JP2013203432A - Package and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a package of a nonwoven fabric composed of a discontinuous carbon fiber, in which breaking of the nonwoven fabric or break of the carbon fiber are hardly generated in the nonwoven fabric composed of the discontinuous carbon fiber and which has high transportation efficiency by increasing bulk density at packing, and to provide a manufacturing method of the package.SOLUTION: In a package which can be handled as a freight by laminating two or more sheet materials 19 prepared by cutting a nonwoven fabric composed of a discontinuous carbon fiber and being packed in a compression state, the bulk density of the sheet material after compression is 7 to 75 kg/m.

Description

  In the present invention, a sheet-like product obtained by cutting a non-woven fabric composed of carbon fibers into a certain size is less susceptible to fiber breakage due to rubbing that occurs during handling or transportation, and the bulk density is increased to increase transportation efficiency. The present invention relates to a package and a packaging method thereof.

  Nonwoven fabric composed of discontinuous carbon fibers that is suitably used as a base material for molding fiber reinforced composite materials is excellent in specific strength and specific rigidity, such as electrical / electronic equipment parts, transportation equipment parts, etc. It has been used for various purposes. Such a non-woven fabric may be in the form of a sheet and is generally packed by roll winding. However, non-woven fabric composed of discontinuous carbon fibers has a low bulk density and cannot wind a sufficient length around the roll, resulting in a large space (dead space) that cannot be placed when the roll is loaded. There was a problem that the volumetric efficiency of the packaging was poor and the transportation cost was high. Moreover, when the bulk density is increased by increasing the winding tension of the roll winding, the nonwoven fabric is broken and the carbon fibers are damaged, and the handling property of the nonwoven fabric composed of discontinuous carbon fibers is deteriorated. . Under such circumstances, various studies have been made on such a method for packing a nonwoven fabric.

In Patent Document 1, in a compressed packing of glass fiber, a wool-like glass fiber aggregate (not a sheet) is packed in a bag after being compressed within a range of a bulk density of 80 to 135 kg / m ³ , so that It is described that it is possible to achieve an increase in storage and transport efficiency, and that a glass fiber package without fiber breakage and fiber adhesion is obtained. Here, as a glass fiber package, after compressing wooly glass fiber in the examples, it is mainly packed in a bag, but a sheet made by wet papermaking in the definition of a glass fiber aggregate is used. It is supposed to be included.

Patent literature 2 and patent literature 3, are described and their method bale of discontinuous reinforcing fibers as a nonwoven material, each of which bulk density ^{100~500kg / m 3, 630~690kg / m} 3 It is described within the range. Here, the compression packing object which patent document 2 and patent document 3 make object is a packing object of a short fiber, and there is no description regarding a sheet-like object.

In Patent Document 4, there is no description about compression packaging, but regarding the form of carbon fiber paper for use in porous materials for fuel cells, it is wound around a roll in a bulk density of 300 to 800 kg / m ^3. It is described that.

  Patent Document 5 describes a paper manufacturing method, and is based on roll winding as shown in the drawings. In addition, although there is a description that the papermaking base material is cut into a certain size and laminated, there is no description about a method for making the laminate into a compressed package or compressing and packing.

Thus, at least the bulk density of the fiber aggregate is 80 kg / m ³ or more, and if it is a sheet-like material made of carbon fiber, the bulk density is 300 kg / m ³ or more (Patent Document 4), and the low bulk density. The rolling of the sheet-like material was not described in any patent document.

JP 2008-265874 A JP 2001-278353 A JP 2005-171455 A International WO01-056103 JP 2011-157737 A

  The present invention is a discontinuous carbon fiber that can increase the bulk density of the package, increase the transport efficiency, and has excellent handling properties without breakage of the nonwoven fabric or damage of the carbon fiber, as compared with the conventional roll winding. The package of the nonwoven fabric comprised from these, and the manufacturing method of the package are provided.

