.
    Inventors: Benjamin Lehman, Jonathan Hughes, Swezin Than Tun, Nobuyuki Arai
  • Publication number: 20190359785
    Abstract: A prepreg includes; sizing agent-coated carbon fibers coated with a sizing agent; and a thermosetting resin composition impregnated into the sizing agent-coated carbon fibers. The sizing agent includes an aliphatic epoxy compound (A) and an aromatic compound (B) at least containing an aromatic epoxy compound (B1). The thermosetting resin composition includes a thermosetting resin (D) and a latent hardener (E), and optionally includes an additive (F) other than the thermosetting resin (D) and the latent hardener (E). The (a)/(b) ratio is within a predetermined range where (a) is the height of a component at a binding energy assigned to CHx, C—C, and C?C and (b) is the height of a component at a binding energy assigned to C—) in a C1s core spectrum of the surfaces of the sizing agent-coated carbon fibers analyzed by X-ray photoelectron spectroscopy.
    Type: Application
    Filed: August 6, 2019
    Publication date: November 28, 2019
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Nobuyuki ARAI, Tomoko ICHIKAWA, Hiroshi TAIKO, Makoto ENDO, Masanobu KOBAYASHI, Jun MISUMI
  • Patent number: 10409192
    Abstract: An optical scanner includes a light source including a plurality of light emitting elements, a polygon mirror which deflects light from the light source for scanning a surface of a subject, an optical element arranged between the light source and the polygon mirror, having optical power in a sub scanning direction, a synchronous detector which detects the light deflected by the polygon mirror for synchronous detection and generates a signal for controlling a timing at which the scanning of the surface is started, and a fixing element which secures one end of the optical element. The light emitting elements of the light source are aligned with a certain tilt angle relative to the sub scanning direction. Light from one of the light emitting elements disposed closest to the fixing element in a main scanning direction is used for synchronous detection.
    Type: Grant
    Filed: November 7, 2017
    Date of Patent: September 10, 2019
    Assignee: RICOH COMPANY, LTD.
    Inventors: Tomoya Fujii, Tadashi Nakamura, Nobuyuki Arai, Yoshinobu Sakaue, Noboru Kusunose, Daisuke Imaki
  • Patent number: 10400076
    Abstract: An epoxy resin composition including [A1] a hardener represented by Formula (1), and [B] an aromatic epoxy resin having tri- or higher functionality, wherein a carbon nuclear relaxation time T1C corresponding to a benzene ring carbon atom in the main backbone of Formula (1) assigned to 130 ppm in a solid-state 13C-NMR spectrum is 42 seconds or longer, and a prepreg and a carbon fiber-reinforced composite material obtained using the epoxy resin composition: wherein X represents any one selected from —CH2—, —O—, —CO—, —C(?O)O—, —S—, —SO2—, and —NHC(?O)—; n represents 1 to 5; and R1 to R6 each represent at least one selected from the group consisting of a hydrogen atom, an aliphatic hydrocarbon group having 1 to 4 carbon atoms, an alicyclic hydrocarbon group having 4 or less carbon atoms, and an a halogen atom, wherein when X is —C(?O)O— or —NHC(?O)—, X may be in either direction.
    Type: Grant
    Filed: July 10, 2014
    Date of Patent: September 3, 2019
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Shizue Ueno, Nobuyuki Arai, Jun Misumi, Hiroshi Taiko
  • Publication number: 20190219801
    Abstract: There is provided a projection optical system capable of projecting an image formed on an image forming unit on a projection plane, which has an extremely short projection distance and a small size.
    Type: Application
    Filed: March 21, 2019
    Publication date: July 18, 2019
    Applicant: Ricoh Company, Ltd.
    Inventors: Yohei TAKANO, Hibiki TATSUNO, Nobuyuki ARAI, Hirotoshi NAKAYAMA
  • Publication number: 20190169356
    Abstract: The embodiments herein relate to an epoxy resin composition containing a specific type of amine-based epoxy resin containing four epoxy groups per molecule, a prepreg, and a fiber-reinforced composite material. More specifically, the embodiments herein relate to an epoxy resin composition containing a combination of particular types of epoxy resin and curatives that provides high flexural modulus that is suitable for preparing a fiber-reinforced composite material capable of withstanding extreme use environments such as low-temperature environments and high-temperature moisture-absorbing environments. In addition, the embodiments herein relate to epoxy resin systems capable of achieving a high degree of cure (e.g., 85% or more) within a relatively short period of time (e.g., less than two hours) at a relatively low temperature (e.g., 132° C.).
    Type: Application
    Filed: August 24, 2017
    Publication date: June 6, 2019
    Applicant: Toray Industries, Inc.
    Inventors: Swezin Than Tun, Jonathan Hughes, Nobuyuki Arai, Benjamin Lehman
  • Patent number: 10241308
    Abstract: There is provided a projection optical system capable of projecting an image formed on an image forming unit on a projection plane, which has an extremely short projection distance and a small size.
    Type: Grant
    Filed: September 18, 2017
    Date of Patent: March 26, 2019
    Assignee: Ricoh Company, Ltd.
    Inventors: Yohei Takano, Hibiki Tatsuno, Nobuyuki Arai, Hirotoshi Nakayama
  • Publication number: 20180355132
    Abstract: A permeable laminate body containing at least one partially impregnated prepreg which includes at least component (A) containing a matrix of reinforcing fiber, component (B) containing a thermosetting resin, and, optionally, component (C) containing a particle or a fiber of a thermoplastic resin exhibits long out time processability with good storage stability, achieving when molded and cured a fiber reinforced composite having a low void ratio and providing excellent mechanical performance.
    Type: Application
    Filed: December 14, 2016
    Publication date: December 13, 2018
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Alfred P. Haro, Nobuyuki Arai