Patents by Inventor Tetsuya Motohashi

Tetsuya Motohashi 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: 12030218
    Abstract: A fiber-reinforced resin molding material [C] includes a chopped fiber bundle [A] and a matrix resin [B], the material being characterized in that, when divided into n layers along the thickness direction of the fiber-reinforced resin molding material [C], the number-average fiber length [Lk] of the chopped fiber bundle [Ak] constituting each layer Fk (1?k?n) gradually increases from one outermost layer F1 of the fiber-reinforced resin molding material [C] toward the other outermost layer Fn. Also provided is a molded article obtained by molding the fiber-reinforced resin molding material. This fiber-reinforced resin molding material exhibits excellent flowability, and can exhibit excellent mechanical properties when made into a molded article.
    Type: Grant
    Filed: October 30, 2019
    Date of Patent: July 9, 2024
    Assignee: Toray Industries, Inc.
    Inventors: Yasukazu Ono, Takafumi Hashimoto, Tetsuya Motohashi, Tadashi Watanabe
  • Patent number: 11794419
    Abstract: A fiber-reinforced resin molding material molded product includes a fiber-reinforced resin molding material prepared by impregnating chopped fiber bundles obtained by cutting a reinforcing fiber bundle with a matrix resin, wherein in a region excluding 30 mm from an edge of the molded product, when an arbitrary rectangular region having an area of 40 mm2 or more and defined by a thickness of the molded product and a width in a direction perpendicular to a thickness direction of the molded product is set in a cross section in an arbitrary thickness direction of the molded product, with respect to a bundle thickness of the chopped fiber bundles present in the set rectangular region.
    Type: Grant
    Filed: March 9, 2020
    Date of Patent: October 24, 2023
    Assignee: Toray Industries, Inc.
    Inventors: Yusuke Yamanaka, Takafumi Hashimoto, Tetsuya Motohashi, Yasukazu Ono
  • Patent number: 11746200
    Abstract: A fiber-reinforced resin molding material is obtained by impregnating a chopped fiber bundle with a matrix resin, has a layered structure including three or more layers in a thickness direction thereof, and satisfies the relationships Lao>Lam and Wao>Wam, where Lao and Wao represent the number average fiber length and the number average fiber bundle width, respectively, of the chopped fiber bundle in the outermost layer thereof, and Lam and Wam represent the number average fiber length and the number average fiber bundle width, respectively, of the chopped fiber bundle in a middle layer thereof.
    Type: Grant
    Filed: September 24, 2019
    Date of Patent: September 5, 2023
    Assignee: Toray Industries, Inc.
    Inventors: Yasukazu Ono, Takafumi Hashimoto, Akira Shimoyama, Tetsuya Motohashi
  • Patent number: 11492731
    Abstract: A method of producing a partially separated fiber bundle wherein, while a fiber bundle includes a plurality of single fibers travels along a lengthwise direction of the fiber bundle, a separator provided with a plurality of projected parts is penetrated into the fiber bundle to create a separation-processed part, and entangled parts, where the single fibers are interlaced, are formed at contact parts with the projected parts in at least one separation-processed part, thereafter the separator is removed from the fiber bundle, and after passing through an entanglement accumulation part including the entangled parts, the separator is penetrated again into the fiber bundle, characterized in that a separation processing time t1 during being penetrated with the separator and a time t2 from being removed with the separator to being penetrated again into the fiber bundle satisfy Equation (1): 0.03?t2/(t1+t2)?0.5.
    Type: Grant
    Filed: December 22, 2020
    Date of Patent: November 8, 2022
    Assignee: Toray Industries, Inc.
    Inventors: Tetsuya Motohashi, Takafumi Hashimoto, Katsuhiro Miyoshi, Yoshihiro Kawahara, Tamotsu Suzuki, Chiasa Sato
  • Patent number: 11371171
    Abstract: A production method for a separated fiber bundle includes at least: [A] a partial separation step for obtaining a partially separated fiber bundle in which separation-processed parts, each separated into a plurality of bundles, and not-separation-processed parts are alternately formed along the lengthwise direction of a fiber bundle comprising a plurality of single fibers; and [B] a cutting step for cutting the not-separation-processed parts of the partially separated fiber bundle formed in the step [A] along the lengthwise direction of the fiber bundle. A separated fiber bundle produced by the method, a fiber-reinforced resin molding material that uses the separated fiber bundle, and a production method for the fiber-reinforced resin molding material.
    Type: Grant
    Filed: June 6, 2017
    Date of Patent: June 28, 2022
    Assignee: Toray Industries, Inc.
