Toray Industries, Inc.

Mitsui Chemicals, Inc.

Atsuki Tsuchiya

Masato Honma

Yuki Mitsutsuji

Shin Hirata

Kentaro Sano

Naokichi Imai

Noriyuki Hirano

Keiichi Asami

Ryuji Sawaoka

Hideaki Sasaki

Satoshi Matsumoto

Keisuke Inose

Shigeru Kawashima

Sora Bang

Koji Yamauchi

Makoto Endo

Shunsuke Horiuchi

Yoshiki Takebe

Takashi Fujioka

Tomoko Ichikawa

Akihiko Kitano

Kohei Yamashita

Naoya Ouchiyama

Soichi Ishibashi

Shoji Murai

Kazuki Yoshihiro

Yasunori Nagashima

Kazuhiro Hatanaka

Ichiji Kageishi

Yumi Ando

Kaori Narimatsu

Satomi Matsuo

Yuji Kojima

Yuki Nitsutsuji

Syuji Ishikawa

Chiasa Kitani

A fiber-reinforced composite molded article which is obtained by molding reinforcing fibers and an epoxy resin, while containing a silicone oil as an internal mold release agent, and which is characterized in that the fragment ion intensity ratio A/B as detected in case where the molded article surface is analyzed by time-of-flight secondary ion mass spectrometry is expressed by the relationship of 3≤A/B≤20. A: The intensity of a fragment ion that has the highest intensity among the fragment ions derived from the silicone oil. B: The intensity of a fragment ion that has the highest intensity among the fragment ions derived from the epoxy resin. A fiber-reinforced resin molded article according to the present invention is capable of achieving high productivity and high quality by effectively exhibiting releasability from a mold with a small addition amount of a mold release agent without using an external mold release agent, while being capable of exhibiting high adhesion to other members without requiring a special surface treatment such as sanding.

Internal mold release agent-containing fiber-reinforced composite molded article

Provided are a fiber-reinforced composite molded article prepared by heat-curing, as a molding material of a fiber-reinforced resin material, a resin composition to which an internal mold release agent is added, the fiber-reinforced composite molded article being capable of effectively producing mold releasability even with a small amount of the mold release agent added, and being capable of achieving high productivity, and a method of forming the fiber-reinforced composite molded article. A fiber-reinforced composite molded article prepared by curing reinforcing fibers and a resin composition, the resin composition including an internal mold release agent, wherein the value obtained by normalizing a Poisson-corrected ion intensity derived from the internal mold release agent detected on the surface of the fiber-reinforced composite molded article, by the Poisson-corrected gross positive secondary ion intensity detected in the predetermined area is higher than 0.1, and a molding method therefor.

Fiber-reinforced composite molded article and method for molding same

A fiber reinforced thermoplastic resin molded article contains inorganic fibers (A), organic fibers (B), and a thermoplastic resin (C), the fiber reinforced thermoplastic resin molded article containing 5 to 45 parts by weight of the inorganic fibers (A), 1 to 45 parts by weight of the organic fibers (B), and 10 to 94 parts by weight of the thermoplastic resin (C), based on 100 parts by weight of the total of the inorganic fibers (A), the organic fibers (B), and the thermoplastic resin (C), the inorganic fibers (A) in the fiber reinforced thermoplastic resin molded article having a weight average fiber length (L) of 0.01 mm or more and 3 mm or less, the organic fibers (B) having a weight average fiber length (L) of more than 4 mm and 20 mm or less.

Fiber reinforced thermoplastic resin molded article and fiber reinforced thermoplastic resin molding material

To provide a fiber reinforced thermoplastic resin molded article having excellent impact strength and flexural strength, provided is a fiber reinforced thermoplastic resin molded article, including: a carbon fiber (A), an organic fiber (B) having a strand strength of 1500 MPa or more and, a thermoplastic resin (C), wherein the fiber reinforced thermoplastic resin molded article contains 5 to 45 parts by weight of the carbon fiber (A), 1 to 45 parts by weight of the organic fiber (B), and 20 to 94 parts by weight of the thermoplastic resin (C) with respect to 100 parts by weight of the total of the carbon fiber (A), the organic fiber (B), and the thermoplastic resin (C), wherein a ratio (L/l) of the critical fiber length Lof the organic fiber (B) to the number average fiber length lof the organic fiber (B) is 0.9 or more and 2.0 or less, and wherein an interfacial shear strength between the organic fiber (B) and the thermoplastic resin (C) is 3.0 MPa or more and 50 MPa or less.

