Patents by Inventor Satoshi Kaji

Satoshi Kaji 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: 11931927
    Abstract: A main object of the present invention is to provide beneficial improvements relating to a method for producing a fiber reinforced plastic product, the method including curing while pressurizing a prepreg preform by using a core having a fusible part as means for pressurizing.
    Type: Grant
    Filed: September 3, 2021
    Date of Patent: March 19, 2024
    Assignee: Mitsubishi Chemical Corporation
    Inventors: Satoshi Kaji, Tsuneo Takano, Takashi Honma
  • Publication number: 20240033977
    Abstract: The present invention provides an improvement relating to a method for producing a fiber-reinforced resin article at least partially having a structure comprising a bent or curved wall surface, such as a hollow structure part or a U-shaped cross-sectional structure part. A method for manufacturing a fiber-reinforced resin article according to the present invention has a molding step of heating, in a press metal mold, a prepreg preform together with a core comprising a wax material to obtain a cured product and a core removal step of removing the core from the cured product, where the core has an expansion part comprising a first wax material and a stamper part comprising a second wax material that is incompatible with the first wax material, the stamper part is disposed on a surface of the core, and a portion mirroring a shape of a surface of the stamper part is formed on a surface of the cured product.
    Type: Application
    Filed: October 11, 2023
    Publication date: February 1, 2024
    Applicant: Mitsubishi Chemical Corporation
    Inventors: Tsuneo Takano, Satoshi Kaji, Takashi Honma
  • Publication number: 20240002613
    Abstract: The present invention provides a beneficial improvement relating to a method for producing a fiber-reinforced resin article at least partially having a hollow structure part. A method for a producing fiber-reinforced resin article according to the present invention includes a molding step of disposing, in a press mold, a prepreg preform including a core-containing part in which a fusible core comprising a wax material is disposed in an inner side, and heating the disposed prepreg preform to obtain a cured product having a hollow structure part and a core removal step of removing the fusible core from the cured product. In the prepreg preform, a through hole is formed in the core-containing part, and an elastomer stopper is inserted into the through hole.
    Type: Application
    Filed: September 19, 2023
    Publication date: January 4, 2024
    Applicant: Mitsubishi Chemical Corporation
    Inventors: Satoshi KAJI, Tsuneo TAKANO, Takashi HONMA
  • Patent number: 11660785
    Abstract: A method for producing a fiber reinforced plastic can suppress with which wrinkling or bridging in a convex surface or a concave surface having a large curvature at the same time even if the fiber reinforced plastic has a complicated three-dimensional shape. Such methods for producing a fiber reinforced plastic may involve shaping a prepreg sheet in which continuous fibers are impregnated with a resin material into a three-dimensional shape to produce a fiber reinforced plastic (a); wherein at least a portion of the continuous fibers in an area (X) of the prepreg sheet corresponding to an area (X?) in which the fiber reinforced plastic (a) is shear-deformed is bent in an in-plane direction in advance.
    Type: Grant
    Filed: July 8, 2019
    Date of Patent: May 30, 2023
    Assignee: Mitsubishi Chemical Corporation
    Inventors: Tsuneo Takano, Takashi Honma, Satoshi Kaji
  • Publication number: 20230047112
    Abstract: The purpose of the present disclosure is to enhance the degree of freedom for settlement, even once the settlement method has been selected by the user.
    Type: Application
    Filed: August 8, 2022
    Publication date: February 16, 2023
    Inventors: Masato Yamamoto, Satoshi Kaji, Mayumi Numasaki
  • Publication number: 20220168974
    Abstract: Provided is a method of manufacturing a FRP product that is obtained by integrally curing a prepreg where fibers are arranged in a specific direction, such as a unidirectional prepreg, a cloth prepreg, or a tow prepreg and a chopped fiber prepreg, such as a sheet molding compound, in which disorder of fiber arrangement in a portion obtained by curing the prepreg is suppressed to obtain an expected strength.
