Abstract: A method of RTM molding includes placing a reinforcing fiber substrate in a mold, placing resin distribution media exhibiting a resin flow resistance lower than a resin flow resistance of said reinforcing fiber substrate on both surfaces of said reinforcing fiber substrate, and after pressure in said mold is reduced by evacuation, injecting a resin into said mold through said resin distribution media to impregnate said reinforcing fiber substrate with said resin injected, wherein resin flow resistance of a first resin distribution medium placed on a first surface of said reinforcing fiber substrate is lower than resin flow resistance of a second resin distribution medium placed on a second surface of said reinforcing fiber substrate, and said evacuation is carried out through said second resin distribution medium while said resin is injected into said first resin distribution medium to impregnate said reinforcing fiber substrate with said resin injected.

Abstract: A method of RTM molding including laminating a plurality of reinforcing fiber materials in a mold to form a reinforcing fiber material laminate, and impregnating a resin into said reinforcing fiber material laminate by injecting a resin in a direction from an end surface of said reinforcing fiber material laminate along a laminate surface while reducing pressure in said mold by evacuation.

Abstract: A structure for a passenger vehicle interior is a structure for constituting the vehicle interior of a passenger vehicle, is formed in a monocoque structure in which the entire structure from the front side to the rear side of the vehicle interior is integrally formed by a fiber-reinforced resin, has a bowl-shaped structure part which is provided at least on the front side among the front side and the rear side of the structure and which opens toward the rear side, and has a side-wall part formed as a vertical wall that is continuous with the bowl-shaped structure part and extends in a front-rear direction of the structure, at each of both side parts of the structure, and a manufacturing method therefor.

Abstract: A method for laser-cutting a carbon fiber substrate such as a preform is configured from fabric material comprising at least carbon fibers, characterized by cutting the carbon fiber substrate at initial conditions which have been set so that the state of the substrate that is being cut with a laser can be suppressed with or prevented from deviating from a target state. By the method, it is possible to effectively solve various problems such as dissipation of heat, positional shifting from the focal length range of the laser, and soot, and the carbon fiber substrate can be stably cut at the target desired state.

Abstract: A process for producing a fiber reinforced resin which comprises placing at least a reinforcing fiber substrate in a cavity of a mold, injecting a resin into the cavity, and curing the resin, characterized in that a substrate for forming a skin layer, and a resin distribution medium, which is located between the substrate for forming the skin layer and the reinforcing fiber substrate and in which the ratio of the coefficient of impregnation thereof to that of the substrate for forming the skin layer is 1.5-10, are disposed on at least one surface of the reinforcing fiber substrate via an interlayer having a cover factor of 90%-100% and comprising at least one woven fabric. The process diminishes pinhole generation in the skin layer in RTM, and can reduce the necessity of a repair step in, e.g., a painting step as a later step, thereby improving productivity.

Abstract: A structure for a passenger vehicle interior is a structure for constituting the vehicle interior of a passenger vehicle, is formed in a monocoque structure in which the entire structure from the front side to the rear side of the vehicle interior is integrally formed by a fiber-reinforced resin, has a bowl-shaped structure part which is provided at least on the front side among the front side and the rear side of the structure and which opens toward the rear side, and has a side-wall part formed as a vertical wall that is continuous with the bowl-shaped structure part and extends in a front-rear direction of the structure, at each of both side parts of the structure, and a manufacturing method therefor.

Abstract: A method of RTM molding including placing a reinforcing fiber substrate in a mold, placing a resin distribution medium having a resin flow resistance lower than a resin flow resistance of said reinforcing fiber substrate on a surface of said reinforcing fiber substrate opposite said mold, providing a degasification medium comprising a gas permeation film and a gas permeable substrate between said reinforcing fiber substrate and said mold, and injecting a resin into said mold through said resin distribution medium after pressure in said mold is reduced by evacuation, whereby the injected resin is impregnated into said reinforcing fiber substrate by evacuating said resin injected from a degasification space formed between said gas permeation film and said mold.

Abstract: A process for producing a molded fiber-reinforced resin by an RTM method includes disposing a molding precursor in a molding cavity of a mold; closing the mold in which the molding precursor is disposed; injecting a heated and pressurized resin into the molding cavity of the mold closed; solidifying the resin injected into the molding cavity; opening the mold after the resin has been solidified; and taking out the molded fiber-reinforced resin from the mold opened.

Abstract: A method of RTM molding wherein a reinforcing fiber substrate is placed in a mold, each of a first and a second resin distribution media exhibiting a resin flow resistance lower than the resistance of the reinforcing fiber substrate is placed on each surface of the reinforcing fiber substrate, and the inside of the mold is evacuated and a resin is injected into the mold to thereby impregnate the reinforcing fiber substrate with the resin injected, characterized in that the first resin distribution medium exhibits a resin flow resistance lower than that of the second resin distribution medium, and the evacuation is carried out through the second resin distribution medium while the resin is injected through the first resin distribution medium. The method can be advantageously employed for producing, in particular, FRP structure which is thick and excellent in designability, lightweight property and/or strength.

Abstract: A method for laser-cutting a carbon fiber substrate such as a preform is configured from fabric material comprising at least carbon fibers, characterized by cutting the carbon fiber substrate at initial conditions which have been set so that the state of the substrate that is being cut with a laser can be suppressed with or prevented from deviating from a target state. By the method, it is possible to effectively solve various problems such as dissipation of heat, positional shifting from the focal length range of the laser, and soot, and the carbon fiber substrate can be stably cut at the target desired state.

