Provided are a process and an apparatus for producing a fiber-reinforced thermoplastic resin tape, the process and the apparatus being capable of preventing fiber cut from occurring at the start of production of the fiber-reinforced thermoplastic resin tape. The provided process includes a resin impregnation step of opening a fiber bundle and impregnating the fiber bundle with molten thermoplastic resin and a through-nozzle passing step of passing the fiber bundle having undergone the resin impregnation step through a slit formed in a nozzle. The through-nozzle passing step includes setting, at the start of production, a gap dimension of the slit to a dimension larger than a normal dimension and changing the gap dimension of the slit to the normal dimension when a predetermined condition is satisfied, after the production start.

A method of producing a reinforcing bar (Sc) involves impregnating and integrating reinforcing fibers (Fb) with a thermoplastic polymer. The method may include: immersing and passing the reinforcing fibers (Fb), initially in a non-flat bundle form, through a storage tank (2) containing the thermoplastic polymer in a liquid form; flattening the reinforcing fibers (Fb), while being passed (moving) through the storage tank (2) and immersed in the liquid thermoplastic polymer, into a flatter state to cause the liquid thermoplastic polymer to better infiltrate and coat the reinforcing fibers (Fb); and then convergently shaping the flat reinforcing fibers (Fb) infiltrated with the liquid thermoplastic polymer into a non-flat bundle form again while the reinforcing fibers are still immersed in the liquid thermoplastic polymer.

Provided are a method and a device for producing a pultruded material that improve the homogeneity of a thermosetting resin. The device for producing a pultruded material comprises a first opening section, a second opening section, a closing section, a tension-applying section, an impregnating section, and a mold. The first opening section and the second opening section open a bundle of reinforcing fibers and thereby obtain a bundle of reinforcing fibers. The closing section closes the bundle of opened reinforcing fibers and thereby obtains a bundle of reinforcing fibers. The tension-applying section applies tension along the direction in which the reinforcing fibers extend to the bundle of reinforcing fibers that pass through the closing section. The impregnating section impregnates the bundle of reinforcing fibers with a thermosetting resin. The mold pultrudes the bundle of reinforcing fibers that have been impregnated with the thermosetting resin.

A hybrid fiber-reinforced composite material according to an aspect of the present disclosure may comprise a first continuous fiber layer, a long fiber layer laminated on one surface of the first continuous fiber layer, and a second continuous fiber layer laminated on one surface of the long fiber layer, and may further comprise at least one of a first thermosetting resin laminated on the other surface of the first continuous fiber layer and a second thermosetting resin laminated on one surface of the second continuous fiber layer.

The invention enhances the production efficiency in the production of prepreg by allowing the arrangement property and rectilinearity of reinforcing fibers to be well maintained, allowing the basis weight uniformity of an applied resin to be good, and further allowing a high line speed and suppression of contamination in the process to be achieved. The invention provides a method of producing a prepreg, which includes: discharging a molten resin from a discharge portion; introducing the discharged resin by an air flow; and capturing the discharged resin on a reinforcing fiber sheet conveyed continuously, wherein a key point is that the discharged resin is captured in a region in which the reinforcing fiber sheet is conveyed substantially in planar form.

Embodiments of the present technology may include a method of making a thermoplastic composite concentrates. The method may include melting a low-viscosity reactive resin to form a molten reactive resin. The method may also include fully impregnating a plurality of continuous fibers with the molten reactive resin in an impregnation device. The method may further include polymerizing the molten reactive resin to form a thermoplastic composite strand. In addition, the method may include chopping the thermoplastic composite strand into a plurality of pellets to form a plurality of thermoplastic composite concentrates.

The present invention relates to a (meth)acrylic composition suitable for (meth)acrylic polymeric compositions and (meth)acrylic polymeric composites, its method of preparation and its use. In particular the present invention relates to a (meth)acrylic composition that is slightly crosslinked once polymerized and that is suitable for (meth)acrylic composites and more particular for rebars. More particularly the present invention relates to a (meth)acrylic composition suitable for rebars, preparing such a (meth)acrylic compositions, composite rebar comprising is and method of preparing such a composite rebar. The present invention also relates also to the use of such a (meth)acrylic composition and use of rebars.

A fiber-reinforced resin material used for molding a fiber-reinforced resin which includes a matrix resin and reinforcing fiber bundles A including chopped fiber bundles each including 100 or more single fibers, wherein the product of an average porosity within fiber bundles P.sub.fav (−) and an average fiber bundle thickness t.sub.fav (mm) is 0 mm or more and 0.01 mm or less and a porosity of composite P.sub.c (−) is 0.02 or more and 0.4 or less, and a method for producing the same. The fiber-reinforced resin material is a molding material excellent in terms of productivity and reduction in LCA, which can give high mechanical properties to a molded article using the molding material and further which is excellent also in flowability during molding.

According to one embodiment, a system for manufacturing a fully impregnated thermoplastic prepreg includes a mechanism for moving a fabric or mat and a drying mechanism that removes residual moisture from at least one surface of the fabric or mat. The system also includes a resin application mechanism that applies a reactive resin to the fabric or mat and a press mechanism that presses the coated fabric or mat to ensure that the resin fully saturates the fabric or mat. The system further includes a curing oven through which the coated fabric or mat is moved to polymerize the resin and thereby form a thermoplastic polymer so that upon exiting the oven, the fabric or mat is fully impregnated with the thermoplastic polymer. During at least a portion of the process, humidity in the vicinity of the coated fabric or mat is maintained at substantially zero.

Methods, apparatuses, and systems for making prepregs are disclosed. A method may include depositing a resin material onto a surface of a fiber bed and forming a number of discrete resin regions thereon. A distance between the resin regions may be measured to provide desired exposed portions of the surface to facilitate permeation of air through the exposed portions of the surface in a direction perpendicular to a plane of the fiber bed during a curing process of the prepreg.