Patents by Inventor Noriya Hayashi
Noriya Hayashi 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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Patent number: 11919204Abstract: Provided is a method for making a mold of a gap between components, the method comprising: a step for preparing a curable composition by mixing a resin material with a curing agent that promotes curing of the resin material; a step for cooling the curable composition (M) to a predetermined temperature at which curing of the curable composition is not initiated, so as to manufacture a mold-making kit; a step for placing the mold-making kit in a gap between a first member and a second member so as to fill the gap; a step for curing the mold-making kit between the first member and the second member to mold the mold-making kit into the shape of the gap; and a step for removing the cured mold-making kit from the gap.Type: GrantFiled: December 24, 2019Date of Patent: March 5, 2024Assignee: MITSUBISHI HEAVY INDUSTRIES, LTD.Inventors: Yusuke Kobayashi, Noriya Hayashi
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Patent number: 11667748Abstract: A curable composition of the present invention includes a cationic polymerizable compound; a thermal polymerization initiator; and a storage stabilizer, in which the cationic polymerizable compound includes at least two selected from the group consisting of a glycidyl ether compound, an alicyclic epoxy compound, and an oxetane compound, a content of the thermal polymerization initiator is from 0.3 to 3 parts by mass with respect to 100 parts by mass of the cationic polymerizable compound, and chain curing is enabled by thermal energy generated by a polymerization reaction of the cationic polymerizable compound.Type: GrantFiled: August 29, 2017Date of Patent: June 6, 2023Assignee: MITSUBISHI HEAVY INDUSTRIES, LTD.Inventors: Noriya Hayashi, Toshikatsu Sakakibara, Yusuke Kobayashi, Tatsuya Kimura
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Patent number: 11603874Abstract: A joint member is formed of a composite including reinforcement fibers and resin. The joint member is configured to be joined with another joint member to form a joint structure capable of enduring a tensile load in a load direction in which the joint member and the other joint member are separated from each other at a joined portion of the joint structure in a longitudinal direction of the joint member. The joint member includes a main body part and a joint part connected with the main body part at an end part of the main body part in the longitudinal direction of the joint member. The joint part has an orientation pattern having anisotropy such that fiber directions of the reinforcement fibers included in the joint part include a fiber direction different from the longitudinal direction of the joint member.Type: GrantFiled: February 14, 2020Date of Patent: March 14, 2023Assignee: MITSUBISHI HEAVY INDUSTRIES, LTD.Inventors: Hidetaka Hattori, Noriya Hayashi
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Publication number: 20220009131Abstract: Provided is a method for making a mold of a gap between components, the method comprising: a step for preparing a curable composition by mixing a resin material with a curing agent that promotes curing of the resin material; a step for cooling the curable composition (M) to a predetermined temperature at which curing of the curable composition is not initiated, so as to manufacture a mold-making kit; a step for placing the mold-making kit in a gap between a first member and a second member so as to fill the gap; a step for curing the mold-making kit between the first member and the second member to mold the mold-making kit into the shape of the gap; and a step for removing the cured mold-making kit from the gap.Type: ApplicationFiled: December 24, 2019Publication date: January 13, 2022Inventors: Yusuke KOBAYASHI, Noriya HAYASHI
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Publication number: 20210088063Abstract: A joint member of a composite including reinforcement fibers and resin and to be joined to a joining part according to an aspect includes: a main body part; and a joint part connecting with the main body part and to be joined to the joining part. The joint part includes a bulging part bulging toward the joining part in an opposed direction in which the joint part is opposed to the joining part, and has an orientation pattern having anisotropy such that fiber directions of the reinforcement fibers included in the joint part include a fiber direction different from a load direction of a load applied to a joined portion of the joint part and the joining part.Type: ApplicationFiled: February 14, 2020Publication date: March 25, 2021Inventors: Hidetaka HATTORI, Noriya HAYASHI