    Inventors: Tetsuya Motohashi, Takafumi Hashimoto, Katsuhiro Miyoshi, Chiasa Sato
  • Publication number: 20220176647
    Abstract: A fiber-reinforced resin molding material molded product includes a fiber-reinforced resin molding material prepared by impregnating chopped fiber bundles obtained by cutting a reinforcing fiber bundle with a matrix resin, wherein in a region excluding 30 mm from an edge of the molded product, when an arbitrary rectangular region having an area of 40 mm2 or more and defined by a thickness of the molded product and a width in a direction perpendicular to a thickness direction of the molded product is set in a cross section in an arbitrary thickness direction of the molded product, with respect to a bundle thickness of the chopped fiber bundles present in the set rectangular region.
    Type: Application
    Filed: March 9, 2020
    Publication date: June 9, 2022
    Inventors: Yusuke Yamanaka, Takafumi Hashimoto, Tetsuya Motohashi, Yasukazu Ono
  • Publication number: 20220049061
    Abstract: A fiber-reinforced resin molding material is obtained by impregnating a chopped fiber bundle with a matrix resin, has a layered structure including three or more layers in a thickness direction thereof, and satisfies the relationships Lao>Lam and Wao>Wam, where Lao and Wao represent the number average fiber length and the number average fiber bundle width, respectively, of the chopped fiber bundle in the outermost layer thereof, and Lam and Wam represent the number average fiber length and the number average fiber bundle width, respectively, of the chopped fiber bundle in a middle layer thereof.
    Type: Application
    Filed: September 24, 2019
    Publication date: February 17, 2022
    Inventors: Yasukazu Ono, Takafumi Hashimoto, Akira Shimoyama, Tetsuya Motohashi
  • Patent number: 11230630
    Abstract: A partially separated fiber bundle having a surface of a reinforcing fiber coated with a sizing agent containing a water-soluble polyamide-based resin, in which a separated fiber section consisting of a plurality of separated fiber bundles and an unseparated fiber section are provided alternately along a longitudinal direction of the reinforcing fiber bundle consisting of a plurality of single yarns, wherein the reinforcing fiber bundle contains 600 fibers/mm or more and less than 1,600 fibers/mm of fibers per unit width while the reinforcing fiber has a drape level of 120 mm or more and 240 mm or less.
    Type: Grant
    Filed: January 26, 2018
    Date of Patent: January 25, 2022
    Assignee: Toray Industries, Inc.
    Inventors: Mitsuki Fuse, Masaru Tateyama, Hiroshi Hirano, Satoshi Seike, Akihiko Matsui, Kazuma Ura, Tetsuya Motohashi
  • Patent number: 11168190
    Abstract: A random mat includes a chopped fiber bundle [A] obtained by obliquely cutting a partially separated fiber bundle [B] prepared by alternately forming separation-processed sections, each of which is separated into a plurality of bundles, and not-separation-processed sections, along the lengthwise direction of a fiber bundle, wherein the total cross-sectional area of reinforcing fibers exhibits a specific change amount between both tips of the chopped fiber bundle [A]; a production method produces the random mat; and a fiber-reinforced resin molding material uses the random mat.
    Type: Grant
    Filed: September 28, 2017
    Date of Patent: November 9, 2021
    Assignee: Toray Industries, Inc.
    Inventors: Tetsuya Motohashi, Takafumi Hashimoto
  • Patent number: 11162196
    Abstract: A partially separated fiber bundle includes separation-processed sections and not-separation-processed sections that are alternately formed along the lengthwise direction of a fiber bundle that includes a plurality of single fibers, wherein the separation-processed sections include a plurality of divided fiber bundles that have been divided by separation processing. The partially separated fiber bundle is characterized in that the numbers of single fibers of the divided fiber bundles in the separation-processed section are nonuniform.
    Type: Grant
    Filed: June 1, 2017
    Date of Patent: November 2, 2021
    Assignee: Toray Industries, Inc.
    Inventors: Tetsuya Motohashi, Takafumi Hashimoto, Katsuhiro Miyoshi, Chiasa Sato
  • Publication number: 20210323196
    Abstract: A fiber-reinforced resin molding material [C] includes a chopped fiber bundle [A] and a matrix resin [B], the material being characterized in that, when divided into n layers along the thickness direction of the fiber-reinforced resin molding material [C], the number-average fiber length [Lk] of the chopped fiber bundle [Ak] constituting each layer Fk (1?k?n) gradually increases from one outermost layer F1 of the fiber-reinforced resin molding material [C] toward the other outermost layer Fn. Also provided is a molded article obtained by molding the fiber-reinforced resin molding material. This fiber-reinforced resin molding material exhibits excellent flowability, and can exhibit excellent mechanical properties when made into a molded article.
