Patents by Inventor Takeshi Unohara

Takeshi Unohara 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).

  • Publication number: 20250011563
    Abstract: A method of separating a polyarylene sulfide (PAS) includes step 1: heating a PAS resin composition or a molded article thereof to a temperature of 200° C. or higher and 400° C. or lower in a polar organic solvent to dissolve the PAS and thereby obtain a PAS solution (A); step 2: separating the PAS solution (A) into a solid and a PAS solution (B) by solid-liquid separation; step 3: cooling the PAS solution (B) obtained in step 2 to a temperature of 20° C. or higher and 200° C. or lower to allow deposition of the PAS; and step 4: performing solid-liquid separation of a mixture obtained in step 3 to separate the PAS.
    Type: Application
    Filed: July 11, 2022
    Publication date: January 9, 2025
    Applicant: Toray Industries, Inc.
    Inventors: Yuji Yamanaka, Ryosuke Yarimizu, Takuto Fuwa, Takeshi Unohara, Shunsuke Horiuchi
  • Publication number: 20240343905
    Abstract: A method of producing a glass fiber-reinforced recycled PPS resin composition, includes: crushing a molded product containing a polyphenylene sulfide resin and glass fibers to obtain a crushed molded product (A), and mixing the crushed molded product (A) and a PPS resin composition (B) containing 40 to 90 wt % of the PPS resin having a weight average molecular weight of 20,000 to 60,000 and 10 to 60 wt % of glass fibers. The glass fiber-reinforced recycled PPS resin composition suppresses breakage of glass fibers at the time of recycling the glass fiber-reinforced PPS resin composition, and has excellent mechanical properties.
    Type: Application
    Filed: July 14, 2022
    Publication date: October 17, 2024
    Applicant: Toray Industries, Inc.
    Inventors: Yuji Yamanaka, Ryosuke Yarimizu, Hiroyuki Isago, Takeshi Unohara, Syunsuke Horiuchi
  • Publication number: 20240182715
    Abstract: A polyphenylene sulfide resin composition obtained by blending a (A) polyphenylene sulfide resin, an (B) amino group-containing resin, an (C) epoxy group-containing elastomer, and (X) at least one compound having a molecular weight of 1000 or less and selected from among carboxylic acids and carboxylic anhydrides, wherein, when a total amount of the (A) polyphenylene sulfide resin, the (B) amino group-containing resin, and the (C) epoxy group-containing elastomer is 100% by mass, an amount of the (A) polyphenylene sulfide resin is 20% by mass or more and 60% by mass or less, and in a morphology of a molded article made of the polyphenylene sulfide resin composition as observed with a transmission electron microscope, the (A) polyphenylene sulfide resin forms a continuous phase, and the (B) amino group-containing resin and the (C) epoxy group-containing elastomer form a dispersed phase.
    Type: Application
    Filed: March 25, 2022
    Publication date: June 6, 2024
    Inventors: Yuji Yamanaka, Ryosuke Yarimizu, Takeshi Unohara, Syunsuke Horiuchi
  • Publication number: 20240166875
    Abstract: A polyphenylene sulfide resin composition includes (a) a polyphenylene sulfide resin and (b) a silicone-based polymer; the content of the component (b) is not less than 3 parts by weight and not more than 40 parts by weight with respect to 100 parts by weight of the component (a); in terms of morphology (phase structure), the polyphenylene sulfide resin composition has a phase-separated structure wherein the component (a) forms a continuous phase and the component (b) forms a dispersed phase in which the component (b) is dispersed with a number average dispersion diameter of not more than 3.0 ?m; a test specimen obtained by injection molding of the polyphenylene sulfide resin composition at a cylinder temperature of 310° C. and a mold temperature of 145° C. has a flexural modulus of not more than 3.0 GPa as determined by a flexural test according to ISO 178.
    Type: Application
    Filed: March 15, 2022
    Publication date: May 23, 2024
    Inventors: Tomohiro Hirase, Hiroyuki Isago, Takeshi Unohara, Shunsuke Horiuchi
  • Publication number: 20230220162
    Abstract: A method of producing a polyarylene sulfide composed of amino groups, the method including allowing at least a dihalogenated aromatic compound, an inorganic sulfurizing agent and a compound (A) to react in an organic polar solvent and in the presence of an alkali metal hydroxide, wherein: said compound (A) is present in an amount of 0.04 moles or more and 0.5 moles or less with respect to 1 mole of said inorganic sulfurizing agent, in a reaction vessel; and said compound (A) is a compound comprising at least one aromatic ring, and having, on said one aromatic ring, an amino group, and at least one functional group selected from the group consisting of hydroxyl group, a salt of hydroxyl group, thiol group and a salt of thiol group.