    Type: Application
    Filed: February 16, 2022
    Publication date: June 2, 2022
    Applicant: Mitsubishi Chemical Corporation
    Inventors: Satoshi Kaji, Tsuneo Takano, Yuma Furuhashi
  • Patent number: 11325325
    Abstract: Provided is a method for manufacturing a fiber reinforced plastic molded body, the method including: performing thermocompression molding, by using a molding die, on a molding precursor which is obtained by arranging a prepreg including a thermosetting resin and a fiber around a thermoplastic solid body.
    Type: Grant
    Filed: April 23, 2019
    Date of Patent: May 10, 2022
    Assignee: Mitsubishi Chemical Corporation
    Inventors: Tsuneo Takano, Takashi Honma, Satoshi Kaji
  • Patent number: 11312090
    Abstract: This fiber-reinforced resin molded article has: a sheet molding compound layer; a continuous fiber reinforcing material layer; and a harrier layer, wherein the barrier layer is interposed between the sheet molding compound layer and the continuous fiber reinforcing material layer.
    Type: Grant
    Filed: April 10, 2019
    Date of Patent: April 26, 2022
    Assignee: Mitsubishi Chemical Corporation
    Inventors: Satoshi Kaji, Tsuneo Takano, Kazuhisa Ikeda
  • Publication number: 20210394462
    Abstract: A main object of the present invention is to provide beneficial improvements relating to a method for producing a fiber reinforced plastic product, the method including curing while pressurizing a prepreg preform by using a core having a fusible part as means for pressurizing.
    Type: Application
    Filed: September 3, 2021
    Publication date: December 23, 2021
    Applicant: Mitsubishi Chemical Corporation
    Inventors: Satoshi Kaji, Tsuneo Takano, Takashi Honma
  • Publication number: 20200402160
    Abstract: A method of determining whether or how to present a loan offer to a user includes determining, by at least one processor, whether or how to present a loan offer to a user on the basis of the user's financial demand.
    Type: Application
    Filed: May 29, 2020
    Publication date: December 24, 2020
    Inventors: Satoshi KAJI, Daisuke TORIGOE
  • Patent number: 10472738
    Abstract: A method for producing a flame-proofed fiber by performing a flame-proofing treatment on a carbon-fiber precursor fiber bundle with a heat treatment furnace including a gas supply blowout nozzle, including: a nozzle body including an inclined plate that guides a gas flowing straightly from a gas inlet port to a rectification board; and the rectification board which rectifies the flow of the gas to blow out toward a yarn from a gas outlet port, where a gas introduction direction in the nozzle is different from a gas blowing out direction, a gas guiding zone is between the inclined plate and the rectification board and includes a guide plate in a space between the gas inlet port and the rectification board and divides the gas supplied from the inlet port into two or more streams, and at least one of between the inclined plate and the guide plate or between the guide plates, an upstream passage width W1 perpendicular to a gas flowing direction inside the gas passage and any downstream passage width W2 satisfy
    Type: Grant
    Filed: July 23, 2014
    Date of Patent: November 12, 2019
    Assignee: Mitsubishi Chemical Corporation
    Inventors: Risa Arai, Satoshi Kaji, Atsushi Kawamura
  • Publication number: 20190329460
    Abstract: Provided is a method for producing a fiber reinforced plastic with which the occurrence of wrinkling or bridging in a convex surface or a concave surface having a large curvature can be suppressed at the same time even if the fiber reinforced plastic has a complicated three-dimensional shape, the method for producing a fiber reinforced plastic, including a step of shaping a prepreg sheet in which continuous fibers are impregnated with a resin material into a three-dimensional shape to produce a fiber reinforced plastic(a); wherein at least a portion of the continuous fibers in an area (X) of the prepreg sheet corresponding to an area (X?) in which the fiber reinforced plastic (a) is sheared and deformed is bent in an in-plane direction in advance.
