Toray Industries, Inc.

Katholieke Universiteit Leuven

Yoshiki Takebe

Masato Honma

Noriyuki Hirano

Atsuki Tsuchiya

Jun Misumi

Takashi Fujioka

Kotaro Shinohara

Hiroki Kihara

Naokichi Imai

Hideaki Tanisugi

Haruo Obara

Kosuke Shiho

Takashi Hasegawa

Souichi Ishibashi

Takeshi Nishizawa

Seiichiro Eto

Shoji Murai

Yoshifumi Nakayama

Daisuke Konishi

Yuta Naito

Hidetaka Muramatsu

Yoshihumi Nakayama

Syuji Ishikawa

Joris Baets

Ignace Verpoest

Takeshi Park-City Kitaoji 412 Nishizawa

A fiber-reinforced plastic substrate is described in which a plurality of resins having different properties are firmly compounded and that includes components [A], [B], and [C]:

Fiber-reinforced resin substrate, integrated molded article, and method for manufacturing fiber-reinforced resin substrate

A method is described for producing a fiber-reinforced plastic substrate that simultaneously satisfies three points of joinability, mechanical characteristics, and productivity, the method including the following components [A], [B], and [C], wherein at least the following drawing step, first impregnating step, second impregnating step, and take-up step are continuously and sequentially performed while the component [A] is caused to run:

Method for producing fiber-reinforced plastic substrate, and fiber-reinforced plastic substrate and integrated molding thereof

A laminate includes a core obtained by impregnating a mat of fibers with a thermoplastic resin (B); and a skin obtained by impregnating continuous fiber(s) with a thermoplastic resin (A), wherein sheet-form intermediate substrates in the laminate have a thermal expansibility, the usable temperature region of said thermoplastic resin (A) and that of said thermoplastic resin (B) overlap over a temperature range of at least 5° C., said thermoplastic resin (A) has a temperature region that does not melt at a lower limit of said usable temperature region, said fibers contained in said mat penetrate through interface layers formed by said thermoplastic resin (A) and said thermoplastic resin (B), and said thermoplastic resin (A) and said thermoplastic resin (B) form interface layers each with a concave-convex shape having a maximum height Ry of not less than 50 μm and an average roughness Rz of not less than 30 μm.

Sandwich laminate, sandwich structure and unified molded product using same and processes for producing both

A molded product having both small specific gravity and high stiffness and also suffering few sink marks is described along with a method for the production thereof, where the molded product includes a porous body (A) integrated with an injection molded body (B), the porous body (A) having an apparent density of 0.05 to 0.8 g/cm, the average thickness (tA) of the porous body (A) and the average thickness (tB) of the injection molded body (B) satisfying the relation tA&#x2265;3&#xd7;tB, and the injection molded body (B) covering at least one face of the porous body (A).

Molded article and production method therefor

A method is described for manufacturing a molded product having a recessed/protruding part from a molded substrate (A) including reinforcing fibers and a matrix resin by press molding, the method comprising: a step (I) of placing the molded substrate (A) between molds including an upper mold and a lower mold and deforming the molded substrate (A) in an in-plane direction by heating and pressing the molds; and a step (II) of deforming the molded substrate (A) in an out-of-plane direction by depressurizing the molds subsequent to the step (I), wherein a deformation rate ratio T represented by the following formula (1) is within a range of 0.1 to 1:&#x2003;&#x2003;(1)where X and Z are as defined.

Method for manufacturing molded article

Provided is a structure having excellent flexibility represented by elastic restoring from compression or tensile elongation at break, and excellent lightness. A structure according to the present invention includes reinforced fibers, first plastic, and second plastic that exhibits rubber elasticity at room temperature, the reinforced fibers being discontinuous fibers, and the first plastic and/or the second plastic coating a crossing point between the reinforced fibers in contact with each other.

Structure

A method for manufacturing a composite structure in which a first member and a structure material as a second member are integrated, the method including: an arrangement step of arranging a structure precursor including a resin and reinforced fibers in a mold made of the first member; a heating step of heating the structure precursor to equal to or higher than a temperature at which a storage elastic modulus (G') of the structure precursor is less than 1.2&#xd7;10Pa; a shaping step of expanding the structure precursor by heating to form a structure material as a second member, and bringing the structure material into close contact with the first member to obtain a composite structure; and a cooling step of cooling the composite structure.

