Idemitsu Petrochemical Co., Ltd.

Other

Kyowa Industrial Co., Ltd.

Tomokazu Abe

Yoshiaki Saito

Manabu Nomura

Kaoru Wada

Terunobu Fukushima

Tsuneo Matsui

Takayoshi Tanaka

Yasunobu Yamazaki

Toshifumi Shimazaki

Satoshi Matsumoto

Atsushi Sato

Shigeki Tamura

The method of forming a light-weight, fiber-reinforced, particularly glass fiber-reinforced-thermoplastic resin product includes the steps of melting and mixing thermoplastic resin pellets containing parallely oriented fibers 2-100 mm long, injecting the melted resin into a cavity which is closed so that its volume is smaller than that of the final molded product, and, before or after the resin injection is completed, opening the cavity until its volume is equal to that of the final molded product. Unlike the conventional injection-molded products, this product does not require a foaming agent and, if it uses any, requires only a small amount of foaming agent. The product thus formed is light in weight and has fibers uniformly entangled inside, providing an excellent appearance of the surface. Further a skin layer is formed over the surface. These features combined with the reinforcement by the glass fibers offer high strength and high stiffness.

Method of forming a light-weight, fiber-reinforced thermoplastic resin product and a light-weight molded product

A molding die for molding a laminated molding having a molding body with compressible surface members and partially laminated thereonto, where a flow-regulating portion for regulating flow of molten resin flowing toward the surface members and is provided to a die body to regulate the flow of the molten resin flowing on the same plane as the surface members and toward the surface members and . Accordingly, since resin lap at an peripheral end portion of the surface members and , and position shift of the surface members and by the flow of the resin, laminated molding having good quality and appearance can be obtained.

Molding die of laminated molding and manufacturing method of laminated molding

A molding die drive unit capable of both of compressing and expanding (volume enlargement) molten resin in molding die and having thin shape and superior mechanical efficiency, molding unit and molding process are provided. A molding die drive unit for advancing and retracting a movable die B relative to a cavity C has a large-diameter main cylinder unit , and a plurality of small-diameter sub cylinder unit disposed around the main cylinder unit . After loading the molten resin, the cylinder units and are driven to advance and retract the movable die B to the cavity C to compress or expand the molten resin in the cavity to conduct molding process.

Molding die drive unit, molding unit and molding method

A molding die for shaping a laminated molding including a molding body and a compressible surface member laminated thereonto has centering pins for determining a position of the surface member protrudable and retractable relative to a cavity inside a die body. Accordingly, since the surface member can be accurately and easily positioned and held, position shift of the surface member can be securely prevented. Further, by sinking the centering pins before molten resin is solidified, influence by the centering pins can be eliminated.

Molding die for laminated molding

A method of producing a laminated structural molding formed from molded resin and an outer layer of facing material. The method comprises the step of initially placing the facing material in a mold. Molten resin is injected into the mold. The resin is spread throughout the mold by locating mold sections adjacent each other at a set compressive force. The partially assembled molding is then subjected to a cooling process in which the compressive force to which the molding is exposed is reduced so that the force is greater than zero but less than the compressive force used to spread the resin. The mold sections do not retract or move during the reduction in the compressive force. The cooling process is performed just before or after the completion of the spreading of the resin. In this way, the damage to the facing material of the molding is kept to a minimum.

Method for producing laminated moldings

A compression apparatus for molding which applies uniform compression force to molten resin, and facilitates downsizing of the overall compression apparatus and attachment of the compression apparatus to a molding machine. Also, an injection compression molding machine and an injection compression molding method which use the compression apparatus for molding are disclosed. The compression apparatus is disposed in the rear of the movable mold of a die of a molding machine in which the movable mold is advanced toward the stationary mold of the die in order to apply compression force to the charged molten resin, to thereby mold the molten resin. The compression apparatus has a function of generating a pressing force for pushing the movable mold toward the stationary mold. The compression apparatus includes first and second slant members and having respective slant faces and in surface contact with each other. The slant members are advanced toward the slant members in order to generate pressing fore. A plurality of slant members moving in the same direction are engaged with each other via a single interlock plate. This configuration enables synchronized movements of all the slant members. In addition, since the weight and size of the synchronization mechanism are decreased, attachment to the molding machine is facilitated. Further, slant portions moving in different directions are provided. Slant portions moving in the same direction are engaged with each other via the interlock plate, and slant portions moving in different directions are engaged with each other via a link. The employment of the above-described structure enables the object of the present invention to achieve more effectively.

Compression apparatus for molding, injection compression molding machine, and injection compression molding method using the compression device

Disclosed is a method of molding a fiber-reinforced resin laminate which can manufacture a lightweight laminated molding having excellent mechanical characteristics regardless of the shape of a molding, which can readily unite a surface coat material and a molding while the surface coat material is held in good condition, and which can impart excellent appearance to a laminated molding. Also disclosed is a laminated molding manufactured by the method. The method uses a molding material which contains fiber-containing thermoplastic resin pellets which, in turn, contain reinforcing fibers having a length of 2 mm to 100 mm. The reinforcing fibers account for 5% to 70% by weight of the molding material. A molten resin obtained through the plasticization of the molding material is injected into a die, onto which a surface coat material for covering the surface of a molding is previously attached. After injection of the molten resin into the die cavity is started, a movable die is advanced so as to compress the molten resin contained in the die cavity, followed by expansion of the volume of the die cavity to that of an intended molding.

Method of molding a fiber-reinforced resin laminate and a laminated

Method of forming a light-weight, fiber-reinforced thermoplastic resin

A method of producing a laminated molding, such as an air current control valve used in an air conditioner for a vehicle, is made to be united with an facing material having the flexible surface of a basic plate made of resin. When the above laminated molding is produced, a used mold should be split into a stationary mold portion and a movable mold portion. Also, a compression core is provided in the movable mold portion. The facing material is temporarily fixed on a mold-face of the stationary mold portion and a mold-face of the compressive core of the movable mold portion opposite the mold-face of the stationary mold portion, during the aforementioned state, a melting synthetic resin is fed into a mold and then the fed melting synthetic resin is compressed by moving the compression core toward the stationary mold portion. By compressing the compression core, it makes a space providing a larger volume than a molding in the cavity which is being fed with the melting synthetic resin; this allows the melting synthetic resin to be quickly fed under a high injection pressure, whereby each cycle process takes place in a shorter time. Furthermore, after the melting synthetic resin is filled in the cavity, the pressure force exerted on the compression core is capable of being decreased, without the flexible facing material being damaged.

Method of producing a laminated molding

A die for injection molding for charging molten resin onto a surface material set on the cavity surface is disclosed. The die comprises direction changing means for changing the direction of flow of the molten resin charged through the gate to directions along the surface of the surface material. The direction changing means may be a substantially conical direction changing member for changing the direction of flow of the molten resin. Since the direction changing means can change the direction of flow of the molten resin charged into the die, which is completely closed or slightly open, to directions along the surface of the surface material, the molten resin does not strike the surface material. Thus, damage to the surface material in the neighborhood of the gate can be prevented, and the surface material can be protected against the collision with molten resin which is at a high temperature and under a high pressure.

Method for forming a laminate structural molding

A compression equipment possesses generality of various injection molding machine by which injection and mold under compression is performed. The compression equipment is composed as a unit and is installed between a moving die plate of the injection molding press and a moving mold. The compression equipment possesses a moving mechanism containing first tapered members moved by a cylinder and second tapered members contacting with the first tapered members and the moving mold moves toward a stationary mold by the cylinder.

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Ichihara, Japan

Tomokazu Abe