    Type: Application
    Filed: October 30, 2019
    Publication date: October 21, 2021
    Inventors: Yasukazu Ono, Takafumi Hashimoto, Tetsuya Motohashi, Tadashi Watanabe
  • Patent number: 11097448
    Abstract: A fiber-reinforced resin molding material containing at least bundled aggregates [A] of discontinuous reinforcing fibers and a matrix resin [M], wherein each of the bundled aggregates [A] is obtained by cutting a partially-separated fiber bundle, prepared by forming separation treatment sections separated into a plurality of bundles and non-separation treatment sections alternately along a lengthwise direction of a fiber bundle including a plurality of single fibers, at an angle ? (0°<?<90°) with respect to the lengthwise direction of the fiber bundle.
    Type: Grant
    Filed: February 23, 2017
    Date of Patent: August 24, 2021
    Assignee: Toray Industries, Inc.
    Inventors: Tetsuya Motohashi, Takafumi Hashimoto, Katsuhiro Miyoshi, Tamotsu Suzuki, Yasumoto Noguchi
  • Patent number: 11007675
    Abstract: A discontinuous fiber-reinforced composite material including a discontinuous reinforcing fiber aggregate of a discontinuous reinforcing fiber having a number average fiber length of 3 to 100 mm and a matrix resin, the discontinuous reinforcing fiber aggregate including a plurality of discontinuous reinforcing fiber bundles having a predetermined number of unidirectionally-bundled single yarns of the discontinuous reinforcing fiber, wherein the discontinuous reinforcing fiber bundle has a cut surface inclined at a predetermined angle with respect to an orientation direction of the single yarn of the discontinuous reinforcing fiber bundle and has different fiber bundle lengths defined as a distance between both ends along the orientation direction of the single yarn of the discontinuous reinforcing fiber bundle, and the longer the fiber bundle length of the discontinuous reinforcing fiber bundle is, the smaller a tip angle defined as an acute angle at an end of a two-dimensional plane projection of the discont
    Type: Grant
    Filed: February 15, 2017
    Date of Patent: May 18, 2021
    Assignee: Toray Industries, Inc.
    Inventors: Katsuhiro Miyoshi, Takafumi Hashimoto, Tetsuya Motohashi
  • Patent number: 11001012
    Abstract: A molded article of a fiber-reinforced resin contains at least a bundled aggregate [A] of discontinuous reinforcing fibers and a matrix resin [M], wherein the average layer thickness h in the molded article of the fiber-reinforced resin is 100 ?m or less and the CV value of the average layer thickness h is 40% or less; and a compression molding method therefor. It is possible to reliably and greatly reduce the occurrence of stress concentration in the molded article and to thereby achieve higher mechanical properties and further reduce variation in the mechanical properties.
    Type: Grant
    Filed: February 23, 2017
    Date of Patent: May 11, 2021
    Assignee: Toray Industries, Inc.
    Inventors: Tetsuya Motohashi, Takafumi Hashimoto, Chiasa Sato, Ichiro Taketa
  • Publication number: 20210108342
    Abstract: A method of producing a partially separated fiber bundle wherein, while a fiber bundle includes a plurality of single fibers travels along a lengthwise direction of the fiber bundle, a separator provided with a plurality of projected parts is penetrated into the fiber bundle to create a separation-processed part, and entangled parts, where the single fibers are interlaced, are formed at contact parts with the projected parts in at least one separation-processed part, thereafter the separator is removed from the fiber bundle, and after passing through an entanglement accumulation part including the entangled parts, the separator is penetrated again into the fiber bundle, characterized in that a separation processing time t1 during being penetrated with the separator and a time t2 from being removed with the separator to being penetrated again into the fiber bundle satisfy Equation (1): 0.03?t2/(t1+t2)?0.5.
    Type: Application
    Filed: December 22, 2020
    Publication date: April 15, 2021
    Inventors: Tetsuya Motohashi, Takafumi Hashimoto, Katsuhiro Miyoshi, Yoshihiro Kawahara, Tamotsu Suzuki, Chiasa Sato
  • Patent number: 10907280
    Abstract: A method of producing a partially separated fiber bundle includes a partial separation processing step for alternately forming separation-processed sections, each divided into a plurality of bundles, and not-separation-processed sections along the lengthwise direction of a fiber bundle, wherein a separation means provided with a plurality of projected parts is penetrated into the fiber bundle to create separation-processed parts, the separation means is removed from the fiber bundle, and the separation means is penetrated into the fiber bundle again, characterized in that a sizing agent is applied at an arbitrary timing during the production process of the partially separated fiber bundle. A partially separated fiber bundle is obtained by the production method, a fiber-reinforced resin molding material uses the partially separated fiber bundle, and a production method makes the fiber-reinforced resin molding material.