Method for manufacturing composite structure and method for manufacturing integrated composite structure

A sandwich laminate, includes as a layer forming a core, a sheet-form intermediate substrate obtained by impregnating a mat composed of reinforcement fibers with a thermoplastic resin; and, as layers forming a skin, sheet-form intermediate substrates obtained by impregnating a mat composed of reinforcement fibers or continuous reinforcement fibers with a thermoplastic resin, wherein at least the sheet-form intermediate substrate used as the layer forming a core has a thermal expansibility, the usable temperature region of a thermoplastic resin (A) constituting the layers forming a skin and that of a thermoplastic resin (B) constituting the layer forming a core overlap each other over a temperature range of at least 5&#xb0; C., and the thermoplastic resin (A) has a temperature region where it does not melt at a lower limit of the usable temperature region of the thermoplastic resin (B).

A composite structure includes a structure that contains first reinforced fibers and first resin and a laminate that is disposed on at least one surface of the structure and has a plurality of layers containing second reinforced fibers and second resin, with the structure and the laminate integrated, the first reinforced fibers being discontinuous fibers and having a thickness-wise average fiber orientation angle in a range of 5 to 60&#xb0;, the second reinforced fibers being discontinuous fibers and having a thickness-wise average fiber orientation angle in a range of 0 to 5&#xb0;, the structure having a density in a range of 0.01 to 1 g/cm, the laminate having a variation in volume content of the second reinforced fibers in a range of 0 to 10%, and the composite structure having a protruding portion on a laminate's surface opposite from a laminate's surface in contact with the structure.

Composite structure and method for manufacturing same

Provided is a mountain-shaped structure material being excellent in stiffness and lightness. The present invention is a structure material including a resin, reinforced fibers and voids. The structure material has a specific bending stiffness represented as Ec&#xb7;&#x3c1;being 2.5 or more where a bending modulus is Ec and a density is &#x3c1;. The structure material has a mountain shape.

Structure material and manufacturing method therefor

An electronic device housing includes: a bottom cover; a top cover; a partition structure that is disposed in a space divided by the bottom cover and the top cover and has an opening; and a heat generation member. The partition structure is joined to the bottom cover or the top cover to form a hollow structure, and the heat generation member is disposed on a surface of the partition structure on the hollow structure side.

Electronic device housing

A method for manufacturing a structure material is a method for manufacturing a structure material that includes a thermoplastic resin, reinforced fibers, and voids. The method includes: a first process for arranging a structure precursor comprising the thermoplastic resin and the reinforced fibers in a mold with a surface temperature of 80&#xb0; C. or less; a second process for raising the surface temperature of the mold up to a temperature at which a storage elastic modulus (G') of the structure precursor is less than 1.2&#xd7;10Pa; a third process for lowering the surface temperature of the mold down to a temperature at which the storage elastic modulus (G&#x2032;) of the structure precursor is 1.2&#xd7;10Pa or more; and a fourth process for removing a structure material obtained after end of the third process from the mold.

Method for manufacturing structure material

A structure material includes a resin, reinforced fibers, and voids, a volume content of the resin being within a range of 2.5% by volume or more and 85% by volume or less, a volume content of the reinforced fibers being within a range of 0.5% by volume or more and 55% by volume or less, the voids being contained in the structure material in a rate within a range of 10% by volume or more and 97% by volume or less, a thickness St of the structure material satisfying a conditional expression: St&#x2265;Lf&#xb7;(1&#x2212;cos(&#x3b8;f)) where a length of the reinforced fibers is Lf and an oriented angle of the reinforced fibers in a sectional direction of the structure material is &#x3b8;f, and a compression strength in an in-plane direction at 50% compression of the structure material measured in accordance with JIS K7220 being 3 MPa or more.

Structure material

A structure material includes a resin, reinforced fibers, and voids. The structure material includes a volume content of the resin being within a range of 2.5% by volume or more and 85% by volume or less, a volume content of the reinforced fibers being within a range of 0.5% by volume or more and 55% by volume or less, the voids being contained in the structure material in a rate within a range of 10% by volume or more and 97% by volume or less, a thickness St of the structure material satisfying a conditional expression: St&#x2265;Lf&#xb7;(1&#x2212;cos(&#x3b8;f)), and a specific bending modulus of the structure material represented as Ec&#xb7;&#x3c1;being within a range of 3 or more and 20 or less, and a bending modulus Ec of the structure material being 3 GPa or more.

A fiber-reinforced resin sheet and an integrally molded article are provided. The fiber-reinforced resin sheet comprises a nonwoven fabric made of reinforcing fibers having a thermoplastic resin (A) impregnated on one side of the nonwoven fabric. The fiber-reinforced resin sheet satisfies any one of the following conditions (I) and (II):

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Ehime, Japan

Yoshiki Takebe