In order to achieve the above object, the package and the manufacturing method thereof according to the present invention employ the following configurations.
(1) A packaged product in which a plurality of sheet-like materials obtained by cutting a nonwoven fabric composed of at least discontinuous carbon fibers are laminated, and the bulk density thereof is compressed within a range of 7 to 75 kg / m ³ . .
(2) A protective sheet and / or a protective plate are arranged on both surfaces of a laminate in which a plurality of the sheet-like materials are laminated, and the corners thereof are rounded so as to form an arc shape having a radius of 1 mm or more. Or a package according to (1), wherein a protective corner cover is disposed at a corner of the laminate.
(3) The package according to (1) or (2), wherein a release sheet is disposed between the sheet-like materials.
(4) The package according to any one of (1) to (3), wherein the entire package is fixed with a binding string.
(5) The package according to any one of (1) to (4), wherein the nonwoven fabric is formed by a papermaking method, an airlaid method, or a carding method.
(6) The basis weight of the non-woven fabric is in the range of 10 to 1000 g / m ² , and the unloaded thickness is in the range of 0.1 to 100 mm, according to any one of (1) to (5). Packing material.
(7) A non-woven fabric composed of at least discontinuous carbon fibers is formed, the non-woven fabric is cut into a sheet, a plurality of the sheets are laminated to form a laminate, and the bulk density is 7 to 75 kg / compressed to be within a range of m ^3, the production method of the shipping carton.
(8) The method for manufacturing a package according to (7), wherein the nonwoven fabric is formed by a papermaking method, an airlaid method, or a carding method, and the nonwoven fabric is cut online in the step.
(9) The package according to (7), wherein the nonwoven fabric is formed by a papermaking method, an airlaid method, or a carding method, wound on the nonwoven fabric roll in the step, and then cut off the nonwoven fabric offline. Production method.
(10) The protective sheet and / or the protective plate are disposed on both surfaces of the laminate, and the corners thereof are rounded so as to form an arc shape having a radius of 1 mm or more, or at the corners of the laminate. The method for manufacturing a package according to any one of (7) to (9), wherein a protective corner cover is disposed.
(11) The method for manufacturing a package according to any one of (7) to (10), wherein a release sheet is disposed between the sheet-like objects.
(12) The method for manufacturing a package according to any one of (7) to (11), wherein the entire package is fixed with a binding string.

According to the present invention, the sheet-like material obtained by cutting the nonwoven fabric composed of discontinuous carbon fibers is configured as a compressed package having a bulk density in the range of 7 to 75 kg / m ^3. Compared to winding, the bulk density and volumetric efficiency of the package can be increased to improve transportation efficiency, achieve stable quality without tearing due to the difference in circumference between the inner and outer layers, and reduce drapeability. It is possible to provide a non-woven fabric compressed package made of carbon fibers excellent in handleability and a method for producing the same.

It is a model figure which shows an example of the package form which concerns on this invention. It is a model figure which shows an example of the apparatus which manufactures the nonwoven fabric of the discontinuous carbon fiber used for this invention.

  Hereinafter, the present invention will be described with reference to the drawings. In addition, this invention is not restrict | limited at all by these drawings.

In the present invention, a plurality of sheet-like materials 19 obtained by cutting a nonwoven fabric 16 composed of discontinuous carbon fibers 7 are laminated, and the bulk density of the laminate 1 is compressed within a range of 7 to 75 kg / m ³ . It is a package.

  The non-woven fabric 16 composed of the discontinuous carbon fibers 7 of the present invention is a cloth formed by intertwining the discontinuous carbon fibers 7, for example, while mechanically combing the discontinuous carbon fibers 7. Entangling is achieved by paper making by dispersing discontinuous carbon fiber 7 in a solvent such as water, dry nonwoven fabric manufactured by carding method that forms entanglement, airlaid method that uses air flow to form entanglement, etc. Although there are wet nonwoven fabrics to be formed, it is not particularly limited.

  Carbon fibers can be used as the fibers constituting the laminate 1 of the sheet-like material 19 of the nonwoven fabric 16 of the present invention. A fiber-reinforced composite material in which a nonwoven fabric 16 composed of discontinuous carbon fibers 7 is integrated with a resin as a molding substrate is lightweight and excellent in mechanical properties, and can reduce the weight of parts such as aircraft and automobile members. It can be done.

  The carbon fiber used in the present invention is preferably a carbon fiber having a tensile elongation at break of 0.6% or more. When the tensile elongation at break is less than 0.6%, fiber breakage of carbon fibers may occur during compression packaging and transportation, and fluffing may occur after opening the compression packaging. From the viewpoint of fluffing after opening the compressed package, the tensile elongation at break is preferably 1.2% or more, more preferably 1.5% or more, and particularly preferably 1.8% or more. There is no upper limit to the tensile elongation at break of the carbon fiber used in the present invention, but it is generally less than 5%.

  Examples of the carbon fiber used in the present invention include polyacrylonitrile (PAN), pitch, and cellulose. Among these, PAN-based carbon fibers that are excellent in strength, elastic modulus, elongation, and the like are preferable. Examples of the spinning method of the PAN-based carbon fiber include wet spinning and dry wet spinning, and any spinning method can be selected depending on desired characteristics.