    Type: Grant
    Filed: June 1, 2017
    Date of Patent: February 2, 2021
    Assignee: Toray Industries, Inc.
    Inventors: Tetsuya Motohashi, Takafumi Hashimoto, Masaru Tateyama, Mitsuki Fuse, Akihiko Matsui, Chiasa Sato
  • Patent number: 10688734
    Abstract: A fiber-reinforced material includes a discontinuous reinforcing fiber aggregate of a discontinuous reinforcing fiber having a number average fiber length of 3 to 100 mm and a matrix resin, the discontinuous reinforcing fiber aggregate including a plurality of discontinuous reinforcing fiber bundles having a predetermined number of unidirectionally-bundled single yarns of the discontinuous reinforcing fiber, wherein the discontinuous reinforcing fiber bundle has a cut surface inclined at a predetermined angle with respect to an orientation direction of the single yarn of the discontinuous reinforcing fiber bundle and has different fiber bundle lengths defined as a distance between both ends along the orientation direction of the single yarn of the discontinuous reinforcing fiber bundle, the shorter the fiber bundle length of the discontinuous reinforcing fiber bundle, the smaller a tip angle defined as an acute angle at an end of a two-dimensional plane projection of the discontinuous reinforcing fiber bundle
    Type: Grant
    Filed: February 15, 2017
    Date of Patent: June 23, 2020
    Assignee: Toray Industries, Inc.
    Inventors: Katsuhiro Miyoshi, Takafumi Hashimoto, Tetsuya Motohashi
  • Patent number: 10569986
    Abstract: A partially separated fiber bundle includes separation-processed sections, each divided into a plurality of bundles of at least three bundles, and not-separation-processed sections, that are alternately formed along the lengthwise direction of a fiber bundle that comprises a plurality of single fibers. The partially separated fiber bundle is characterized in that, at any width-direction cross-section taken along the lengthwise direction thereof, a rate of single fibers contained in a region at which adjacent divided fiber bundles are joined by a not-separation-processed part is 67% or less relative to the total single fibers in the width-direction cross-section.
    Type: Grant
    Filed: June 1, 2017
    Date of Patent: February 25, 2020
    Assignee: Toray Industries, Inc.
    Inventors: Tetsuya Motohashi, Takafumi Hashimoto, Yasumoto Noguchi, Yoshihiro Kawahara, Tamotsu Suzuki, Chiasa Sato
  • Publication number: 20190352474
    Abstract: A partially separated fiber bundle having a surface of a reinforcing fiber coated with a sizing agent containing a water-soluble polyamide-based resin, in which a separated fiber section consisting of a plurality of separated fiber bundles and an unseparated fiber section are provided alternately along a longitudinal direction of the reinforcing fiber bundle consisting of a plurality of single yarns, wherein the reinforcing fiber bundle contains 600 fibers/mm or more and less than 1,600 fibers/mm of fibers per unit width while the reinforcing fiber has a drape level of 120 mm or more and 240 mm or less.
    Type: Application
    Filed: January 26, 2018
    Publication date: November 21, 2019
    Inventors: Mitsuki Fuse, Masaru Tateyama, Hiroshi Hirano, Satoshi Seike, Akihiko Matsui, Kazuma Ura, Tetsuya Motohashi
  • Publication number: 20190263625
    Abstract: A partially separated fiber bundle includes separation-processed sections, each divided into a plurality of bundles of at least three bundles, and not-separation-processed sections, that are alternately formed along the lengthwise direction of a fiber bundle that comprises a plurality of single fibers. The partially separated fiber bundle is characterized in that, at any width-direction cross-section taken along the lengthwise direction thereof, a rate of single fibers contained in a region at which adjacent divided fiber bundles are joined by a not-separation-processed part is 67% or less relative to the total single fibers in the width-direction cross-section.
    Type: Application
    Filed: June 1, 2017
    Publication date: August 29, 2019
    Inventors: Tetsuya Motohashi, Takafumi Hashimoto, Yasumoto Noguchi, Yoshihiro Kawahara, Tamotsu Suzuki, Chiasa Sato