Resin pellets (7) supplied to a resin block forming space (150) are heated and melted by a heater unit (300) and the melted resin pellets (7) are cooled and solidified to form a resin layer. Since a lifting mechanism (230) of a lifting unit (200) lowers a bottom surface plate (215) whenever forming each of the resin layers, the resin layers formed by the resin block forming space (150) are sequentially laminated to form a large resin block.

A carbon fiber-reinforced resin molded body of the present invention derives from kneaded materials of a thermoplastic resin and a carbon fiber and includes at least a three-dimensional complex shaped region and a substantially flat plate-shaped region arranged in a profile direction. Fluidity of the kneaded materials at predetermined temperature is such that fluidity of the kneaded material forming the substantially flat plate-shaped region is lower than fluidity of the kneaded material forming the three-dimensional complex shaped region, which makes it unlikely to cause defects in ribs, posses, and other portions. Thus, a carbon fiber-reinforced resin molded body with low cost and high strength can be provided.

A strip-shape softened resin sheet (S) which is continuously extruded from a molten resin extruder is cut to a unit resin sheet and a press molded product is manufactured by press-molding the unit resin sheet in a press-molding machine. Prior to cutting the continuously extruded strip-shape softened resin sheet (S) to the unit resin sheet (U) , the slits C.sub.1, C.sub.2, C.sub.3, C.sub.4 and C.sub.5 which promote the molding to the press molded part from the unit resin sheet (U) (improve an inflow property of the material) are formed by a cutter which is upwardly and downwardly driven by an air cylinder at a portion P.sub.3 in which the material therein is out of a range of the press molded products P.sub.1 and P.sub.2 obtained by press-molding the press molded product by using the press molding machine and becomes a scrap. The inflow property of the resin material for vertical walls and embossment portions when press-molding is improved and the defects of the product can be prevented.

A strip-shape softened resin sheet (S) which is continuously extruded from a molten resin extruder is cut to a unit resin sheet and a press molded product is manufactured by press-molding the unit resin sheet in a press-molding machine 20. Prior to press-molding the unit resin sheet (U) by the press-molding machine, the unit resin sheet (U) is heated by a heating machine 16. The heating machine 16 comprises a first heating furnace 84 and a second heating furnace 86. The first heating furnace 84 includes a series of heaters 84-3 and 84-4 whose heat source is infrared ray in a far-infrared region and the second heating furnace 86 includes a series of heaters 86-3 and 86-4 whose heat source is the infrared ray in a middle-infrared region. In the first furnace 84, the unit resin sheet (U) is continuously conveyed with a low velocity and is gradually heated by the far-infrared ray up to temperature which is slightly lower than the temperature which is suitable for press-molding the unit resin sheet (U). In the second furnace 86, the unit resin sheet (U) is stopped and is rapidly heated by the middle-infrared ray. By efficiently heating the unit resin sheet (U), a cycle time can be shortened and the production speed can be improved.

Methods of producing polymer-metal hybrid components that are bonded by C—O-M bonds at the interface using at least one of the hot pressing, rolling, and injection molding methods to create chemical bond formation conditions at the polymer and metal interface. When the thermal cycle and compressive pressure specified herein is combinationally created at the polymer and metal interfaced, strong C—O-M bonds forms at the interface and strongly bonds the metal and polymer together through the reaction carbonyl groups (C═O) in polymer and the metal surface. For polymers lacking enough carbonyl groups, new functional groups can be in-situ generation through introducing distributed air pockets at the polymer-metal interface for forming 3-dimensional distributed C—O-M bonds at the interface.

Methods of producing polymer-metal hybrid components that are bonded by C—O-M bonds at the interface using at least one of the hot pressing, rolling, and injection molding methods to create chemical bond formation conditions at the polymer and metal interface. When the thermal cycle and compressive pressure specified herein is combinationally created at the polymer and metal interfaced, strong C—O-M bonds forms at the interface and strongly bonds the metal and polymer together through the reaction carbonyl groups (C═O) in polymer and the metal surface. For polymers lacking enough carbonyl groups, new functional groups can be in-situ generation through introducing distributed air pockets at the polymer-metal interface for forming 3-dimensional distributed C—O-M bonds at the interface.

An apparatus for automated encapsulation of motor rotor core with magnet steel is introduced. The apparatus includes at least one encapsulation unit, a plastic granule feeding device, a waste removing device, a conveyance device and a control device. Under a coordinated control of the control device, a rotor core feeding mechanism of the encapsulation unit feeds rotor cores to a plastic dispensing mechanism in cycles, the plastic granule feeding device separates, outputs and dispenses plastic granules, so that they are arrayed before being dispensed onto the rotor cores, and the conveyance device conveys plastic granules and moves the waste removing device to carry waste to a waste removal zone. With these arrangements, it is able to realize automated feeding of rotor cores, automated feeding of plastic granules and automated removal of waste to achieve completely automated rotor core encapsulation operation while enables mass production of motor rotor cores.

An apparatus for automated encapsulation of motor rotor core with magnet steel is introduced. The apparatus includes at least one encapsulation unit, a plastic granule feeding device, a waste removing device, a conveyance device and a control device. Under a coordinated control of the control device, a rotor core feeding mechanism of the encapsulation unit feeds rotor cores to a plastic dispensing mechanism in cycles, the plastic granule feeding device separates, outputs and dispenses plastic granules, so that they are arrayed before being dispensed onto the rotor cores, and the conveyance device conveys plastic granules and moves the waste removing device to carry waste to a waste removal zone. With these arrangements, it is able to realize automated feeding of rotor cores, automated feeding of plastic granules and automated removal of waste to achieve completely automated rotor core encapsulation operation while enables mass production of motor rotor cores.

A method comprises the following steps: providing a pre-processed element made of at least one polymeric material, introducing the pre-processed element in a female mould part having a forming cavity, shaping the pre-processed element between the female mould part and a male mould part, the female mould part and the male mould part being movable relative to one another along a moulding direction so as to form a concave object from the pre-processed element.

The forming cavity has a transversal dimension measured transversely relative to the moulding direction, the forming cavity further having a transition zone in which the transversal dimension passes from a larger value to a smaller value, the forming cavity further having a bottom.

During the introducing step, the pre-processed element is placed on the transition zone, so that the pre-processed element rests on the transition zone at a distance from the bottom of the forming cavity.

A method comprises the following steps: providing a pre-processed element made of at least one polymeric material, introducing the pre-processed element in a female mould part having a forming cavity, shaping the pre-processed element between the female mould part and a male mould part, the female mould part and the male mould part being movable relative to one another along a moulding direction so as to form a concave object from the pre-processed element.

The forming cavity has a transversal dimension measured transversely relative to the moulding direction, the forming cavity further having a transition zone in which the transversal dimension passes from a larger value to a smaller value, the forming cavity further having a bottom.

During the introducing step, the pre-processed element is placed on the transition zone, so that the pre-processed element rests on the transition zone at a distance from the bottom of the forming cavity.