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Publication number: 20200190251Abstract: A curable composition of the present invention includes a cationic polymerizable compound; a thermal polymerization initiator; and a storage stabilizer, in which the cationic polymerizable compound includes at least two selected from the group consisting of a glycidyl ether compound, an alicyclic epoxy compound, and an oxetane compound, a content of the thermal polymerization initiator is from 0.3 to 3 parts by mass with respect to 100 parts by mass of the cationic polymerizable compound, and chain curing is enabled by thermal energy generated by a polymerization reaction of the cationic polymerizable compound.Type: ApplicationFiled: August 29, 2017Publication date: June 18, 2020Inventors: Noriya HAYASHI, Toshikatsu SAKAKIBARA, Yusuke KOBAYASHI, Tatsuya KIMURA
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Patent number: 10518487Abstract: In an artificial defect material 10 of an FRP structure, a heat-resistant high-linear-expansion material 20 arranged between the layers thermally expands in case of high-temperature shaping of the FRP structure, so that a predetermined shape is shaped between a plurality of layers of the fiber reinforcing base material 14 and the material 20 thermally shrinks at the room temperature after the shaping, so that a space is formed due to the shrinkage difference from the fiber reinforcing base materials 14. The material 20 has a linear expansion coefficient larger than that of the FRP structure by a predetermined value or more, and has the shape keeping property and the heat resistance to endure the shaping temperature.Type: GrantFiled: October 30, 2015Date of Patent: December 31, 2019Assignee: MITSUBISHI HEAVY INDUSTRIES, LTD.Inventors: Seiji Kobayashi, Mitsuyoshi Uematsu, Takahito Shimomukai, Noriya Hayashi, Yuji Maruyama, Hidetaka Hattori, Junko Watanabe
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Patent number: 10086563Abstract: A method of producing a composite material includes preparing at least one molded product raw material by primary curing; preparing an assembled body by assembling the primarily cured molded product raw material with another molded product raw material; and integrally forming the molded product raw materials by heating the assembled body to a temperature equivalent to or higher than a glass transition point of the primarily cured molded product raw material to cause a phase of the at least one molded product raw material to transition to a rubberized state, by allowing an adhesive adjacent to the molded product raw material or the other molded product raw material adjacent to the molded product raw material to coexist with the molded product raw material in the rubberized state, and by secondarily curing the primarily cured at least one molded product raw material.Type: GrantFiled: December 18, 2013Date of Patent: October 2, 2018Assignee: MITSUBISHI HEAVY INDUSTRIES, LTD.Inventors: Hidetaka Hattori, Noriya Hayashi, Akihisa Watanabe
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Patent number: 9919463Abstract: An RTM molding device and an RTM molding method which enable resin impregnation of even large members and thick members without causing non-impregnated regions or fiber wrinkle, and yield a molded body having superior toughness and excellent precision. In the RTM molding device, a surface molding layer, which is disposed between a fiber-reinforced base material and a molding die, has a plurality of through-holes formed therein, and has sufficient rigidity that the thickness does not substantially change under the pressure inside the cavity when the inside of the cavity is placed under reduced pressure, and a resin diffusion portion, which is located on the side of the surface molding layer opposite the fiber-reinforced base material, and comprises a resin flow path formed so as to connect with the plurality of through-holes of the surface molding layer, are provided on at least one surface of the fiber-reinforced base material.Type: GrantFiled: February 17, 2012Date of Patent: March 20, 2018Assignee: MITSUBISHI HEAVY INDUSTRIES, LTD.Inventors: Noriya Hayashi, Masayuki Kanemasu
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Publication number: 20170274604Abstract: In an artificial defect material 10 of an FRP structure, a heat-resistant high-linear-expansion material 20 arranged between the layers thermally expands in case of high-temperature shaping of the FRP structure, so that a predetermined shape is shaped between a plurality of layers of the fiber reinforcing base material 14 and the material 20 thermally shrinks at the room temperature after the shaping, so that a space is formed due to the shrinkage difference from the fiber reinforcing base materials 14. The material 20 has a linear expansion coefficient larger than that of the FRP structure by a predetermined value or more, and has the shape keeping property and the heat resistance to endure the shaping temperature.Type: ApplicationFiled: October 30, 2015Publication date: September 28, 2017Inventors: Seiji KOBAYASHI, Mitsuyoshi UEMATSU, Takahito SHIMOMUKAI, Noriya HAYASHI, Yuji MARUYAMA, Hidetaka HATTORI, Junko WATANABE