    Type: Application
    Filed: August 24, 2021
    Publication date: July 13, 2023
    Inventors: Yuichiro Miyabara, Takuto Fuwa, Katsuya Shokyu, Takeshi Unohara
  • Publication number: 20230133345
    Abstract: A polyarylene sulfide in which when the cumulative integral value from the molecular weight of 100 to the molecular weight of 10,000 in a molecular weight distribution curve is 100, the cumulative integrated value at the molecular weight of 4000 is 48 to 53, and when the melt flow rate of the polyarylene sulfide is defined as MFR1, and when the melt flow rate obtained after mixing the polyarylene sulfide with an epoxy silane coupling agent at a weight ratio of 100:1 and heating the resulting mixture at 315.5° C. for 5 minutes is defined as MFR2, the rate of change represented by MFR2/MFR1 is not more than 0.085.
    Type: Application
    Filed: March 22, 2021
    Publication date: May 4, 2023
    Inventors: Naoto Kumagai, Hideyuki Nakashima, Tomoya Yoshida, Takeshi Unohara
  • Patent number: 11440997
    Abstract: A polyarylene sulfide copolymer has a glass transition temperature of 95° C. or higher and 190° C. or lower and has a melting point of 300° C. or lower or does not have a melting point, as measured by differential scanning calorimetry, and the copolymer containing as a structural unit arylene sulfide units having a number average molecular weight (Mn) of 1,000 or more and 10,000 or less. The polyarylene sulfide copolymer can be provided with high physical stability such as in rigidity at high temperature and excellent moldability and chemical resistance.
    Type: Grant
    Filed: January 30, 2019
    Date of Patent: September 13, 2022
    Assignee: Toray Industries, Inc.
    Inventors: Yuichiro Miyahara, Yuji Yamanaka, Takeshi Unohara
  • Publication number: 20220267542
    Abstract: A fiber-reinforced polyarylene sulfide copolymer composite base material includes a continuous reinforcing fiber, or a reinforcing fiber base material with discontinuous reinforcing fibers dispersed therein; and a polyarylene sulfide copolymer impregnated into the continuous reinforcing fiber or the reinforcing fiber base material; in which the glass transition temperature of the polyarylene sulfide copolymer is 95° C. to 190° C. The fiber-reinforced polyarylene sulfide copolymer composite base material has high workability during molding of molded articles from the composite base material and increased rigidity at high temperature, while having chemical resistance of polyarylene sulfide.
    Type: Application
    Filed: July 27, 2020
    Publication date: August 25, 2022
    Inventors: Yuichiro Miyabara, Takeshi Unohara
  • Patent number: 11174388
    Abstract: A polyphenylene sulfide resin composition exhibits excellent initial toughness and toughness after a long-term high temperature treatment typified by a tensile elongation at break after a dry heat treatment without impairing mechanical strength, chemical resistance and electrical insulation properties. The polyphenylene sulfide resin composition includes 0.01 to 10 parts by weight of an organosilane compound and 0.01 to 5 parts by weight of a metal salt of phosphorus oxoacid based on 100 parts by weight of a polyphenylene sulfide resin, and a tensile elongation at break, which is measured in accordance with ASTM-D638 under the conditions of a tensile speed of 10 mm/min and an ambient temperature of 23° C. after treating at 200° C. for 500 hours using an ASTM No. 4 dumbbell test piece obtained by injection molding the composition, is 10% or more.
    Type: Grant
    Filed: February 15, 2018
    Date of Patent: November 16, 2021
    Assignee: Toray Industries, Inc.
    Inventors: Tomoya Yoshida, Hiroyuki Isago, Takeshi Unohara, Hideki Matsumoto
  • Publication number: 20200339755
    Abstract: A polyarylene sulfide copolymer has a glass transition temperature of 95° C. or higher and 190° C. or lower and has a melting point of 300° C. or lower or does not have a melting point, as measured by differential scanning calorimetry, and the copolymer containing as a structural unit arylene sulfide units having a number average molecular weight (Mn) of 1,000 or more and 10,000 or less. The polyarylene sulfide copolymer can be provided with high physical stability such as in rigidity at high temperature and excellent moldability and chemical resistance.
