Abstract: Apparatus and methods are provided for producing a long fiber-reinforced thermoplastic resin compositions by initially loosening a continuous fiber bundle by a fiber loosening device so as to form a moving web-like continuous fiber bundle. At least one side of the moving web-like continuous fiber bundle which passes through the die is coated with a thermoplastic resin melt extruded through a slit disposed in the die by an extruder. The slit has substantially the same width as that of the web-like continuous fiber bundle to provide an even supply of the resin melt in the width direction of the web-like continuous fiber bundle. A thermoplastic resin melt is supplied to the slit via a plurality of resin supply paths which are branched successively on the same plane. The resin supply paths are positioned so as to be symmetrically planar with respect to the central axis of the root paths thereof.

Abstract: Apparatus and methods are provided for producing a long fiber-reinforced thermoplastic resin compositions by initially loosening a continuous fiber bundle by a fiber loosening device so as to form a moving web-like continuous fiber bundle. At least one side of the moving web-like continuous fiber bundle which passes through the die is coated with a thermoplastic resin melt extruded through a slit disposed in the die by an extruder. The slit has substantially the same width as that of the web-like continuous fiber bundle to provide an even supply of the resin melt in the width direction of the web-like continuous fiber bundle. However, the slit has a spacing which changes at a point in the widthwise direction of the web-like continuous fiber bundle so as to be increased as the point is more remote from a feed port and have a constant spacing in the flowing direction of the thermoplastic resin melt.

Abstract: A cross-head die for the manufacture of long fiber-reinforced resin structures enhances fiber loosening and resin melt impregnation of fiber bundle near its inlet. A passageway along which the fiber bundle travels is defined between the die inlet and outlet and is in communication with a resin port to allow a resin melt to be introduced thereinto so as to impregnate the traveling fiber bundle. The passageway meanders relative to the common plane so as to establish a plurality of alternating successive peak and valley portions each having a substantially constant pitch dimension as measured at adjacent crossing points of the passageway with the common plane. A first peak or valley portion adjacent to the inlet has a greater height dimension as measured from the common plane as compared to a last peak or valley portion adjacent the outlet.

Abstract: Apparatus and method for manufacturing a resin structure reinforced with long fibers. A continuous fiber bundle is impregnated with a resin melt while the fiber bundle is being drawn continuously. Thereafter, the continuous resin-impregnated fiber bundle is shaped so as to have a cross-section of the intended final product. The shaped resin-impregnated fiber bundle is then cut at a downstream location. Shaping of the resin-impregnated fiber bundle is accomplished by a plurality of rolls, each having grooves formed on the outer periphery thereof which receive the continuous resin-impregnated fiber bundle. The grooves and the rolls are arranged such that the rolls are placed, in an alternating manner, at upper and lower positions with respect to the fiber bundle which is being drawn and such that the grooves of the rolls on the elevation plane perpendicular to the running direction of the fiber bundle forms a shape of the cross-section of the intended final product.

Abstract: Apparatus and method for manufacturing a resin structure reinforced with long fibers by impregnating a continuous fiber bundle with a molten resin, shaping the resin-impregnated continuous fiber bundle so as to have a cross section of an intended final product; and then taking up the resin-impregnated and shaped continuous fiber bundle shaped with upper and lower endless belts or rolls. A comb-shaped structure is positioned at a location on an upstream side of the endless belts or rolls so as to hold the resin-impregnated continuous fiber bundle between two adjacent teeth thereof. The comb-shaped structure is oscillated in a widthwise direction of the endless belts or rolls with the resin-impregnated continuous fiber bundle held between the two adjacent teeth thereof so as to responsively oscillate the resin-impregnated continuous fiber bundle in the widthwise direction of the endless belts or rolls.

Abstract: A method of continuously taking out a twist-free fiber bundle from the inner side of a plurality of fiber bundle packages each having a hollow cylindrical shape is disclosed. The trailing end of a fiber bundle package and the leading end of another fiber bundle package are spliced to each other in advance. The plurality of fiber bundle packages thus spliced are attached to a body of revolution, and a fiber bundle is then taken out at a speed which is determined based on the taking-out speed of the fiber bundle in a direction so as to eliminate twist of the fiber bundle thus taken out while the rotary member is rotated. Also disclosed is a method of manufacturing a resin structure reinforced with long fibers using the thus prepared twist-free fiber bundle by impregnating it with a resin while drawing.

Abstract: A method of manufacturing a resin structure reinforced with long fibers in which a continuous fiber bundle is loosened in a fiber-loosening step and the loosened continuous fiber bundle is impregnated with a resin melt in an impregnation step. The fiber-loosening index S of the loosened continuous fiber bundle represented by equation (I) is within the range of 2.0 to 18.0:S=5.times.10.sup.-2.T/L.1/D (I)in which T is the Tex number of the continuous fiber bundle, D is a diameter (micrometer) of the continuous fibers contained in the fiber bundle, and L is a width (cm) of the continuous fiber bundle. Mechanical properties of the resin structure of the invention and the appearance of the final products are improved. Moreover, further improvements are obtained with respect to the prevention of dropping-off of fiber filaments from the product, smooth operation in the impregnation step, and the production efficiency.