    Type: Application
    Filed: July 8, 2019
    Publication date: October 31, 2019
    Applicant: Mitsubishi Chemical Corporation
    Inventors: Tsuneo Takano, Takashi Honma, Satoshi Kaji
  • Publication number: 20190270225
    Abstract: Provided is a method for manufacturing a fiber reinforced plastic molded body, the method including: performing thermocompression molding, by using a molding die, on a molding precursor which is obtained by arranging a prepreg including a thermosetting resin and a fiber around a thermoplastic solid body.
    Type: Application
    Filed: April 23, 2019
    Publication date: September 5, 2019
    Applicant: Mitsubishi Chemical Corporation
    Inventors: Tsuneo TAKANO, Takashi HONMA, Satoshi KAJI
  • Publication number: 20190232577
    Abstract: This fiber-reinforced resin molded article has: a sheet molding compound layer; a continuous fiber reinforcing material layer; and a harrier layer, wherein the barrier layer is interposed between the sheet molding compound layer and the continuous fiber reinforcing material layer.
    Type: Application
    Filed: April 10, 2019
    Publication date: August 1, 2019
    Applicant: Mitsubishi Chemical Corporation
    Inventors: Satoshi KAJI, Tsuneo TAKANO, Kazuhisa IKEDA
  • Patent number: 9834869
    Abstract: To perform a flame-resistant treatment on a precursor fiber strand by sending hot air to a heat treatment chamber (2) through a hot air blowing nozzle (4) in a direction parallel to a running direction of a precursor fiber strand (10). The hot air blowing from the hot air blowing nozzle (4) passes through a porous plate and a rectifying member that satisfy the following conditions (1) to (4), wherein the conditions are set as follows: (1) A/B?4.0; (2) 0.15???0.35; (3) 0?B?d?20; and (4) 80% or more of an area of one opening of the porous plate when causing facing surfaces of the porous plate and the rectifying member to overlap each other is included in one opening of the rectifying member, A indicating a hot air passage distance (mm) of the rectifying member, B indicating a horizontal maximum distance (mm) of one opening of the rectifying member, ? indicating a rate of hole area of the porous plate, and d indicating an equivalent diameter (mm) of the porous plate.
    Type: Grant
    Filed: September 14, 2015
    Date of Patent: December 5, 2017
    Assignee: Mitsubishi Chemical Corporation
    Inventors: Satoshi Kaji, Nobuyuki Yamamoto, Atsushi Kawamura, Hitoshi Tomobe
  • Publication number: 20160160395
    Abstract: The nozzle body of the gas supply blowout nozzle (11) includes an inclined plate (13) guiding a gas flowing straightly from a gas inlet port to a rectification board (12), which is connected with the nozzle body. The rectification board (12) rectifies the flow of the gas guided by the inclined plate (13) so that the gas blows out perpendicular or parallel to a yarn from a gas outlet port. A gas guiding zone formed between the inclined plate (13) and the rectification board (12) includes one or more guide plates (14) which divide the gas supplied from the gas inlet port (11a) of the gas supply blowout nozzle (11) into two or more streams. In each gas passage formed at least one of between the inclined plate (13) and the guide plate (14) or between the guide plates (14), an upstream passage width W1 and any downstream passage width W2 thereof satisfy the relation of W1?W2.
    Type: Application
    Filed: July 23, 2014
    Publication date: June 9, 2016
    Applicant: MITSUBISHI RAYON CO., LTD.
