Toray Industries, Inc.

Masayuki Koshi

Yoshihiro Naruse

Shoma Ishida

Hiroyuki Ome

Naoya Ouchiyama

Masaru Tateyama

Kenichi Utazaki

Ken Sudo

Kenji Ishitake

Eita Konno

Koki Yoshino

A fiber-reinforced thermoplastic resin substrate has good mechanical properties. The fiber-reinforced thermoplastic resin substrate includes a plurality of continuous reinforcing fibers and a polyphenylene sulfide resin with which the plurality of continuous reinforcing fibers are impregnated, wherein the polyphenylene sulfide resin has a weight average molecular weight of 75,000 or more and 150,000 or less, and the polyphenylene sulfide resin has an ash content of 0.001 wt % or more and 0.30 wt % or less.

Fiber-reinforced thermoplastic resin substrate

A fiber-reinforced resin base material includes continuous reinforcing fibers or a reinforcing fiber base material in which discontinuous fibers are dispersed, the continuous reinforcing fibers or a reinforcing fiber base material being impregnated with a polyphenylene sulfide resin composition, wherein the fiber-reinforced resin base material has a glass-transition temperature, as measured by the DMA method (bending mode), of 115° C. or higher.

Fiber-reinforced resin base material

A method produces thermoplastic resin-impregnated sheet-shaped reinforcing fiber bundle obtained by impregnating reinforcing fibers made from continuous fibers with a thermoplastic resin, said method including: an application step in which a sheet-shaped reinforcing fiber bundle obtained by arranging reinforcing fibers made from continuous fibers in one direction is passed through an application section which retains thermoplastic resin, and the thermoplastic resin is applied to the sheet-shaped reinforcing fiber bundle to constitute a thermoplastic resin-impregnated sheet-shaped reinforcing fiber bundle; a further impregnation step in which the applied thermoplastic resin is further impregnated into the inside of the thermoplastic resin-impregnated sheet-shaped reinforcing fiber bundle; and a shaping step in which the thermoplastic resin-impregnated sheet-shaped reinforcing fiber bundle is shaped and solidified by cooling.

Method of producing thermoplastic resin-impregnated sheet-shaped reinforcing fiber bundle

A fiber-reinforced polymer alloy substrate, in which continuous reinforcing fibers are arranged in parallel and are impregnated with a polymer alloy, is characterized in that: a polymer alloy obtained by combining thermoplastic resins of at least two types is used as the polymer alloy; the fiber volume content is in the range of 40 to 70% by volume; and the dispersion parameter D of the fibers is 90% or more. In the obtained fiber-reinforced polymer alloy substrate, the reinforcing fibers are dispersed with high uniformity, and high mechanical properties and heat resistance are stably exhibited with low variation.

Fiber-reinforced polymer alloy substrate and molded article using same

A fiber-reinforced thermoplastic resin filament is obtained by impregnating a continuous reinforcing fiber with a thermoplastic resin, and satisfies all of conditions (a) to (c).

Fiber-reinforced thermoplastic resin filament and shaped product of same

A fiber-reinforced polyamide resin base material comprises continuous reinforcing fibers, or comprises a reinforcing fiber base material in which discontinuous reinforcing fibers are dispersed, impregnated with a polyamide resin. In the polyamide resin, at least part of the polymer constituting the polyamide resin is an end-modified polyamide resin having, at an end group of the polymer, a structure constituted by a structural unit different from a repeating structural unit constituting the backbone of the polymer. A fiber-reinforced polyamide resin base material having an excellent impregnation property and thermal stability, less void, and excellent surface quality is provided.

Fiber-reinforced polyamide resin base, method for producing same, molded article containing same, and composite molded article

A fiber-reinforced thermoplastic-resin base includes continuous reinforcing fibers aligned in parallel to each other and a thermoplastic resin is impregnated thereinto, wherein the base has a fiber volume content of 40-65 vol % and a dispersion parameter D of the fibers, determined by (i)-(iv), of 90% or more: (i) a cross-section of the fiber-reinforced thermoplastic-resin base that is perpendicular to the alignment direction of the reinforcing fibers is divided into a plurality of sections, and one of the sections is photographed, (ii) the photograph image of the section is divided into a plurality of square units each having a one-side length t, (iii) a dispersion parameter d is calculated, (iv) with respect to other sections, (i) to (iii) are repeatedly performed, and an average value of dispersion parameters d of the plurality of sections is dispersion parameter D.

Fiber-reinforced thermoplastic-resin base and molded article obtained therefrom

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.

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Nagoya, Japan

Masayuki Koshi