    Type: Application
    Filed: January 30, 2019
    Publication date: October 29, 2020
    Inventors: Yuichiro Miyabara, Yuji Yamanaka, Takeshi Unohara
  • Patent number: 10577501
    Abstract: A polyphenylene sulfide resin composition includes a polyphenylene sulfide resin (A), an amino group-containing compound (B), an epoxy group-containing elastomer (C), wherein the polyphenylene sulfide resin (A) forms a continuous phase and the amino group-containing compound (B) and the epoxy group-containing elastomer (C) form a dispersed phase in the morphology of a forming product composed of the resin composition observed with a transmission electron microscope, and the modulus of elongation (the elastic modulus determined by performing a tensile test on an ASTM type 1 dumbbell test piece obtained by injection molding at a cylinder temperature of 300° C. and at a mold temperature of 150° C., under the conditions in which the distance between chucks is 114 mm, the test piece distance is 100 mm, and the elongation rate is 10 mm/min) of the resin composition is 1.0 MPa or more and 1000 MPa or less.
    Type: Grant
    Filed: June 23, 2017
    Date of Patent: March 3, 2020
    Assignee: Toray Industries, Inc.
    Inventors: Yuji Yamanaka, Kei Saito, Hiroyuki Isago, Takeshi Unohara, Hideki Matsumoto
  • Publication number: 20190367730
    Abstract: A polyphenylene sulfide resin composition exhibits excellent initial toughness and toughness after a long-term high temperature treatment typified by a tensile elongation at break after a dry heat treatment without impairing mechanical strength, chemical resistance and electrical insulation properties. The polyphenylene sulfide resin composition includes 0.01 to 10 parts by weight of an organosilane compound and 0.01 to 5 parts by weight of a metal salt of phosphorus oxoacid based on 100 parts by weight of a polyphenylene sulfide resin, and a tensile elongation at break, which is measured in accordance with ASTM-D638 under the conditions of a tensile speed of 10 mm/min and an ambient temperature of 23° C. after treating at 200° C. for 500 hours using an ASTM No. 4 dumbbell test piece obtained by injection molding the composition, is 10% or more.
    Type: Application
    Filed: February 15, 2018
    Publication date: December 5, 2019
    Inventors: Tomoya Yoshida, Hiroyuki Isago, Takeshi Unohara, Hideki Matsumoto
  • Publication number: 20190330470
    Abstract: A polyphenylene sulfide resin composition includes a polyphenylene sulfide resin (A), an amino group-containing compound (B), an epoxy group-containing elastomer (C), wherein the polyphenylene sulfide resin (A) forms a continuous phase and the amino group-containing compound (B) and the epoxy group-containing elastomer (C) form a dispersed phase in the morphology of a forming product composed of the resin composition observed with a transmission electron microscope, and the modulus of elongation (the elastic modulus determined by performing a tensile test on an ASTM type 1 dumbbell test piece obtained by injection molding at a cylinder temperature of 300° C. and at a mold temperature of 150° C., under the conditions in which the distance between chucks is 114 mm, the test piece distance is 100 mm, and the elongation rate is 10 mm/min) of the resin composition is 1.0 MPa or more and 1000 MPa or less.
    Type: Application
    Filed: June 23, 2017
    Publication date: October 31, 2019
    Inventors: Yuji Yamanaka, Kei Saito, Hiroyuki Isago, Takeshi Unohara, Hideki Matsumoto
  • Patent number: 10040910
    Abstract: A heat-resistant, chemical-resistant polyphenylene sulfide block copolymer containing polyphenylene sulfide units and aromatic polyester units, wherein the polyphenylene sulfide units have a number average molecular weight in the range of 6,000 to 100,000. Provided is a polyphenylene sulfide block copolymer that overcomes the disadvantages of block copolymers including a low-molecular-weight polyphenylene sulfide segment and having poor heat resistance and chemical resistance.
    Type: Grant
    Filed: December 24, 2014
    Date of Patent: August 7, 2018
    Assignee: TORAY INDUSTRIES, INC.
    Inventors: Kohei Yamashita, Takeshi Unohara, Kosaku Takeuchi, Daisuke Yamamoto, Koji Yamauchi
  • Patent number: 9938407
    Abstract: A polyarylene sulfide resin composition includes: (A) a polyarylene sulfide resin having a carboxyl group content of more than 100 ?mol/g and less than 400 ?mol/g, and also having a weight average molecular weight of 10,000 or more and less than 100,000; and (B) a filler. The polyarylene sulfide resin composition has improved mechanical properties and chemical resistance while maintaining intrinsic high melting point of a polyarylene sulfide.