Moldings of fiber-reinforced thermoplastic resin

A fiber reinforced thermoplastic resin molded article includes 5 to 45 parts by weight of carbon fibers (A), 1 to 45 parts by weight of organic fibers (B), and 10 to 94 parts by weight of a thermoplastic resin (C), based on 100 parts by weight of the total amount of the carbon fibers (A), the organic fibers (B), and the thermoplastic resin (C). The carbon fibers (A) in the fiber reinforced thermoplastic resin molded article have an average fiber length (L) of 0.3 to 3 mm. The organic fibers (B) in the fiber reinforced thermoplastic resin molded article have an average fiber length (L) of 0.5 to 5 mm, and a number average fiber diameter (d) of 1 to 10 &#x3bc;m. The fiber reinforced thermoplastic resin molded article excellent in impact strength.

Fiber-reinforced thermoplastic resin molded article, and fiber-reinforced thermoplastic resin molding material

A fiber reinforced thermoplastic resin molded article includes (A) carbon fibers, (B) graphite and (C) a thermoplastic resin, wherein the carbon fibers (A), the graphite (B) and the thermoplastic resin (C) are contained in amounts of 1 to 30 parts by weight, 1 to 40 parts by weight and 30 to 98 parts by weight, respectively, relative to 100 parts by weight, of the carbon fibers (A), the graphite (B) and the thermoplastic resin (C), the weight average fiber length of the carbon fibers (A) is 0.3 to 3 mm and the specific gravity of the molded article is 1.1 to 1.9 g/cm. The fiber reinforced thermoplastic resin molded article has excellent bending strength and heat conductivity.

Fiber-reinforced thermoplastic resin molded article and fiber-reinforced thermoplastic resin molding material

A fiber reinforced thermoplastic resin molded article includes 5 to 45 parts by weight of carbon fibers (A), 1 to 45 parts by weight of organic fibers (B), and 10 to 94 parts by weight of a thermoplastic resin (C), based on 100 parts by weight of the total amount of the carbon fibers (A), the organic fibers (B), and the thermoplastic resin (C). The carbon fibers (A) in the fiber reinforced thermoplastic resin molded article have an average fiber length (L) of 0.3 to 3 mm. The organic fibers (B) in the fiber reinforced thermoplastic resin molded article have an average fiber length (L) of 0.5 to 5 mm, and a number average fiber diameter (d) of 35 to 300 &#x3bc;m. The fiber reinforced thermoplastic resin molded article is excellent in impact strength and surface appearance.

A carbon fiber-reinforced resin composition of the present invention includes: sizing agent-coated carbon fibers in which carbon fibers are coated with a sizing agent; and a matrix resin. The sizing agent includes at least an aliphatic epoxy compound (A) and an aromatic epoxy compound (B1) as an aromatic compound (B). The sizing agent-coated carbon fibers have a ratio (a)/(b) of 0.50 to 0.90 where (a) is the height (cps) of a component having a binding energy (284.6 eV) attributed to CHx, C&#x2014;C, and C&#x2550;C and (b) is the height (cps) of a component having binding energy (286.1 eV) attributed to C&#x2014;O in a Ccore spectrum of the surface of the sizing agent measured by X-ray photoelectron spectroscopy at a photoelectron takeoff angle of 15&#xb0;.

