Toyota Boshoku Kabushiki Kaisha

Toyota Jidosha Kabushiki Kaisha

Toray Industries, Inc.

Nof Corporation

Araco Kabushiki Kaisha

Toyota Tsusho Corporation

Toyota Auto Body Co., Ltd.

Toyota Boshoku Co. Ltd.

Masanori Hashiba

Yuhei Maeda

Takashi Inoh

Hisashi Okuyama

Hiroshi Urayama

Hideki Kawashiri

Katsuhiko Mochizuki

Takehiro Kato

Kazuya Matsumura

Tomomichi Fujiyama

Hideo Kamiya

Osamu Mito

Makoto Hattori

Eiji Sugiyama

Kousuke Tamaki

Kouichi Matsui

Kenichi Ioroi

Shintaro Maruyama

To provide a resin molding and a method for producing the same. A resin molding includes a plate-like substrate including reinforcing fibers and a first thermoplastic resin binding the reinforcing fibers to each other, and an extension part that is constituted of an injection-molded member and is extended from an end surface of the substrate along the plate face direction of the substrate. It is preferred that the reinforcing fibers be plant fibers, such as kenaf. It is preferred that the substrate and the extension part be connected flush to each other on, of the one surface and the other surface of the connection part of the substrate and the extension part, at least the side of one surface. Moreover, the extension part may further be provided with a plate-like part that constitutes an outer edge part of the resin molding and forms a shape involute toward the other surface. The method for producing a resin molding includes a shaping step of shaping the substrate and an extension part formation step of forming the extension part by injection-molding.

Resin molding and method for producing the same

Provided is a resin molding in which two types of substrates have a connection part constituted of a thin part provided from the one substrate to the other substrate with a boundary defined by end surfaces of the respective substrates, wherein the density of the one substrate in the connection part is higher than the density of a base part excluding the connection part. The resin molding can have a configuration in which the one substrate is a plate-like substrate including reinforcing fibers and a first thermoplastic resin binding the reinforcing fibers to each other and the other substrate is an injection-molded member connected along the plate face direction of the one substrate from an end surface of the one substrate. Moreover, it is preferred that the connection part have, on the side thereof closer to the other substrate, a section gradually thinned from a position at which the connection part extends and the connection interface be located at an intermediate part of the part that is gradually thinned. It is preferred that the reinforcing fibers be plant fibers, such as kenaf.

A process for producing a molded article includes the mixing step of mixing a plant material, water and a thermoplastic resin to obtain a molding material, and the injecting and molding step of injecting the molding material in a molding die and molding the molding material with the molding die to obtain the molded article. In the mixing step, a material containing lignin in an amount of 10% by mass or more when the total amount of the plant material is taken as 100% by mass is used as the plant material, the thermoplastic resin is mixed in an amount of 5 to 50% by mass and the plant material is mixed in an amount of 50 to 95% by mass when the total amount of the thermoplastic resin and the plant material is taken as 100% by mass, water is mixed in an amount of 5 to 200% by mass based on 100% by mass of the plant material, and the plant material, water and the thermoplastic resin are nixed while thernofusing the thermoplastic resin.

Process for injection molding resin with plant material

The present invention is an interior material for a vehicle having a skin layer and a base layer. The skin layer contains an olefin-based thermoplastic elastomer, a polyolefin resin, a polylactic acid resin and a styrene-based thermoplastic elastomer, in amounts of respectively 20% to 70% by weight, 10% to 50% by weight, 5% to 30% by weight and 5% to 30% by weight based on 100% by weight of the total of these. The base layer is preferably a thin layer in which a natural fiber is dispersed in a phase of a thermoplastic resin such as a polyolefin resin, or a polyurethane foam layer.

Interior material for vehicle

The invention provides a method for manufacturing a molded woody article, which includes compression molding a base material containing wood fibers, polylactic acid fibers and an inorganic filler at a temperature not less than a melting point of the polylactic acid fibers, and maintaining the molded base material at a temperature close to a crystallization temperature of the polylactic acid fibers for a desired period of time, thereby crystallizing the polylactic acid fibers. In the molding step, the base material is entirely deformed and molded into a desired shape while the polylactic acid fibers are melted, and in the crystallizing step, the polylactic acid fibers are solidified, thereby producing the molded article. In the crystallizing step, polylactic acid crystallizes rapidly and reliably utilizing the inorganic filler as a crystal nucleating agent.

Process for producing woody molding

The present invention provides a method for production of a molded article comprising a plant-derived composite material in which a plant-derived material is evenly dispersed and a plant-derived composite material molded article prepared therewith, and a method for production of a plant-derived composite material in which a plant-derived material is evenly dispersed and a plant-derived composite material prepared therewith. The present method for production of a molded article is a method for producing a molded article composed of a plant-derived composite material comprising a plant-derived material (e.g., a kenaf core) and a thermoplastic resin (e.g., polypropylene, polylactic acid), and comprises a process in which the plant-derived material is pressed to obtain raw-material pellets, a process in which the raw-material pellets and the thermoplastic resin are kneaded to obtain a plant-derived composite material, and a process in which the plant-derived composite material is molded into a molded article composed of the plant-derived composite material. The present molded article is obtained by the method.

Method for production of molded article of plant-derived composite material, molded article of plant-derived composite material, method for production of plant-derived composite material, and plant-derived composite material

A method for manufacturing a molded article includes the step of pressing a pre-molding material that is prepared by dispersing a polylactic acid-base aliphatic polyester and a compatible copolymer into kenaf fibers. The compatible copolymer contains a first polymerizable monomer and a second polymerizable monomer. The pressing step is performed at a temperature that permit the polylactic acid-base aliphatic polyester to be changed to a softened state or a molten state. The first polymerizable monomer has a polymerizable double bond part and a hydrophilic group. The second polymerizable monomer has a polymerizable double bond part and an epoxy group.

Molded woody article and process for producing molded woody article

To provide a fiberboard capable of reducing a load on the environment at all states of producing, using, and abolishing and moreover having a high degree of bending strength and a high bending-strength retention rate at high temperature and high humidity so as to be usable for an automobile interior material or building material and a fiber-board producing method. The fiberboard is formed by mixing natural fiber with polylactic acid resin serving as a binder and has an apparent density of 0.2 g/cm.

Fiber board and its producing method

Methods are taught for manufacturing a press molded article () that comprises a profiled substrate layer () and a foamed layer (). A substrate material () may be press molded with a foamable material () under pressure in order to join or attach the foamable material to the substrate material. In addition, a profile may be imparted to the substrate material during the press molding step, thereby forming the profiled substrate layer. After the press molding step has been completed, the foamable material is foamed and expanded, to thereby form the foamed layer. A skin material () optionally may be applied to the foamable layer before the press molding step. Optionally, embossed patterns may be imparted to the skin material during the press molding step, thereby forming an embossed skin layer () that is attached to the foamed layer.

Growing community of inventors

Mizunami, Japan

Masanori Hashiba