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Patent number: 9416219Abstract: Provided is an RTM moldable chain curing resin composition which can be molded with less energy in a short time, and which makes it possible to obtain a cured product that is superior in mechanical strength. A chain curing resin composition of the present invention includes an alicyclic epoxy compound (A) having two cyclohexene oxides in a molecule and a specific modified bisphenol A-type epoxy resin (B), and the content of the alicyclic epoxy compound (A) is 25 to 90% by mass, when the total of the component (A) and the component (B) is taken as 100% by mass.Type: GrantFiled: October 4, 2010Date of Patent: August 16, 2016Assignee: MITSUBISHI HEAVY INDUSTRIES, LTD.Inventors: Atsushi Nohara, Manabu Kaneko, Noriya Hayashi
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Publication number: 20150367559Abstract: A method of producing a composite material includes preparing at least one molded product raw material by primary curing; preparing an assembled body by assembling the primarily cured molded product raw material with another molded product raw material; and integrally forming the molded product raw materials by heating the assembled body to a temperature equivalent to or higher than a glass transition point of the primarily cured molded product raw material to cause a phase of the at least one molded product raw material to transition to a rubberized state, by allowing an adhesive adjacent to the molded product raw material or the other molded product raw material adjacent to the molded product raw material to coexist with the molded product raw material in the rubberized state, and by secondarily curing the primarily cured at least one molded product raw material.Type: ApplicationFiled: December 18, 2013Publication date: December 24, 2015Inventors: Hidetaka HATTORI, Noriya HAYASHI, Akihisa WATANABE
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Patent number: 8945683Abstract: A prepreg of FRP (fiber reinforced plastic) having with (i) a matrix resin composition containing a bifunctional isocyanate and/or a trifunctional isocyanate, a polyol and a bifunctional chain extender having two active hydrogen groups at a molar ratio, as a functional group, of isocyanate:polyol:chain extender=5.0 to 1.0:1.0:4.0 to 0, or containing a bifunctional isocyanate and/or a trifunctional isocyanate and a polyol at a molar ratio, as a functional group, of liquid isocyanate:polyol=0.9 to 1.1:1.0; and (ii) a fibrous material. A production process of the prepreg. According to the present invention, the prepreg has a sufficient pot life and permits convenient production of an FRP molding.Type: GrantFiled: November 17, 2009Date of Patent: February 3, 2015Assignee: Mitsubishi Heavy Industries, Ltd.Inventors: Noriya Hayashi, Shunichi Hayashi, Norio Miwa, Toshikatsu Nohara
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Publication number: 20140147676Abstract: A method for producing a composite material including a fiber reinforced resin and a lightweight core adjacent thereto, is capable of preventing inflow of a resin into holes on the surface of the lightweight core without increasing the weight of the composite material and also capable of producing a composite material with a high molding accuracy and at a high production rate. In order to produce a composite material including a lightweight core and a fiber reinforced resin that is adjacent to at least a part of a surface of the lightweight core, the method includes arranging, inside a molding tool, a fiber base material adjacently to a foundry core which includes a part which has a part having a shape substantially the same as a shape of a part of the lightweight core which is adjacent to the fiber reinforced resin, which is performed first.Type: ApplicationFiled: July 11, 2012Publication date: May 29, 2014Inventors: Hidetaka Hattori, Akhihisa Watanabe, Noriya Hayashi
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Publication number: 20140138872Abstract: A production method and a production device are capable, in producing at least two products including a fiber reinforced resin, of easily impregnating a resin material into a fiber base material even if a volume of the product to be produced is large, by using a molding tool having a simple structure, and of easily performing control and management of a temperature and time for curing the resin material, and which enable easy cleaning of the molding tool. In order to produce a plurality of flat-shaped products including a fiber reinforced resin at the same time, first, a molding tool is prepared, which is formed so that a plurality of cavity portions having the flat shape of the plurality of products is overlaid with each other via a foundry core.Type: ApplicationFiled: July 11, 2012Publication date: May 22, 2014Inventors: Hidetaka Hattori, Akihisa Watanabe, Noriya Hayashi