Carbon fiber-reinforced resin composition, method for manufacturing carbon fiber-reinforced resin composition, molding material, method for manufacturing molding material, and carbon fiber-reinforced resin molded article

A fiber reinforced thermoplastic resin molding material includes a thermoplastic resin; a resin impregnated reinforcing fiber filament obtained by impregnating reinforcing fibers with a resin having a melt viscosity at 200&#xb0; C. lower than a melt viscosity of the thermoplastic resin; and a reinforcing fiber modifier having a melt viscosity at 200&#xb0; C. lower than the melt viscosity of the thermoplastic resin and a difference in solubility parameter value from the thermoplastic resin equal to or larger than 1.0, the molding material including 50 to 98.9 parts by weight of the thermoplastic resin; 1 to 40 parts by weight of the reinforcing fiber; 0.1 to 10 parts by weight of the reinforcing fiber modifier; and 0.2 to 12 parts by weight of the resin relative to total 100 parts by weight of the thermoplastic resin, the reinforcing fiber, and the reinforcing fiber modifier.

Fiber reinforced thermoplastic resin molding material, and fiber reinforced thermoplastic resin molded article

A fiber-reinforced resin composition includes a polyarylene sulfide (A), a carbodiimide compound (B) and carbon fibers (C) in specific blending amounts and in which the carbon fibers (C) are surface-treated with a sizing agent (D), the carbodiimide compound (B) is an aliphatic carbodiimide compound, and the sizing agent (D) is a compound having three or more specific functional groups in one molecule; and a fiber-reinforced composite material includes a thermoplastic resin (A'), an adhesive compound (B&#x2032;) and reinforcing fibers (C&#x2032;) and in which the adhesive compound (B&#x2032;) is a compound having two or more specific structures in one molecule, the thermoplastic resin (A&#x2032;) is a thermoplastic resin containing an element other than carbon in a repeating unit structure of a main chain, and an abundance ratio Rb of the adhesive compound (B&#x2032;) is 1.2 or more.

Fiber-reinforced resin composition, and fiber-reinforced composite material

A molding material includes 5 to 50 parts by mass of reinforcing fibers (A) with a sizing agent (s) deposited thereon, 1 to 20 parts by mass of a component (B) containing a polycarbodiimide compound (B-1) that is liquid at 50&#xb0; C., and 30 to 94 parts by mass of a thermoplastic resin (C) containing an element other than carbon in the repeating unit structure of the main chain, based on 100 parts by mass of the total of the components (A) to (C), wherein the molding material is a composite in which a composite fiber bundle (D) with the component (A) impregnated with the component (B) is covered with the component (C).

Molding material, method of producing same, and master batch used in same

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&#xb0; 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.

Molding material, molding method using same, method for producing molding material, and method for producing fiber-reinforced composite material

The present invention provides a light-weight fiber-reinforced composite material that has excellent flame retardance and mechanical properties and never emits a halogen gas. The present invention also provides a prepreg and en epoxy resin composition suited to obtain the above described fiber-reinforced composite material. The present invention also provides an integrated molding which is produced using the above described fiber-reinforced composite material, thereby suitable for use in electric/electronic casings. The epoxy resin composition is such that it contains the following components [A], [B] and [C]:

Fiber-reinforced composite sheet and integrated molding

Provided are the following: a sandwich structure formed from a core component comprising a discontinuous reinforcing fiber, a thermoplastic resin and voids, and a skin component comprising a continuous reinforcing fiber and a matrix resin, wherein in the core component, 30% or more of the discontinuous reinforcing fiber is covered with the thermoplastic resin and monofilaments of the discontinuous reinforcing fiber intersect one another via the thermoplastic resin; an integrally formed article using the sandwich structure; and methods for the production therefor.

Sandwich structure and integrally formed article using the same, and methods for production thereof

A molded article excellent in dynamic characteristics and water degradation resistance can be obtained by using a fiber-reinforced polypropylene resin composition including a carbodiimide-modified polyolefin (a), a polypropylene resin (b) and reinforcing fibers (c), wherein the content of the carbodiimide group contained in a resin component in the fiber-reinforced polypropylene resin composition is 0.0005 to 140 mmol based on 100 g of a matrix resin component, and the reinforcing fibers (c) are sizing-treated with a polyfunctional compound (s); and a molding material using the fiber-reinforced polypropylene resin composition.

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Nagoya, Japan

Atsuki Tsuchiya