A production method for a fiber-reinforced resin molded object is provided whereby a large apparatus is not used when molding, by heating and pressing, a fiber-reinforced resin base material that includes a matrix resin, a molded object with excellent precision and quality can be obtained, and for which work is simple.

The production method includes arranging, on an inner surface of a lower mold 3, a fiber-reinforced resin base material 1 obtained by impregnating a matrix resin into reinforcing fibers; filling a core space 5 of the mold, in which the fiber-reinforced resin base material 1 is arranged, with a powder mixture 2a that has liquidity and that includes thermally expandable microcapsules and another powder; sealing the lower mold 3 and an upper mold 4; heating at from a heat expansion starting temperature to a maximum expansion temperature of the thermally expandable microcapsules to cause the thermally expandable microcapsules to expand; and pressing the fiber-reinforced resin base material 1 against the inner surface of the lower mold 3 to produce a molded object.

An expansion device, including: an irradiation unit configured to irradiate the thermally expandable sheet placed on a placing unit with light; a conveyance unit configured to reciprocably convey the irradiation unit between a first position and a second position; an exhaust fan fixed to a housing and configured to discharge air from the housing; and an air supply fan which is movable with the irradiation unit and configured to supply outside air into the housing, wherein the exhaust fan is provided at a position where air can be discharged from the second position side when the irradiation unit is returned from the first position to the second position after being moved from the second position toward the first position.

An insulating structure for an appliance includes an outer layer and an inner layer, wherein an insulating cavity is defined therebetween. A plurality of hollow nano-spheres are disposed within the insulating cavity, wherein each of the hollow nano-spheres includes a diameter in the range of from approximately 50 nanometers to approximately 1000 nanometers and has a wall that defines the internal space, and wherein the wall of each hollow nano-sphere has a thickness that is in a range of from approximately 0.5 nanometers to approximately 100 nanometers. A fill material is disposed in the insulating cavity and wherein the fill material is disposed in the space defined between the plurality of hollow nano-spheres, and wherein the fill material includes at least one of powdered silica, granulated silica, other silica material, aerogel and insulating gas.

A three-dimensional image forming system according to the present invention includes a conveying unit which conveys a heat-expandable sheet along a conveyance path, a heating unit which heats the heat-expandable sheet by irradiating the heat-expandable sheet with light, and a control unit which preheats the surroundings of the heating unit to a previously determined preheat temperature and then causes the conveying unit to convey the heat-expandable sheet.

A heating apparatus for emitting thermal energy, includes a heater which emits the thermal energy directed at a thermal expansion sheet that expands according to a heating amount absorbed, a relative mover which causes the heater and the thermal expansion sheet to move relatively in a predetermined direction, and a controller which changes one of a speed of the relative movement by the relative mover and a heat generation amount by the heater, according to the relative movement of the heater and the thermal expansion sheet, so that the heating amount received by the thermal expansion sheet is close to uniform regardless of the position in the predetermined direction while the thermal energy is emitted by the heater.

A thermally expandable sheet includes: a first thermally expansive layer that is formed on one side of a base and contains a first thermally expandable material and a first binder, the first thermally expansive layer having a first ratio of the first thermally expandable material with respect to the first binder; and a second thermally expansive layer that is formed on the first thermally expansive layer and contains a second thermally expandable material and a second binder, the second thermally expansive layer having a second ratio of the second thermally expandable material with respect to the second binder, wherein the first ratio is lower than the second ratio.

A shaped object production method includes a first preparation step (S30) of preparing a molding sheet that includes a base, a thermally expansive layer laminated on a first main surface of the base, the thermally expansive layer including a thermally expandable material, and a brushed layer laminated on a surface of the thermally expansive layer on a side that is opposite to the base, the brushed layer including fiber; a first heat conversion layer laminating step (S40) of laminating a heat conversion layer that converts electromagnetic waves into heat onto a surface of the molding sheet on a side that is opposite to the brushed layer; and a first unevenness forming step (S50) of forming an unevenness on the surface of the thermally expansive layer on the side that is opposite to the base by irradiating the heat conversion layer with electromagnetic waves, thereby causing the thermally expandable material to expand.

A thermally expandable sheet includes: a first thermally expansive layer that is formed on one side of a base and contains a first thermally expandable material and a first binder, the first thermally expansive layer having a first ratio of the first thermally expandable material with respect to the first binder; and a second thermally expansive layer that is formed on the first thermally expansive layer and contains a second thermally expandable material and a second binder, the second thermally expansive layer having a second ratio of the second thermally expandable material with respect to the second binder, wherein the first ratio is lower than the second ratio.

A 3D printed thermal expansion structure includes a thermoplastic material and a thermal expansion material, wherein the thermoplastic material is in a range from 50 to 90 wt % based on a weight of the 3D printed thermal expansion structure, and the thermal expansion material is in a range from 10 to 50 wt % based on the weight of the 3D printed thermal expansion structure. The thermoplastic material and the thermal expansion material are mixed to form a mixed material, and the mixed material is utilized by a 3D printing apparatus to form a solid object, and the solid object is heated to form the 3D printed thermal expansion structure. A manufacturing method of a 3D printed thermal expansion structure is provided herein.

Methods of forming a lightweight reinforced thermoplastic core layer and articles including the core layer are described. In some examples, the methods use a combination of thermoplastic material, reinforcing fibers and bicomponent fibers to enhance retention of lofting agents in the core layer. The processes permit the use of less material while still providing sufficient lofting capacity in the final formed core layer.