A composite structure for stab protection includes layers of flat structures placed on top of each other, and an embedding material, wherein, in at least some of the layers placed on top of each other, the flat structures of adjacent layers are offset relative to one another, the flat structures of the composite structure are at least partially embedded in the embedding material, and the composite structure includes separated connecting elements, wherein before they are separated, the separated connecting elements have connected at least some of the flat structures of adjacent layers with one another.

A method for forming a fiber reinforced thermoplastic part may comprise the steps of locating a thermoplastic material over a mold tool, heating the thermoplastic material to a pliable forming temperature, conforming the thermoplastic material to a mold surface of the mold tool, and depositing a plurality of fiber strips over the thermoplastic material.

A method for producing a molded product 70 involves the use of an insert material 80. The method for producing the molded product 70 includes a transfer step for transferring the insert material 80 into a mold 40 using a transfer device 87; a placement step for placing the insert material 80 in the mold 40 by deforming the insert material 80 in the mold 40; and a molding step for injecting a molding material into the mold 40, thereby producing the molded product 70 having the insert material 80.

A seat back assembly that includes a composite seat back cover. The composite seat back cover includes at least one composite layer, that includes a layer of reinforcing fibers and a thermoplastic layer surrounding the reinforcing fibers. The thermoplastic layer is coextensive with the layer of reinforcing fibers. In various embodiments, the seat back includes a seat back frame. The seat back frame includes a side rail, a top rail main section, and a top rail cap. The side rail, the top rail main section, and the top rail cap are fused to each other by a homogenous chemical bond. A homogenous chemical bond is formed between the seat back cover and the seat back frame creating a unitary seat back assembly.

A resin composite in which the flatness ratio of cells in a corner section of a core material is 20% or more is provided.

A seat back assembly that includes a composite seat back cover. The composite seat back cover includes at least one composite layer, that includes a layer of reinforcing fibers and a thermoplastic layer surrounding the reinforcing fibers. The thermoplastic layer is coextensive with the layer of reinforcing fibers. In various embodiments, the seat back includes a seat back frame. The seat back frame includes a side rail, a top rail main section, and a top rail cap. The side rail, the top rail main section, and the top rail cap are fused to each other by a homogenous chemical bond. A homogenous chemical bond is formed between the seat back cover and the seat back frame creating a unitary seat back assembly.

An in-mold molding method of the present invention is a method including: placing an in-mold transfer film in the cavity of an injection molding mold, the in-mold transfer film having a hard coating layer and a transfer section of a printed layer; and peeling, from the base material film of the in-mold transfer film, the transfer section transferred to a molding resin when a molding molded by injecting the molding resin into the cavity is removed by mold opening. The hard coating layer is ruptured in a mold opening process while the in-mold transfer film has a necessary elongation of A % on the side of the molding and the hard coating layer has a rupture elongation of at least A %+2% and less than A %+40% on the side of the molding. With this configuration, the in-mold transfer film can be stably peeled during in-mold molding.

A method for producing a component from a fiber-reinforced thermoplastic material referred to as an organometallic sheet, and which includes an arrangement of fibers embedded in a matrix of a thermoplastic material. To produce the component, the organometallic sheet is thermally shaped and then placed into an injection mold. A mold for carrying out a method for producing a component from a fiber-reinforced thermoplastic material is also provided.

A failure module includes a support element. A reinforcing element is disposed on the support element. The support element is chemically compatible with the reinforcing element. A homogeneous chemical bond is formed between the support element and the reinforcing element.