Toray Industries, Inc.

Masaru Tateyama

Mitsuki Fuse

Akihiko Matsui

Satoshi Seike

Kazuma Ura

Hiroshi Hirano

Koji Yamaguchi

Nobuhiko Shimizu

Atsushi Ishio

Takafumi Hashimoto

Kazuhiko Kobayashi

Tetsuya Motohashi

Norio Shimasaki

Hideo Matsuoka

Masayuki Koshi

Chiasa Sato

Kei Saito

Kuniko Fujita

Hironori Imai

Yoshihiro Yamami

Akihiko Nishizaki

Kazuya Ohno

Sachio Shimizu

Kazuhisa Kodaira

Kazufumi Matsui

A reinforcing fiber bundle is a continuous reinforcing fiber bundle having a length of at least 1 m and is characterized by the number of monofilaments per unit width being at most 1,600/mm and the average number of fibers in the bundle being at most 1,000 in a region (I), and the drape level found in a region (II) being 120-240 mm. The continuous reinforcing fiber bundle has a length of at least 1 m and is characterized by the adhesion amount of a sizing agent (I) in the region (I) being 0.5-10% by weight and the drape level found in the region (II) being 120-240 mm. The continuous reinforcing fiber bundle has superior mechanical properties, formability into complex shapes, and continuous producibility.

Reinforcing fiber bundle

A partially separated fiber bundle includes a separated fiber section and an unseparated fiber section, being configured to give a ratio A/Aof 1.1 or larger and 3 or smaller, when the number of fiber bundles contained in the width direction of the partially separated fiber bundle (fiber separating number: N) measured at a freely selected point P(where, n represents an integer of 1 to 100, and freely selected points Pand P, excluding n=100, being 50 cm or more away from each other), is divided by a full width of Wof the partially separated fiber bundle, to calculate the fiber separating number per unit width A, and assuming its maximum value as Aand its minimum value as A.

Partially separated fiber bundle and method of manufacturing same

A heating apparatus that heats a thermoplastic resin sheet includes a vertically-movable heating wall that is indirectly heated with a saturated steam of a heat medium and heats the thermoplastic resin sheet above a melting point of the thermoplastic resin by bringing the heating wall into contact with the thermoplastic resin sheet.

Heating apparatus for thermoplastic resin sheet and method of manufacturing thermoplastic resin-molded body

A reinforcing fiber mat includes reinforcing fiber bundles having an average fiber length of 5 mm to 100 mm, wherein reinforcing fiber bundles consisting of 86 or more fibers per bundle are contained at a weight content of more than 99 wt % to 100 wt % and the reinforcing fiber bundles contain single yarns by 500 fibers/mm-width or more and 1,600 fibers/mm-width or less and have a drape level of 120 mm or more and 240 mm or less.

Reinforcing fiber mat, and fiber-reinforced resin forming material and method of producing same

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.

Partially separated fiber bundle and method of manufacturing same, chopped fiber bundle using same, and fiber-reinforced resin forming material

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.

Production method for partially separated fiber bundle, partially separated fiber bundle, fiber-reinforced resin molding material using partially separated fiber bundle, and production method for fiber-reinforced resin molding material using partially separated fiber bundle

A method of manufacturing a thermoplastic resin molded article having a hollow portion includes setting a molded article (A) premolded from a thermoplastic resin in a first die, forming a melted thermoplastic resin plate (B) in a shape along an inner surface of a second die facing the first die by being attached to the inner surface of the second die by vacuum pressure, welding the thermoplastic resin plate (B) and the molded article (A) only in a predetermined region by mold-clamping the first die and the second die, and forming at least part of an unwelded region as a hollow portion.

Thermoplastic resin molded article having hollow portion and method of manufacturing same

A seat cushion frame for a vehicle, wherein the weight of the entire frame can be reduced as a result of changing the raw material to a resin; and to give a desired submarine prevention function to the front section of the frame, to greatly reduce the number of components of the frame, and to greatly simplify the entire structure, a C-shaped frame having a C-shaped planar shape opening to the rear side thereof includes a thermoplastic resin, and has a structure wherein the upper surface side of the front section of the C-shaped frame is formed into a surface intermittently extending in the seat width direction and the lower surface side thereof is formed into a surface continuously extending in the seat width direction.