  As the discontinuous carbon fiber 7 used in the present invention, the fiber length of the carbon fiber is preferably from 1 to 150 mm, more preferably from the viewpoint of the reinforcement efficiency of the resin by the reinforcing fiber of the nonwoven fabric, and the manufacturing process passability. It is 2-100 mm, More preferably, it is 3-50 mm. The fiber length of the discontinuous carbon fibers 7 is obtained by randomly extracting at least 400 carbon fibers in the nonwoven fabric 16 and measuring the length to 1 μm unit with an optical microscope or a scanning electron microscope. This is done by calculating the average length. Examples of the carbon fiber extraction method include a method in which a part of the nonwoven fabric is cut out and the resin component adhering to the nonwoven fabric 16 is removed by incineration in a heating furnace to extract the carbon fiber.

In the package of the present invention, a plurality of sheet-like materials 19 obtained by cutting the nonwoven fabric 16 composed of discontinuous carbon fibers 7 described above are laminated, and the bulk density of the laminate 1 is 7 to 75 kg / m ^3. It is compressed within the range. The non-woven fabric 16 made of discontinuous carbon fibers 7 is cut into a predetermined size to obtain a sheet-like material 19, and a plurality of the sheet-like materials 19 are stacked and compressed to increase the volume efficiency occupied by the sheet-like material 19 in the package. It is possible to improve the transportation efficiency when transporting the nonwoven fabric by a general transportation means such as a truck. When the bulk density of the laminate 1 is less than 7 kg / m ³ , the transport efficiency of the compressed package is lowered, which is inappropriate. When the bulk density exceeds 75 kg / m ³ , carbon fiber breakage occurs due to compression packaging, and after the package is opened, it becomes fuzzy, and the handling of the sheet-like material 19 is unsuitable.

  The bulk density of the present invention refers to the outermost surface of the non-woven sheet 19 located on the top of the stack from the horizontal base surface by placing the laminate 1 on which the non-woven fabric 16 sheet 19 cut to a predetermined size is laminated. The height in the vertical direction is randomly measured with calipers at five points, and the volume is calculated from the stacking height obtained by averaging them, and is obtained by dividing from the total weight of the stack 1.

  The number of stacked sheets 19 is not particularly limited, but the height of the package of the present invention is preferably the number that can be transported by a general transportation means such as a truck.

  When the laminate 1 in which a plurality of sheet-like materials 19 are stacked is compressed and packed, the outermost sheet-like material may become fuzzy. Therefore, the protective sheets 2 are arranged on both surfaces of the laminate 1 to suppress fuzziness. It is also preferable. Examples of the protective sheet 2 include a resin film and paper, but are not particularly limited.

  When the laminate 1 in which a plurality of sheet-like materials 19 are stacked is compressed and packed, the sheet-like material 19 may be broken or damaged by the compressive force. Therefore, the protective plates 3 are arranged on both surfaces of the laminate 1. It is also preferable to suppress the breakage of the sheet-like material 19. Examples of the protective plate 3 include, but are not limited to, a metal plate such as a resin plate, a resin honeycomb board, a foamed resin board, and an aluminum plate, a woody plywood such as a veneer plate, and cardboard. Further, from the viewpoint of strength that can withstand the compressive force, the thickness of the protective plate 3 is preferably 1 to 30 mm, and more preferably 1 to 20 mm, because the weight of the protective plate 3 can be reduced.

  Since the protective sheet 2 and the protective plate 3 disposed on both surfaces of the laminate 1 in which a plurality of the sheet-like objects 19 are stacked may damage the sheet-like object 19 at the corners, for example, the protective sheet 2 and the protective plate 3. It is preferable to chamfer the corner R so that the corner R has an arc shape with a radius of 1 mm or more, or to dispose a protective corner cover on the corner R of the laminate 1. If the corner portion R has an arc shape with a radius of 150 mm or more, it may be damaged when it comes into contact with the sheet-like material, which is not preferable. More preferably, the radius is 0.1 mm to 100 mm, and still more preferably the radius is 0.1 mm to 50 mm. Here, the corners of the protective sheet 2, the protective plate 3, and the laminate 1 are the four corners of the protective sheet 2, the protective plate 3, and the laminate 1 and the edges connected by the four corners. . In addition, examples of the protective corner cover include, but are not particularly limited to, an L-shaped angle bracket made of polystyrene and corrugated cardboard that is used as a cushioning material when packing general household electrical appliances.

  When the laminate 1 in which a plurality of the sheet-like materials 19 are laminated is compressed and packed, the sheet-like materials 19 laminated by the compressive force are not easily separated from each other, and fluffing may occur after the package is opened. It is also preferable to arrange a release sheet between the layers of the sheet-like material 19 to suppress fuzz after the package is opened. As a release sheet, for example, a release sheet formed of a film made of a fluorine resin or polymethylpentene having excellent release properties and heat resistance, release properties on the surface of a substrate such as paper or a resin film A release sheet, a nonwoven fabric, a film, a mat, a mesh, a woven fabric, a knitted fabric, etc., laminated with an excellent silicone resin, can be used, but the sheet is not particularly limited as long as it is a sheet.

