Patents by Inventor Shunsuke Horiuchi

Shunsuke Horiuchi 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: 10294330
    Abstract: A polyphenylene sulfide resin composition includes a polyphenylene sulfide resin (a) of 90 to 50% by weight and a polyphenylene sulfide resin (b) and/or a polyphenylene sulfide resin (c) of the total of 10 to 50% by weight blended with the polyphenylene sulfide resin (a), relative to the total of the polyphenylene sulfide resins (a) to (c) as 100% by weight, in which the polyphenylene sulfide resin composition has a change rate of viscosity of 1.5 times or less when the composition is heated at 320° C. for 5 hours.
    Type: Grant
    Filed: July 22, 2016
    Date of Patent: May 21, 2019
    Assignee: Toray Industries, Inc.
    Inventors: Hidenobu Takao, Shu Kaiho, Shunsuke Horiuchi
  • 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: 10138577
    Abstract: A poly(phenylene sulfide) fiber contains 1-10% by weight of a poly(phenylene sulfide) oligomer having a weight-average molecular weight of 5,000 or less, has a difference between a cold crystallization heat quantity (?Hc) and a crystal melting heat quantity (?Hm) during temperature rising in DSC, ?Hm??Hc, of 25 J/g or larger, and has an elongation of less than 40% and a strength of 3.0 cN/dtex or higher. The poly(phenylene sulfide) fiber has high heat resistance and chemical resistance and high strength and, despite this, has excellent suitability for high-order processing, e.g., thermal shapability, because the amorphous parts thereof have high molecular movability.
    Type: Grant
    Filed: May 22, 2015
    Date of Patent: November 27, 2018
    Assignee: Toray Industries, Inc.
    Inventors: Hiroo Katsuta, Takaaki Mihara, Daisuke Yamamoto, Shunsuke Horiuchi, Yoshitsugu Funatsu
  • Patent number: 10106655
    Abstract: A poly(phenylene sulfide) fiber changes little in fiber structure and has excellent long-term heat resistance. Namely, the poly(phenylene sulfide) fiber has a degree of crystallization of 45.0% or higher, a content of movable amorphous components of 15.0% or less, and a weight-average molecular weight of 300,000 or less.
    Type: Grant
    Filed: September 24, 2015
    Date of Patent: October 23, 2018
    Assignee: Toray Industries, Inc.
    Inventors: Hiroo Katsuta, Reo Mitsunaga, Daisuke Yamamoto, Shunsuke Horiuchi, Yoshitsugu Funatsu
  • Publication number: 20180223046
    Abstract: A polyphenylene sulfide resin composition includes a polyphenylene sulfide resin (a) of 90 to 50% by weight and a polyphenylene sulfide resin (b) and/or a polyphenylene sulfide resin (c) of the total of 10 to 50% by weight blended with the polyphenylene sulfide resin (a), relative to the total of the polyphenylene sulfide resins (a) to (c) as 100% by weight, in which the polyphenylene sulfide resin composition has a change rate of viscosity of 1.5 times or less when the composition is heated at 320° C. for 5 hours.
    Type: Application
    Filed: July 22, 2016
    Publication date: August 9, 2018
    Inventors: Hidenobu Takao, Shu Kaiho, Shunsuke Horiuchi
  • 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: 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
  • Patent number: 10000620
    Abstract: A polyarylene sulfide resin composition containing nickel microparticles having an average particle diameter of 0.5 to 20 nm is produced by heating a cyclic polyarylene sulfide in the presence of at least one component selected from components (i), (ii) and (iii).
    Type: Grant
    Filed: June 18, 2014
    Date of Patent: June 19, 2018
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Shu Kaiho, Shunsuke Horiuchi, Kenji Ishitake, Koji Yamauchi
  • Publication number: 20180025957
    Abstract: A polyphenylene sulfide resin composition includes 5-50% by weight of (A) a polyphenylene sulfide resin having a weight-average molecular weight of not less than 10000 and a polydispersity, which is expressed by dividing the weight-average molecular weight by a number-average molecular weight, of not higher than 2.5; and 95-50% by weight of (B) fused silica in a spherical form having a volume-average particle diameter of not less than 0.1 ?m and less than 1.0 ?m, wherein a total of (A) and (B) is kept at 100% by weight.