    Inventors: Risa ARAI, Satoshi KAJI, Atsushi KAWAMURA
  • Publication number: 20160002828
    Abstract: To perform a flame-resistant treatment on a precursor fiber strand by sending hot air to a heat treatment chamber (2) through a hot air blowing nozzle (4) in a direction parallel to a running direction of a precursor fiber strand (10). The hot air blowing from the hot air blowing nozzle (4) passes through a porous plate and a rectifying member that satisfy the following conditions (1) to (4), wherein the conditions are set as follows: (1) A/B?4.0; (2) 0.15???0.35; (3) 0?B?d?20; and (4) 80% or more of an area of one opening of the porous plate when causing facing surfaces of the porous plate and the rectifying member to overlap each other is included in one opening of the rectifying member, A indicating a hot air passage distance (mm) of the rectifying member, B indicating a horizontal maximum distance (mm) of one opening of the rectifying member, ? indicating a rate of hole area of the porous plate, and d indicating an equivalent diameter (mm) of the porous plate.
    Type: Application
    Filed: September 14, 2015
    Publication date: January 7, 2016
    Applicant: Mitsubishi Rayon Co., Ltd.
    Inventors: Satoshi KAJI, Nobuyuki YAMAMOTO, Atsushi KAWAMURA, Hitoshi TOMOBE
  • Patent number: 9157679
    Abstract: A furnace to flame-resistantly treat a precursor fiber strand by sending hot air to a heat treatment chamber through a hot air blowing nozzle in a direction parallel to a running direction of the strand is provided. The hot air passes through a porous plate and a rectifying member satisfying the following conditions: (1) A/B?4.0; (2) 0.15???0.35; (3) 0?B?d?20; and (4) 80% or more of the area of one opening of the porous plate when facing surfaces of the porous plate and the rectifying member overlap is included in one opening of the rectifying member, where A is the rectifying member hot air passage distance (mm), B is a horizontal maximum distance (mm) of one opening of the rectifying member, ? is a rate of hole area of the porous plate, and d is the porous plate equivalent diameter (mm).
    Type: Grant
    Filed: July 26, 2012
    Date of Patent: October 13, 2015
    Assignee: Mitsubishi Rayon Co., Ltd.
    Inventors: Satoshi Kaji, Nobuyuki Yamamoto, Atsushi Kawamura, Hitoshi Tomobe
  • Publication number: 20150184941
    Abstract: The present invention relates to a heating furnace suitable for a step in which a precursor fiber bundle is flameproofed. The heating furnace is provided with a hot air introduction duct disposed in a horizontal space and a heat treating chamber, and in the hot air introduction duct outside the heat treatment chamber, a heating device and a circulation fan for the hot air. The interior of the heat treatment chamber comprises a fiber travel path in which the fiber bundles each having a sheet shape horizontally travels the hot air flowing in a low-temperature region is directed to the high-temperature region side by an air direction change plate to be narrowed and flow in the width direction of the hot air introduction duct As a result, the temperature distribution in the width direction in the treatment chamber can be improved.
    Type: Application
    Filed: June 28, 2013
    Publication date: July 2, 2015
    Applicant: Mitsubishi Rayon Co., Ltd.
    Inventors: Risa Arai, Satoshi Kaji, Atsushi Kawamura, Hiroyuki Nishi, Takafumi Tanaka, Masashi Shimahara
  • Publication number: 20140161711
    Abstract: A furnace to flame-resistantly treat a precursor fiber strand by sending hot air to a heat treatment chamber through a hot air blowing nozzle in a direction parallel to a running direction of the strand is provided. The hot air passes through a porous plate and a rectifying member satisfying the following conditions: (1) AB?4.0; (2) 0.15???0.35; (3) 0?B?d?20; and (4) 80% or more of the area of one opening of the porous plate when facing surfaces of the porous plate and the rectifying member overlap is included in one opening of the rectifying member, where A is the rectifying member hot air passage distance (mm), B is a horizontal maximum distance (mm) of one opening of the rectifying member, ? is a rate of hole area of the porous plate, and d is the porous plate equivalent diameter (mm).
    Type: Application
    Filed: July 26, 2012
    Publication date: June 12, 2014
    Applicant: Mitsubishi Rayon Co., Ltd.
    Inventors: Satoshi Kaji, Nobuyuki Yamamoto, Atsushi Kawamura, Hitoshi Tomobe