Patents by Inventor Yuhei Konagai

Yuhei Konagai 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: 20180244875
    Abstract: There is provided a random mat including carbon fibers and a matrix resin, wherein the carbon fibers in the random mat have an average fiber length in a range of 3 mm to 100 mm, a fiber areal weight of the carbon fibers is 25 to 10,000 g/m2, the carbon fibers include a specific carbon fiber bundles having a specific opening degree in a specific amount per the total carbon fibers, and the specific carbon fiber bundles with a thickness of 100 ?m or more are included in a ratio of less than 3% of the number of the total specific carbon fiber bundles.
    Type: Application
    Filed: February 21, 2018
    Publication date: August 30, 2018
    Inventors: Yuhei Konagai, Katsuyuki Hagihara, Takeshi Naito, Naoaki Sonoda
  • Patent number: 9884954
    Abstract: A random mat contains reinforcing fibers having an average fiber length of 3 to 100 mm and a thermoplastic resin, the reinforcing fiber contains reinforcing fiber bundle (A) defined as the bundle composed of the reinforcing fibers of a critical number of single fiber (defined by the following formula (1)) or more, an average thickness of the reinforcing fiber bundles (A) is 100 ?m or less, and the number (n) of the reinforcing fiber bundles (A) per unit weight (g) of the reinforcing fibers satisfies the following formula (I): Critical number of single fiber=600/D (1) (wherein D is the average fiber diameter (?m) of the reinforcing fiber), and 0.65×104/L<N (I) (wherein L is the average fiber length (mm) of the reinforcing fiber).
    Type: Grant
    Filed: July 25, 2013
    Date of Patent: February 6, 2018
    Assignee: Teijin Limited
    Inventors: Naoaki Sonoda, Yuhei Konagai, Katsuyuki Hagihara
  • Patent number: 9878489
    Abstract: Friction-weld assemblies and methods of spin-welding are provided, where the components being joined are polymeric components. Designs provided for the polymeric components enable the use of relatively low speeds and pressures to achieve superior friction weld joints between the components. Further, large surface area polymeric components can be successfully friction welded with such designs. In certain variations, at least one polymeric component has a weld surface with a plurality of surface features that are concave (e.g., grooves) or convex. In other variations, the first component in the weld region has a distinct non-complementary shape from the second component, thus creating a progressive advancing weld line that avoids high temperatures that might incur damage to the polymeric component and weld joint. Such component designs additionally provide for improved flash management at the weld joint.
    Type: Grant
    Filed: December 18, 2014
    Date of Patent: January 30, 2018
    Assignees: TEIJIN LIMITED
    Inventors: Ingrid A. Rousseau, Yuhei Konagai, Yutaka Yagi
  • Patent number: 9592853
    Abstract: Provided is a load-carrying or non-load carrying structural component for a vehicle having improved impact resistance, such as a gas tank protection shield, an underbody shield, a structural panel, an interior floor, a floor pan, a roof, an exterior surface, a storage area, a glove box, a console box, a trunk, a trunk floor, a truck bed, and combinations thereof. The component has a support structure with ridges, each spaced apart from one another at predetermined intervals, to form a corrugated surface capable of load-carrying. The ridges are longitudinally extending, raised ridges and define top and side walls. A plurality of strategically thickened areas is on at least one of the top wall and side walls.
    Type: Grant
    Filed: July 2, 2014
    Date of Patent: March 14, 2017
    Assignees: GM Global Technology Operations LLC, Teijin Limited
    Inventors: Venkat Aitharaju, Yutaka Yagi, Yuhei Konagai
  • Patent number: 9580568
    Abstract: There is provided a fiber-reinforced composite material is constituted by reinforcing fibers with an average fiber length of 5 mm to 100 mm and a thermoplastic resin, in which in a viscoelastic characteristic that is defined by following formulas (1) and (2), an average value in a range of ?25° C. of the melting point of a matrix resin to +25° C. of the melting point of a matrix resin satisfies following formula (3): tan ?=G?/G???(1) tan ??=Vf×tan ?/(100?Vf)??(2) 0.01?tan ???0.2??(3) wherein G? represents a storage modulus (Pa) of the fiber-reinforced composite material, G? represents a loss modulus (Pa) of the fiber-reinforced composite material, and Vf represents a volume fraction (%) of the reinforcing fibers in the fiber-reinforced composite material.