    Type: Grant
    Filed: September 25, 2014
    Date of Patent: April 10, 2018
    Assignee: Toray Industries, Inc.
    Inventors: Takeshi Unohara, Hideki Matsumoto, Kei Saitoh, Kenichi Okunaga
  • Publication number: 20160319082
    Abstract: A heat-resistant, chemical-resistant polyphenylene sulfide block copolymer containing polyphenylene sulfide units and aromatic polyester units, wherein the polyphenylene sulfide units have a number average molecular weight in the range of 6,000 to 100,000. Provided is a polyphenylene sulfide block copolymer that overcomes the disadvantages of block copolymers including a low-molecular-weight polyphenylene sulfide segment and having poor heat resistance and chemical resistance.
    Type: Application
    Filed: December 24, 2014
    Publication date: November 3, 2016
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Kohei Yamashita, Takeshi Unohara, Kosaku Takeuchi, Daisuke Yamamoto, Koji Yamauchi
  • Publication number: 20160244612
    Abstract: A polyarylene sulfide resin composition includes: (A) a polyarylene sulfide resin having a carboxyl group content of more than 100 ?mol/g and less than 400 ?mol/g, and also having a weight average molecular weight of 10,000 or more and less than 100,000; and (B) a filler. The polyarylene sulfide resin composition has improved mechanical properties and chemical resistance while maintaining intrinsic high melting point of a polyarylene sulfide.
    Type: Application
    Filed: September 25, 2014
    Publication date: August 25, 2016
    Inventors: Takeshi Unohara, Hideki Matsumoto, Kei Saitoh, Kenichi Okunaga
  • Patent number: 8546518
    Abstract: A method is provided for producing a polyarylene sulfide by reacting a sulfidizing agent with a dihalogenated aromatic compound in an organic polar solvent in the presence of an alkali metal hydroxide, the method includes <Step 1>: carrying out the reaction in such a manner that the polymerization time in a temperature range of 230° C. to less than 245° C. (T1a) is not less than 30 minutes and less than 3.5 hours and that the conversion ratio of the dihalogenated aromatic compound at the end of the step is 70 to 98 mol. % and <Step 2>: carrying out the reaction in such a manner that the polymerization time in a temperature range of 245° C. to less than 280° C. (T2) is not less than 5 minutes and less than 1 hour.
    Type: Grant
    Filed: August 26, 2010
    Date of Patent: October 1, 2013
    Assignee: Toray Industries, Inc.
    Inventors: Takeshi Unohara, Hiroyuki Isago, Toru Nishimura, Masahiro Inohara
  • Publication number: 20120178898
    Abstract: A method is provided for producing a polyarylene sulfide by reacting a sulfidizing agent with a dihalogenated aromatic compound in an organic polar solvent in the presence of an alkali metal hydroxide, the method includes <Step 1>: carrying out the reaction in such a manner that the polymerization time in a temperature range of 230° C. to less than 245° C. (T1a) is not less than 30 minutes and less than 3.5 hours and that the conversion ratio of the dihalogenated aromatic compound at the end of the step is 70 to 98 mol. % and <Step 2>: carrying out the reaction in such a manner that the polymerization time in a temperature range of 245° C. to less than 280° C. (T2) is not less than 5 minutes and less than 1 hour.
    Type: Application
    Filed: August 26, 2010
    Publication date: July 12, 2012
    Applicant: Toray Industries, Inc.
    Inventors: Takeshi Unohara, Hiroyuki Isago, Toru Nishimura, Masahiro Inohara
  • Patent number: 7847055
    Abstract: A polyphenylene sulfide resin treated by thermal oxidation has a generated gas amount of 0.23 wt % or less when the resin is heated and melted in vacuum at 320° C. for 2 hours; a residual amount of 3.0 wt % or less as a residue when the resin is dissolved in an amount corresponding to 20 times the weight of the resin, of 1-chloronaphthalene at 250° C. for 5 minutes and, as the 1-chloronaphthalene solution, pressure-filtered in a still hot state by a PTFE membrane filter with a pore size of 1 ?m or less; and a melt flow rate (measured at a temperature of 315.5° C. and at a load of 5000 g according to ASTM D-1238-70) of more than 100 g/10 min to 500 g/10 min.
    Type: Grant
    Filed: November 22, 2005
    Date of Patent: December 7, 2010
    Assignee: Toray Industries, Inc.
    Inventors: Kei Saitoh, Atsushi Ishio, Takeshi Unohara