Abstract: A process for producing a molded fiber-reinforced resin by an RTM method includes disposing a molding precursor in a molding cavity of a mold; closing the mold in which the molding precursor is disposed; injecting a heated and pressurized resin into the molding cavity of the mold closed; solidifying the resin injected into the molding cavity; opening the mold after the resin has been solidified; and taking out the molded fiber-reinforced resin from the mold opened.

Abstract: A molding precursor which includes a main body part and a burr formation part protruding outward from the edge of the main body part and extending continuously along the edge, wherein the main body part includes a first base having many reinforcing fibers and a second base having many fibers and has been superposed on the first base in an outer peripheral part of the main body part, the burr formation part is constituted of that part of the second base which protrudes outward from the edge of the main body part, and spaces among the many fibers constitute passages for a molding resin.

Abstract: An RTM molding method and device includes disposing a reinforcing fiber substrate in a cavity of a mold consisting of a plurality of dies, clamping the mold, and injecting resin to complete molding, wherein divided areas with respect to the surface direction of the reinforcing fiber substrate are assumed, each divided area is one in which injected resin expands over the entire surface in the area and can be substantially uniformly impregnated in the thickness direction of the substrate, and resin introducing paths are formed for respective assumed divided areas to introduce injected resin into the respective divided areas. When a relatively large molded product is molded, a molding step from resin injection to impregnating/curing can be implemented at high speed without generating a non-resin-flowing area, thereby producing a high-quality molded product with a shortened molding time and increased production speed and volume.

Abstract: An RTM molding method includes disposing a reinforcing fiber substrate in a cavity of a mold consisting of a plurality of dies, clamping the mold, and thereafter injecting resin to complete molding, characterized in that divided areas with respect to the surface direction of the reinforcing fiber substrate are assumed, each divided area is one in which injected resin expands over the entire surface in the area and can be substantially uniformly impregnated in the thickness direction of the substrate, and resin introducing paths are formed for respective assumed divided areas for introducing the injected resin into the respective divided areas; and an RTM molding device. When a relatively large molded product is to be molded, a molding step from resin injection to impregnating/curing can be implemented at high speed without generating a non-resin-flowing area, thereby enabling a high-quality molded product to be produced free from voids, etc.

Abstract: A process for producing a fiber reinforced resin which comprises placing at least a reinforcing fiber substrate in a cavity of a mold, injecting a resin into the cavity, and curing the resin, characterized in that a substrate for forming a skin layer, and a resin distribution medium, which is located between the substrate for forming the skin layer and the reinforcing fiber substrate and in which the ratio of the coefficient of impregnation thereof to that of the substrate for forming the skin layer is 1.5-10, are disposed on at least one surface of the reinforcing fiber substrate via an interlayer having a cover factor of 90%-100% and comprising at least one woven fabric. The process diminishes pinhole generation in the skin layer in RTM, and can reduce the necessity of a repair step in, e.g., a painting step as a later step, thereby improving productivity.

Abstract: A molding precursor which includes a main body part and a burr formation part protruding outward from the edge of the main body part and extending continuously along the edge, wherein the main body part includes a first base having many reinforcing fibers and a second base having many fibers and has been superposed on the first base in an outer peripheral part of the main body part, the burr formation part is constituted of that part of the second base which protrudes outward from the edge of the main body part, and spaces among the many fibers constitute passages for a molding resin.

Abstract: An RTM molding method comprising disposing a reinforcing fiber substrate in a cavity of a mold consisting of a plurality of dies, clamping the mold, and thereafter injecting resin to complete molding, characterized in that divided areas with respect to the surface direction of the reinforcing fiber substrate are assumed, each divided area is one in which injected resin expands over the entire surface in the area and can be substantially uniformly impregnated in the thickness direction of the substrate, and resin introducing paths are formed for respective assumed divided areas for introducing the injected resin into the respective divided areas; and an RTM molding device. When a relatively large molded product is to be molded, a molding step from resin injection to impregnating/curing can be implemented at high speed without generating a non-resin-flowing area, thereby enabling a high-quality molded product to be produced free from voids, etc.

Abstract: This invention relates to a method for manufacturing a large FRP member including: disposing a preform containing a reinforcing fiber on a surface of a molding die; covering a molding portion with a bagging material or a mold and providing a suction port and a resin injection port for sealing; evacuating the molding portion through the suction port; heating the molding portion; injecting a thermosetting resin from the resin injection port for impregnating the reinforcing fiber with the resin while a temperature Tm of the molding die and a temperature Tv of the bagging material or the mold are both set to room temperature or more, and a difference ?T in temperature between the Tm and the Tv is set to 10° C. or less; and curing the resin by maintaining the molding portion at a predetermined temperature Tpc which is equal to or more than room temperature.

Abstract: A method of RTM molding wherein a reinforcing fiber substrate is placed in a mold, each of a first and a second resin distribution media exhibiting a resin flow resistance lower than the resistance of the reinforcing fiber substrate is placed on each surface of the reinforcing fiber substrate, and the inside of the mold is evacuated and a resin is injected into the mold to thereby impregnate the reinforcing fiber substrate with the resin injected, characterized in that the first resin distribution medium exhibits a resin flow resistance lower than that of the second resin distribution medium, and the evacuation is carried out through the second resin distribution medium while the resin is injected through the first resin distribution medium. The method can be advantageously employed for producing, in particular, FRP structure which is thick and excellent in designability, lightweight property and/or strength.

Abstract: The present invention relates to a method for manufacturing a large FRP member and has the following structure.