    Type: Grant
    Filed: October 14, 2013
    Date of Patent: February 28, 2017
    Assignee: Teijin Limited
    Inventors: Katsuyuki Hagihara, Yuhei Konagai, Naoaki Sonoda, Masatomo Teshima
  • Publication number: 20160176103
    Abstract: Friction-weld assemblies and methods of spin-welding are provided, where the components being joined are polymeric components. Designs provided for the polymeric components enable the use of relatively low speeds and pressures to achieve superior friction weld joints between the components. Further, large surface area polymeric components can be successfully friction welded with such designs. In certain variations, at least one polymeric component has a weld surface with a plurality of surface features that are concave (e.g., grooves) or convex. In other variations, the first component in the weld region has a distinct non-complementary shape from the second component, thus creating a progressive advancing weld line that avoids high temperatures that might incur damage to the polymeric component and weld joint. Such component designs additionally provide for improved flash management at the weld joint.
    Type: Application
    Filed: December 18, 2014
    Publication date: June 23, 2016
    Applicants: GM Global Technology Operations LLC, Teijin Limited
    Inventors: Ingrid A. ROUSSEAU, Yuhei KONAGAI, Yutaka YAGI
  • Publication number: 20160001816
    Abstract: Provided is a load-carrying or non-load carrying structural component for a vehicle having improved impact resistance, such as a gas tank protection shield, an underbody shield, a structural panel, an interior floor, a floor pan, a roof, an exterior surface, a storage area, a glove box, a console box, a trunk, a trunk floor, a truck bed, and combinations thereof. The component has a support structure with ridges, each spaced apart from one another at predetermined intervals, to form a corrugated surface capable of load-carrying. The ridges are longitudinally extending, raised ridges and define top and side walls. A plurality of strategically thickened areas is on at least one of the top wall and side walls.
    Type: Application
    Filed: July 2, 2014
    Publication date: January 7, 2016
    Inventors: Venkat AITHARAJU, Yutaka YAGI, Yuhei KONAGAI
  • Patent number: 9193840
    Abstract: A composite material includes: carbon fibers having an average fiber length of more than about 10 mm and about 100 mm or less; and a thermoplastic resin. The carbon fibers are substantially two-dimensionally-randomly oriented. The composite material includes a carbon fiber bundle (A) in a ratio of about 30 volume % or more and less than about 90 volume % to a total volume of the carbon fibers, the carbon fiber bundle (A) including the carbon fibers of a critical single fiber number defined by formula (1) or more. An average number (N) of the carbon fibers in the carbon fiber bundle (A) satisfies formula (2). Critical single fiber number=600/D??(1) 6×104/D2<N<2×105/D2??(2) D is an average fiber diameter (?m) of the carbon fibers.
    Type: Grant
    Filed: September 14, 2012
    Date of Patent: November 24, 2015
    Assignee: Teijin Limited
    Inventors: Yuhei Konagai, Yutaka Kondo, Naoaki Sonoda
  • Publication number: 20150258762
    Abstract: There is provided a method of producing a random mat for manufacturing a thermoplastic composite material, including: slitting continuously a strand including reinforcing fibers in a longitudinal direction of the strand to form a plurality of reinforcing fiber strands with narrow width; cutting the reinforcing fiber strands with narrow width continuously to be an average fiber length of 3 mm to 100 mm to form reinforcing fiber strand pieces; spraying gas onto the cut reinforcing fiber strand pieces for opening the reinforcing fiber strand pieces to form reinforcing fiber bundle pieces; and depositing and fixing the reinforcing fiber bundle pieces onto a breathable support together with a thermoplastic resin in a powder or short fibrous form to form an isotropic random mat in which the reinforcing fibers and the thermoplastic resin are mixed.
    Type: Application
    Filed: March 14, 2014
    Publication date: September 17, 2015
    Applicant: Teijin Limited
    Inventors: Katsuyuki Hagihara, Yuhei Konagai, Naoaki Sonoda
  • Publication number: 20150203663
    Abstract: A random mat contains reinforcing fibers having an average fiber length of 3 to 100 mm and a thermoplastic resin, the reinforcing fiber contains reinforcing fiber bundle (A) defined as the bundle composed of the reinforcing fibers of a critical number of single fiber (defined by the following formula (1)) or more, an average thickness of the reinforcing fiber bundles (A) is 100 ?m or less, and the number (n) of the reinforcing fiber bundles (A) per unit weight (g) of the reinforcing fibers satisfies the following formula (I): Critical number of single fiber=600/D (1) (wherein D is the average fiber diameter (?m) of the reinforcing fiber), and 0.65×104/L<N (I) (wherein L is the average fiber length (mm) of the reinforcing fiber).