    Type: Application
    Filed: February 24, 2016
    Publication date: January 25, 2018
    Inventors: Naoya Ouchiyama, Hideki Matsumoto, Kei Saitoh, Shunsuke Horiuchi
  • Patent number: 9796850
    Abstract: A reactive functional group-containing polyarylene sulfide resin composition having a narrow polydispersity and a low gas generation amount is manufactured by mixing a polyarylene sulfide resin (a) and a polyarylene sulfide resin (b), wherein the polyarylene sulfide (a) has a weight reduction ratio ?Wr of not higher than 0.18% under heating and an increase rate of melt viscosity of less than 1.05 times by addition of a reactive compound (c) having a reactive group relative to melt viscosity prior to addition of the reactive compound (c), and the polyarylene sulfide (b) has the weight reduction ratio ?Wr of not higher than 0.18% under heating and the increase rate of melt viscosity of not less than 1.05 times by addition of the reactive compound (c) having the reactive group relative to melt viscosity prior to addition of the reactive compound (c).
    Type: Grant
    Filed: April 26, 2013
    Date of Patent: October 24, 2017
    Assignee: Toray Industries, Inc.
    Inventors: Akinori Kanomata, Shunsuke Horiuchi, Shu Kaiho, Koji Yamauchi
  • Publication number: 20170226292
    Abstract: A poly(phenylene sulfide) fiber changes little in fiber structure and has excellent long-term heat resistance. Namely, the poly(phenylene sulfide) fiber has a degree of crystallization of 45.0% or higher, a content of movable amorphous components of 15.0% or less, and a weight-average molecular weight of 300,000 or less.
    Type: Application
    Filed: September 24, 2015
    Publication date: August 10, 2017
    Inventors: Hiroo Katsuta, Reo Mitsunaga, Daisuke Yamamoto, Shunsuke Horiuchi, Yoshitsugu Funatsu
  • Publication number: 20170198414
    Abstract: A poly(phenylene sulfide) fiber contains 1-10% by weight of a poly(phenylene sulfide) oligomer having a weight-average molecular weight of 5,000 or less, has a difference between a cold crystallization heat quantity (?Hc) and a crystal melting heat quantity (?Hm) during temperature rising in DSC, ?Hm??Hc, of 25 J/g or larger, and has an elongation of less than 40% and a strength of 3.0 cN/dtex or higher. The poly(phenylene sulfide) fiber has high heat resistance and chemical resistance and high strength and, despite this, has excellent suitability for high-order processing, e.g., thermal shapability, because the amorphous parts thereof have high molecular movability.
    Type: Application
    Filed: May 22, 2015
    Publication date: July 13, 2017
    Inventors: Hiroo Katsuta, Takaaki Mihara, Daisuke Yamamoto, Shunsuke Horiuchi, Yoshitsugu Funatsu
  • Publication number: 20170130005
    Abstract: There is provided a polyarylene sulfide configured to satisfy (1) to (4): (1) having a weight-average molecular weight of not less than 10000; (2) having a polydispersity of not greater than 2.5, wherein the polydispersity is expressed by a ratio of the weight-average molecular weight to a number-average molecular weight; (3) having a weight reduction on heating that satisfies an expression of ?Wr=(W1?W2)/W1×100?0.18(%) (where ?Wr denotes a weight reduction ratio (%) and is a value calculated from a sample weight (W2) at temperature reaching 330° C. relative to a sample weight (W1) at temperature reaching 100° C. in thermogravimetric analysis at a temperature rise rate of 20° C./minute in a non-oxidizing atmosphere at ordinary pressure); and (4) having a nitrogen content of not greater than 200 ppm.
    Type: Application
    Filed: June 30, 2015
    Publication date: May 11, 2017
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Shingo Takechi, Tomoyuki Odashima, Shunsuke Horiuchi
  • Patent number: 9416272
    Abstract: There is provided a polyphenylene sulfide resin composition, comprising 5 to 95% by weight of a component (B) which is a polyphenylene sulfide resin having a weight-average molecular weight of not less than 10,000 and a weight loss percentage ?Wr of not greater than 0.18% under heating, relative to 95 to 5% by weight of a component (A) which is a polyphenylene sulfide resin having the weight loss percentage ?Wr of greater than 0.18%, wherein a total of the component (A) and the component (B) is equal to 100% by weight.
    Type: Grant
    Filed: October 13, 2015
    Date of Patent: August 16, 2016
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Naoya Ouchiyama, Shunsuke Horiuchi, Hideki Matsumoto, Kei Saitoh
  • Publication number: 20160137807
    Abstract: A polyarylene sulfide resin composition containing nickel microparticles having an average particle diameter of 0.5 to 20 nm is produced by heating a cyclic polyarylene sulfide in the presence of at least one component selected from components (i), (ii) and (iii).