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Patent number: 8652381Abstract: A resin transfer molding (RTM) molding device is designed to mold a fiber-reinforced plastic (FRP) molded body by injecting a resin composition into a mold and by impregnating the molded body therewith. The resin composition is a chain curing polymer (CCP). A CCP accommodating layer is disposed adjacent to an outer side of the molded body. The layer contains the CCP. The layer is provided with a Vf limit value, the value defined by the curing characteristics of the CCP and the characteristics of dissipation of heat from the CCP to the exterior. An element for separating the molded body is disposed between the body and the layer.Type: GrantFiled: June 26, 2013Date of Patent: February 18, 2014Assignee: Mitsubishi Heavy Industries, Ltd.Inventors: Noriya Hayashi, Hiroshi Mizuno, Koichi Hasegawa, Kazuo Ota
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Patent number: 8647095Abstract: A resin transfer molding (RTM) molding device is designed to mold a fiber-reinforced plastic (FRP) molded body by injecting a resin composition into a mold and by impregnating the molded body therewith. The resin composition is a chain curing polymer (CCP). A CCP accommodating layer is disposed adjacent to an outer side of the molded body. The layer contains the CCP. The layer is provided with a Vf limit value, the value defined by the curing characteristics of the CCP and the characteristics of dissipation of heat from the CCP to the exterior. An element for separating the molded body is disposed between the body and the layer.Type: GrantFiled: June 26, 2013Date of Patent: February 11, 2014Assignee: Mitsubishi Heavy Industries, Ltd.Inventors: Noriya Hayashi, Hiroshi Mizuno, Koichi Hasegawa, Kazuo Ota
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Publication number: 20130285293Abstract: A resin transfer molding (RTM) molding device is designed to mold a fiber-reinforced plastic (FRP) molded body by injecting a resin composition into a mold and by impregnating the molded body therewith. The resin composition is a chain curing polymer (CCP). A CCP accommodating layer is disposed adjacent to an outer side of the molded body. The layer contains the CCP. The layer is provided with a Vf limit value, the value defined by the curing characteristics of the CCP and the characteristics of dissipation of heat from the CCP to the exterior. An element for separating the molded body is disposed between the body and the layer.Type: ApplicationFiled: June 26, 2013Publication date: October 31, 2013Inventors: Noriya HAYASHI, Hiroshi MIZUNO, Koichi HASEGAWA, Kazuo OTA
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Publication number: 20130287877Abstract: A resin transfer molding (RTM) molding device is designed to mold a fiber-reinforced plastic (FRP) molded body by injecting a resin composition into a mold and by impregnating the molded body therewith. The resin composition is a chain curing polymer (CCP). A CCP accommodating layer is disposed adjacent to an outer side of the molded body. The layer contains the CCP. The layer is provided with a Vf limit value, the value defined by the curing characteristics of the CCP and the characteristics of dissipation of heat from the CCP to the exterior. An element for separating the molded body is disposed between the body and the layer.Type: ApplicationFiled: June 26, 2013Publication date: October 31, 2013Inventors: Noriya HAYASHI, Hiroshi MIZUNO, Koichi HASEGAWA, Kazuo OTA
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Publication number: 20130280483Abstract: An RTM molding device and an RTM molding method which enable resin impregnation of even large members and thick members without causing non-impregnated regions or fiber wrinkle, and yield a molded body having superior toughness and excellent precision. In the RTM molding device, a surface molding layer, which is disposed between a fiber-reinforced base material and a molding die, has a plurality of through-holes formed therein, and has sufficient rigidity that the thickness does not substantially change under the pressure inside the cavity when the inside of the cavity is placed under reduced pressure, and a resin diffusion portion, which is located on the side of the surface molding layer opposite the fiber-reinforced base material, and comprises a resin flow path formed so as to connect with the plurality of through-holes of the surface molding layer, are provided on at least one surface of the fiber-reinforced base material.Type: ApplicationFiled: February 17, 2012Publication date: October 24, 2013Inventors: Noriya Hayashi, Masayuki Kanemasu