    Type: Application
    Filed: July 25, 2013
    Publication date: July 23, 2015
    Applicant: Teijin Limited
    Inventors: Naoaki Sonoda, Yuhei Konagai, Katsuyuki Hagihara
  • Publication number: 20150044455
    Abstract: There is provided a random mat including carbon fibers and a matrix resin, wherein the carbon fibers in the random mat have an average fiber length in a range of 3 mm to 100 mm, a fiber areal weight of the carbon fibers is 25 to 10,000 g/m2, the carbon fibers include a specific carbon fiber bundles having a specific opening degree in a specific amount per the total carbon fibers, and the specific carbon fiber bundles with a thickness of 100 ?m or more are included in a ratio of less than 3% of the number of the total specific carbon fiber bundles.
    Type: Application
    Filed: January 31, 2013
    Publication date: February 12, 2015
    Applicant: TEIJIN LIMITED
    Inventors: Yuhei Konagai, Katsuyuki Hagihara, Takeshi Naito, Naoaki Sonoda
  • Patent number: 8946342
    Abstract: There is provided a random mat of the present invention including: reinforcing fibers having an average fiber length of 5 to 100 mm; and a thermoplastic resin, wherein a fiber areal weight of the reinforcing fibers is from 25 to 3,000 g/m2, for a reinforcing fiber bundle (A) including the reinforcing fibers equivalent to or more than a critical single fiber number defined by formula (1), a ratio of the reinforcing fiber bundle (A) to a total amount of the reinforcing fibers in the mat is from 30 vol % to less than 90 vol %, and an average number (N) of the reinforcing fibers in the reinforcing fiber bundle (A) satisfies formula (2): Critical single fiber number=600/D??(1) 0.7×104/D2<N<1×105/D2??(2) wherein D is an average fiber diameter (?m) of single reinforcing fibers.
    Type: Grant
    Filed: August 1, 2013
    Date of Patent: February 3, 2015
    Assignee: Teijin Limited
    Inventors: Yuhei Konagai, Naoaki Sonoda, Noboru Okimoto, Katsuyuki Hagihara
  • Publication number: 20150031257
    Abstract: There is provided a random mat including reinforcing fibers wherein the content of reinforcing fibers having a fiber length of 3 mm or more and less than 15 mm is 50 to 100% by mass based on all the reinforcing fibers contained in the random mat and the content of reinforcing fibers having a fiber length of 15 mm or more and 50 mm or less is 0 to 50% by mass based on all the reinforcing fibers contained in the random mat, and satisfies specific values of fiber areal weight and the degree of opening.
    Type: Application
    Filed: December 20, 2012
    Publication date: January 29, 2015
    Applicant: TEIJIN LIMITED
    Inventors: Makoto Ootsubo, Yuhei Konagai
  • Publication number: 20140339036
    Abstract: A shock absorption member which is lightweight, has a high degree of freedom in shape, and is capable of efficiently absorbing shock energy, is provided. A shock absorption member including a bottom surface part and an upright part provided on the bottom surface part, in which at least one of the bottom surface part and the upright part includes a carbon-fiber-reinforced composite material including a thermoplastic resin, and the other may include a thermoplastic resin, and in which the amount of the thermoplastic resin present therein is 30 to 1,000 parts by mass based on 100 parts by mass of carbon fibers, and the average fiber length of the carbon fibers is 3 to 100 mm.
    Type: Application
    Filed: November 27, 2012
    Publication date: November 20, 2014
    Applicant: TEIJIN LIMITED
    Inventors: Tsukasa ARAI, Yuhei Konagai, Makoto Ootsubo, Masatomo Teshima
  • Patent number: 8829103
    Abstract: A composite material includes: carbon fibers having an average fiber length of more than about 10 mm and about 100 mm or less; and a thermoplastic resin. The carbon fibers are substantially two-dimensionally-randomly oriented. The composite material includes a carbon fiber bundle (A) in a ratio of more than 0 volume % and less than about 30 volume % to a total volume of the carbon fibers, the carbon fiber bundle (A) including the carbon fibers of a critical single fiber number defined by formula (1) or more. An average number (N) of the carbon fibers in the carbon fiber bundle (A) satisfies formula (2). Critical single fiber number=600/D??(1) 1.0×104/D2<N<2.5×104/D2??(2) D is an average fiber diameter (?m) of the carbon fibers.
    Type: Grant
    Filed: September 14, 2012
    Date of Patent: September 9, 2014
    Assignee: Teijin Limited
    Inventors: Yuhei Konagai, Yutaka Kondo, Naoaki Sonoda
  • Publication number: 20140080961
    Abstract: A composite material includes: carbon fibers having an average fiber length of more than about 10 mm and about 100 mm or less; and a thermoplastic resin. The carbon fibers are substantially two-dimensionally-randomly oriented. The composite material includes a carbon fiber bundle (A) in a ratio of about 30 volume % or more and less than about 90 volume % to a total volume of the carbon fibers, the carbon fiber bundle (A) including the carbon fibers of a critical single fiber number defined by formula (1) or more. An average number (N) of the carbon fibers in the carbon fiber bundle (A) satisfies formula (2). Critical single fiber number=600/D??(1) 6×104/D2<N<2×105/D2??(2) D is an average fiber diameter (?m) of the carbon fibers.