    Type: Application
    Filed: June 18, 2014
    Publication date: May 19, 2016
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Shu Kaiho, Shunsuke Horiuchi, Kenji Ishitake, Koji Yamauchi
  • Publication number: 20160032100
    Abstract: There is provided a polyphenylene sulfide resin composition, comprising 5 to 95% by weight of a component (B) which is a polyphenylene sulfide resin having a weight-average molecular weight of not less than 10,000 and a weight loss percentage ?Wr of not greater than 0.18% under heating, relative to 95 to 5% by weight of a component (A) which is a polyphenylene sulfide resin having the weight loss percentage ?Wr of greater than 0.18%, wherein a total of the component (A) and the component (B) is equal to 100% by weight.
    Type: Application
    Filed: October 13, 2015
    Publication date: February 4, 2016
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Naoya OUCHIYAMA, Shunsuke HORIUCHI, Hideki MATSUMOTO, Kei SAITOH
  • Patent number: 9187641
    Abstract: There is provided a polyphenylene sulfide resin composition, comprising 5 to 95% by weight of a component (B) which is a polyphenylene sulfide resin having a weight-average molecular weight of not less than 10,000 and a weight loss percentage ?Wr of not greater than 0.18% under heating, relative to 95 to 5% by weight of a component (A) which is a polyphenylene sulfide resin having the weight loss percentage ?Wr of greater than 0.18%, wherein a total of the component (A) and the component (B) is equal to 100% by weight.
    Type: Grant
    Filed: December 26, 2012
    Date of Patent: November 17, 2015
    Assignee: Toray Industries, Inc.
    Inventors: Naoya Ouchiyama, Shunsuke Horiuchi, Hideki Matsumoto, Kei Saitoh
  • Patent number: 9150695
    Abstract: There is provided a production method of a cyclic polyarylene sulfide from a reaction mixture including at least a sulfidizing agent (a), a dihalogenated aromatic compound (b) and an organic polar solvent (c). The production method includes: a process 1 of heating the reaction mixture having an arylene unit of not less than 0.80 mol but less than 1.05 mol per 1 mol of the sulfur content in the reaction mixture; and subsequent to the process 1, a process 2 of further causing the reaction to proceed after addition of the dihalogenated aromatic compound (b) to have the arylene unit of not less than 1.05 mol and not greater than 1.50 mol per 1 mol of the sulfur content in the reaction mixture.
    Type: Grant
    Filed: October 22, 2012
    Date of Patent: October 6, 2015
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Tomoyuki Odashima, Shunsuke Horiuchi, Naoto Kumagai, Koji Yamauchi
  • Patent number: 9029484
    Abstract: A production method includes a process (I) of heating a cyclic polyarylene sulfide composition under reduced pressure and a process (II) of heating and polymerizing a cyclic polyarylene sulfide composition. This simple method allows for production of a polyarylene sulfide of the higher molecular weight and can produce a polyarylene sulfide having a narrow molecular weight distribution, low gas generation and high industrial usability. Additionally, pelletization after the process (I) can produce a cyclic polyarylene sulfide pellet having ease of conveyance, excellent molding processability, less gas generation amount and high industrial usability.
    Type: Grant
    Filed: February 27, 2013
    Date of Patent: May 12, 2015
    Assignee: Toray Industries, Inc.
    Inventors: Akinori Kanomata, Yosuke Nishimura, Shunsuke Horiuchi, Shu Kaiho, Kazusada Takeda, Koji Yamauchi, Junya Suzuki
  • Publication number: 20150126668
    Abstract: A reactive functional group-containing polyarylene sulfide resin composition having a narrow polydispersity and a low gas generation amount is manufactured by mixing a polyarylene sulfide resin (a) and a polyarylene sulfide resin (b), wherein the polyarylene sulfide (a) has a weight reduction ratio ?Wr of not higher than 0.18% under heating and an increase rate of melt viscosity of less than 1.05 times by addition of a reactive compound (c) having a reactive group relative to melt viscosity prior to addition of the reactive compound (c), and the polyarylene sulfide (b) has the weight reduction ratio ?Wr of not higher than 0.18% under heating and the increase rate of melt viscosity of not less than 1.05 times by addition of the reactive compound (c) having the reactive group relative to melt viscosity prior to addition of the reactive compound (c).
    Type: Application
    Filed: April 26, 2013
    Publication date: May 7, 2015
    Inventors: Akinori Kanomata, Shunsuke Horiuchi, Shu Kaiho, Koji Yamauchi