A fiber reinforced resin molded article includes a fiber reinforced resin layer, and a functional site made up from a resin layer for molding that does not contain reinforcing fibers. An insert member is retained in an integrated manner in the functional site.

An apparatus for molding a part includes a plunger cavity, a plunger, and a mold cavity, wherein the plunger is oriented out-of-plane with respect to a major surface of the mold cavity, and first and second vents couples to respective first and second portions of the mold cavity. In a method, resin and fiber are forced into the mold cavity from a plunger cavity, and at least some of the fibers and resin are preferentially flowed to certain region in the mold cavity via the use of vents.

A method may include placing a dry fabric over a tool; pressing a first resin film over the dry fabric while the dry fabric is draped over the tool to create an outer layer of the laminate composite structural component; repeating the placing and pressing process until a desired thickness of the outer layer is achieved; compressing a second resin film and a dry fiber fabric between two rollers to tack the second resin film to the dry fiber fabric to create a resin-fabric sheet comprising a resin film layer and an dry fiber fabric layer; cutting the resin-fabric sheet to a pre-determined shape to create at least one resin-fabric preform; and draping a first resin-fabric preform over at least a portion of the outer layer, wherein one or more edges of the first resin-fabric preform overlap the outer layer to create an internal edge.

A method is provided in which a fiber-reinforced resin molded article having high dimensional accuracy is obtained by press molding a fiber-reinforced resin. The present invention relates to a method for producing a fiber-reinforced resin molded article by pressing a single prepreg of a fiber-reinforced resin, a plurality of stacked prepregs, or a plurality of stacked prepregs with adhesive resin sheets interposed between the prepregs, said method comprising: a step in which the prepreg is positioned between a heated upper die and a heated lower die; a step in which the upper die is lowered and a load is applied to the prepreg by the upper die and the lower die while further increasing the temperature of the upper die and the lower die; a step in which the upper die and the lower die are maintained at a temperature within a prescribed temperature range while the upper die is positioned at the bottom dead center; a step in which the heating of the upper die and the lower die is reduced or stopped; and a step in which after reducing or stopping the heating, the upper die is raised and the fiber-reinforced resin molded article is extracted.

A luggage shell or case made from a sheet formed by compacting and heating a mat made of either a mixture of randomly oriented first discontinuous non-woven plastic fibers (42) having a first melting temperature and randomly oriented second discontinuous reinforcing non-woven plastic fiber (46) having a second melting temperature higher than the first melting temperature, or a bicomponent fiber having a first plastic portion having a first melting temperature and a second plastic portion having a second melting temperature. The non-woven mat is heated at a temperature between the first melting temperature and the second melting temperature, as well as by forming the compacted non-woven sheet (64) into the luggage shell.

A method for producing a thermoplastic fiber composite component, in particular for an aircraft or spacecraft, has the following method steps: material-removing processing of a first face of a first plate, wherein the first plate comprises a thermoplastic fiber composite material and a local reduction in thickness of the first plate is made by the material-removing processing of the first face; positioning a second plate relative to the first plate such that the first face of the first plate is brought into alignment with a third face of the second plate; and joining the first plate to the second plate to form a single component, wherein the surface of the first face of the first plate is integrally bonded to the surface of the third face of the second plate.

The present invention relates to a method of molding a component (1) having one or more features (5). At least one fibrous substrate (7) is located in a mold (31, 33). A matrix-forming material (29) is also provided in the mold (31, 33). Heat is applied to melt the matrix-forming material (29) to form a matrix (9) and to integrally mold said one or more features (5).

A method produces a seat cover for a vehicle seat made of a form-fit knit part. The form-fit knit part has continuous fibers and reinforcing fibers, and each of the reinforcing fibers is made of a core fiber and a cladding fiber coaxially sheathing the core fiber. The form-fit knit part is first produced using a knitting machine, and the seat cover is subsequently produced from the form-fit knit part using an ironing machine. The ironing machine has at least one lower mold in the shape of the vehicle seat, and the core fiber has a higher melting point than the cladding fiber.

A molding method for fabricating a composite part having inserts is provided including disposing preforms in a mold, each having co-aligned, resin-impregnated fibers, placing the inserts in the mold adjacent to at least one of the preforms, wherein each insert has securement features for receiving a portion of the co-aligned resin-impregnated fibers from at least one preform, and applying heat and pressure in an amount sufficient to consolidate the resin-impregnated fibers into a resin matrix, thereby forming the part, including consolidating the fibers and resin within the securement features. A fiber composite part is also provided including continuous, co-aligned fibers within a resin matrix, and at least one insert disposed in the matrix, the insert comprising at least one securement feature having a second plurality of the fibers therein, the second plurality of fibers extending into the resin matrix and overlapping with some of the first plurality of fibers.

A structure of case body selects a material of PET fibers or PET fibers with PP fibers to prepare a non-woven fabric layer block which is processed by baking and cold molding to form a case body. The case body is formed by combining a left shell and a right shell which are manufactured separately, and then combined into a case body with an accommodation space inside. The left shell is divided into a left top wall, a left sidewall and a left bottom wall which are continuously extended and molded. The right shell is divided into a right top wall, a right sidewall and a right bottom wall which are continuously extended and molded. The left and right top walls and the left and right bottom walls have a weight per unit area of 1200-2000 g/m.sup.2. The left and right sidewalls have a weight per unit area of 600-1200 g/m.sup.2.