    Type: Application
    Filed: September 14, 2012
    Publication date: March 20, 2014
    Applicant: TEIJIN LIMITED
    Inventors: Yuhei Konagai, Yutaka Kondo, Naoaki Sonoda
  • Publication number: 20140080960
    Abstract: A composite material includes: carbon fibers having an average fiber length of more than about 10 mm and about 100 mm or less; and a thermoplastic resin. The carbon fibers are substantially two-dimensionally-randomly oriented. The composite material includes a carbon fiber bundle (A) in a ratio of more than 0 volume % and less than about 30 volume % to a total volume of the carbon fibers, the carbon fiber bundle (A) including the carbon fibers of a critical single fiber number defined by formula (1) or more. An average number (N) of the carbon fibers in the carbon fiber bundle (A) satisfies formula (2). Critical single fiber number=600/D??(1) 1.0×104/D2<N<2.5×104/D2??(2) D is an average fiber diameter (?m) of the carbon fibers.
    Type: Application
    Filed: September 14, 2012
    Publication date: March 20, 2014
    Applicant: TEIJIN LIMITED
    Inventors: Yuhei KONAGAI, Yutaka KONDO, Naoaki SONODA
  • Publication number: 20140039114
    Abstract: There is provided a fiber-reinforced composite material is constituted by reinforcing fibers with an average fiber length of 5 mm to 100 mm and a thermoplastic resin, in which in a viscoelastic characteristic that is defined by following formulas (1) and (2), an average value in a range of ?25° C. of the melting point of a matrix resin to +25° C. of the melting point of a matrix resin satisfies following formula (3): tan ?=G?/G???(1) tan ??=Vf×tan ?/(100?Vf)??(2) 0.01?tan ???0.2??(3) wherein G? represents a storage modulus (Pa) of the fiber-reinforced composite material, G? represents a loss modulus (Pa) of the fiber-reinforced composite material, and Vf represents a volume fraction (%) of the reinforcing fibers in the fiber-reinforced composite material.
    Type: Application
    Filed: October 14, 2013
    Publication date: February 6, 2014
    Applicant: TEIJIN LIMITED
    Inventors: Katsuyuki Hagihara, Yuhei Konagai, Naoaki Sonoda, Masatomo Teshima
  • Publication number: 20130344282
    Abstract: The present invention relates to a shaped product being excellent in isotropy constituted by a fiber-reinforced composite material in which discontinuous reinforcing fibers are isotropic in a plane and are two-dimensionally oriented in the thermoplastic resin, the reinforcing fibers contained in the shaped product includes a reinforcing fiber bundle (A) constituted by the reinforcing fibers of the critical single fiber number defined by formula (1) or more, a ratio of the reinforcing fiber bundle (A) to the total amount of the reinforcing fibers in the shaped product is 20 vol % or more and less than 90 vol %, and the average number (N) of the reinforcing fibers in the reinforcing fiber bundle (A) satisfies formula (2): Critical single fiber number=600/D??(1) 0.7×104/D2<N<1×105/D2??(2) wherein D is an average fiber diameter (?m) of the reinforcing fibers.
    Type: Application
    Filed: August 27, 2013
    Publication date: December 26, 2013
    Applicant: TEIJIN LIMITED
    Inventors: Yutaka Yagi, Toru Sugiyama, Yutaka Kondo, Michiharu Taniguchi, Yuhei Konagai, Ikkou Furukawa
  • Publication number: 20130317161
    Abstract: There is provided a random mat of the present invention including: reinforcing fibers having an average fiber length of 5 to 100 mm; and a thermoplastic resin, wherein a fiber areal weight of the reinforcing fibers is from 25 to 3,000 g/m2, for a reinforcing fiber bundle (A) including the reinforcing fibers equivalent to or more than a critical single fiber number defined by formula (1), a ratio of the reinforcing fiber bundle (A) to a total amount of the reinforcing fibers in the mat is from 30 vol % to less than 90 vol %, and an average number (N) of the reinforcing fibers in the reinforcing fiber bundle (A) satisfies formula (2): Critical single fiber number=600/D ??(1) 0.7×104/D2<N<1×105/D2 ??(2) wherein D is an average fiber diameter (?m) of single reinforcing fibers.
    Type: Application
    Filed: August 1, 2013
    Publication date: November 28, 2013
    Applicant: Teijin Limited
    Inventors: Yuhei Konagai, Naoaki Sonoda, Noboru Okimoto, Katsuyuki Hagihara