Seat cushion frame for vehicle

A seat cushion frame for a vehicle includes a composite material containing reinforcing fibers which extend in at least the frame extension direction is integrated with an injection molded thermoplastic resin. The weight of the entire seat cushion frame can be greatly reduced, the rigidity and strength required for each section of the frame can be readily secured, required functions such as submarine prevention or the like, can be fulfilled, the number of components can be greatly reduced, and the overall structure can be greatly simplified.

Seat cushion frame for vehicle and production method therefor

An injection molded body includes a fiber reinforced thermoplastic resin composition formed by combining fibrous filler with thermoplastic resin so that the weight average fiber length in the injection molded body is 300 &#x3bc;m or more, and the injection molded body has a skin layer, a core layer and a skin layer in this order in the thickness direction. The thickness of the core layer, in which the primary orientation direction of the fibrous filler is 40&#xb0; or less when the direction perpendicular to the flow direction of the resin composition at the time of injection molding is set at 0&#xb0;, is 20% or less relatively to the thickness of the injection molded body.

Injection molded body and method for producing same

A method of manufacturing a fiber-reinforced plastic includes placing a compressible reinforcing fiber base material made of discontinuous reinforcing fibers in a cavity of a mold, injecting melted thermoplastic resin into the cavity, and impregnating the resin into the reinforcing fiber base material, wherein the mold is adapted to change a cavity volume of the mold, and the reinforcing fiber base material after having been or while being impregnated with the thermoplastic resin is compressed in the cavity by reducing the cavity volume of the mold after injecting the melted thermoplastic resin.

Method for manufacturing fiber-reinforced plastic

The present invention is a polyphenylene sulfide resin composition comprising (a) a polyphenylene sulfide resin and (b) an olefin-based resin, and satisfying the following conditions (i) through (v): (i) The mixing ratio of the polyphenylene sulfide resin (a) and the olefin-based resin (b) is such that the amount of the polyphenylene sulfide resin (a) is in a range from 95 to 60 wt %, while the amount of the olefin-based resin (b) is in a range from 5 to 40 wt %, with the total weight of both the ingredients as 100 wt %; (hi) said olefin-based resin (b) comprising two copolymer: (b-1) an epoxy group-containing olefin copolymer and (b-2) an ethylene/(&#x3b1;-olefin copolymer obtained by copolymerizing ethylene and an &#x3b1;-olefin having 3 to 20 carbon atoms; (iii) as the morphology observed by an electron microscope, said polyphenylene sulfide resin (a) forms a continuous phase, and said olefin-based resin (b) forms a dispersion phase and has a core-shell structure having said ethylene/&#x3b1;-olefin copolymer (b-2) acting as a core component contained in said epoxy group-containing olefin copolymer (b-1) acting as a shell component: (iv) the melt flow rate measured at a temperature of 315.5&#xb0; C. and at a load of 5000 g according to ASTM-D-1238 is in a range from 10 to 50 g/10 min; and (v) the notched impact strength measured at &#x2212;40&#xb0; C. according to ASTM-D-256 is 300 J/m or more. This invention provides a PPS resin composition excellent in flowability, impact properties and low-temperature roughness and suitable for injection molding.

Polyphenylene sulfide resin composition

An electroconductive, multilayered hollow molding comprising at least two thermoplastic resin layers, in which at least one layer is a layer of (a) a thermoplastic resin composition consisting essentially of a polyphenylene sulfide resin; one layer is a layer of (b) a thermoplastic resin composition consisting essentially of a thermoplastic resin other than a polyphenylene sulfide resin; and at least one of the layers is a layer of an electroconductive, thermoplastic resin composition comprising an electroconductive filler and/or an electroconductive polymer, and a thermoplastic resin.

Laminates for making electroconductive fuel tubes

Multilayered moldings, which comprise a laminate structure of (A) a layer of a polyphenylene sulfide resin (hereinafter referred to as PPS resin) composition and (B) a layer of a thermoplastic resin except PPS resins and which are characterized in that the PPS resin composition constituting the layer (A) comprises (A1) 100 parts by weight of a PPS resin, (A2) from 1 to 80 parts by weight of a thermoplastic resin having at least one functional group selected from epoxy groups, acid anhydride groups, carboxyl group and its salts, and carboxylate groups, and (A3) from 5 to 80 parts by weight of a thermoplastic resin that is similar in kind to the thermoplastic resin constituting the layer (B), have good hot water resistance, antifreeze resistance, chemical resistance, heat resistance, abrasion resistance, gas permeation resistance and interlayer adhesion.

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Nagoya, Japan

Masaru Tateyama