  In a package that compresses a laminate 1 in which a plurality of sheet-like materials 19 are stacked, the compressed laminate 1 may be restored to its original height, and therefore the height direction is fixed to maintain the compressed state of the laminate 1. It is also preferable. The fixing method is not particularly limited. For example, there is a method in which an elastic film such as polyethylene or polypropylene is fixed around the laminate 1 or is fixed with a binding string 4 such as a string or a resin binding band. is there. Among them, the method of fixing with the tie cord 4 is a preferable method because the compression state can be maintained for a long time even when the compression force is high.

  When the laminate 1 is fixed by such a method, or when transported by a general transportation means such as a truck, the sheet-like material 19 may be broken or damaged due to contact with other packages. It is preferable that the entire package is further covered with a wrapping film 5 so that the laminate 1 does not come into direct contact with fixing means or other packages. Examples of the wrapping film 5 include a resin film, an air cap, and paper, but are not particularly limited.

Basis weight of the discontinuous sheet 19 comprised a nonwoven fabric 16 of carbon fiber 7 is preferably 10 to 1000 g / ^{m 2,} more preferably 30~800g / ^{m 2,} more preferably 50～600G / a m ^2. When it is less than 10 g / m ² , when the sheet-like material 19 is taken out after opening the package, the low-weight sheet-like material 19 may cause a problem in handling such as tearing. If it exceeds 1000 g / m ² , the cut portion of the nonwoven fabric 16 may be broken.

  The unloaded thickness of the sheet 19 of the nonwoven fabric 16 composed of discontinuous carbon fibers 7 is preferably 0.1 to 100 mm, more preferably 0.3 to 60 mm, and 0.5 to 30 mm. Is more preferable. When the thickness is less than 0.1 mm, when the sheet-like material 19 is taken out after opening the package, the sheet-like material 19 may be broken, resulting in problems in handling. If it exceeds 100 mm, the cut portion of the nonwoven fabric 16 may be broken.

  In the description so far, the nonwoven fabric composed of discontinuous carbon fibers has been described. However, the nonwoven fabric 16 composed of the discontinuous carbon fibers 7 has a metal fiber, an organic fiber, The nonwoven fabric may be a combination of two or more types with inorganic fibers. The fiber to be combined is not particularly limited. For example, the metal fiber is a fiber made of metal such as aluminum, brass, and stainless steel, and the organic fiber is an aramid resin, polyphenylenebenzoxazole (PBO) resin, polyphenylene sulfide resin, polyester. Examples of fibers and inorganic fibers made of an organic material such as resin, acrylic resin, nylon resin, polypropylene resin, and polyethylene resin include fibers made of an inorganic material such as glass, basalt, silicon carbide, and silicon nitride.

  From the viewpoint of improving the handleability of the nonwoven fabric 16, the nonwoven fabric 16 composed of discontinuous carbon fibers 7 may be added with a binder for fixing the carbon fibers. As binders to be combined, starch, acrylamide resin, polyvinyl alcohol resin, water-soluble acrylic resin, water-soluble aldehyde resin and other liquid binders, polyester fibers, acrylic fibers, nylon fibers, polypropylene fibers, polyethylene fibers, and cores made of these organic materials Examples thereof include fibrous binders such as sheath fibers.

In the method for manufacturing a package according to the present invention, a nonwoven fabric 16 composed of discontinuous carbon fibers 7 is formed, and then the nonwoven fabric 16 is cut into a sheet-like material 19, and then this sheet-like material is laminated in a plurality of layers. Thus, the laminate 1 is further compressed so that the bulk density is within the range of 7 to 75 kg / m ³ .

  As described above, the method for forming the nonwoven fabric 16 composed of the discontinuous carbon fibers 7 of the present invention uses, for example, a carding method for forming a nonwoven fabric while mechanically scraping the discontinuous carbon fibers, and an air flow. There is a dry method such as an airlaid method for forming a nonwoven fabric, and a wet method (for example, a papermaking base material) for forming a nonwoven fabric by dispersing and making discontinuous carbon fibers in a solvent such as water. Is not to be done. Here, when a wet type or airlaid type non-woven fabric is used, the non-woven fabric is bulky (because the bulk density is low), so that the effects of the packing form and the package manufacturing method of the present invention can be maximized. This is one of the most preferred embodiments. On the other hand, when using a carded nonwoven fabric, the nonwoven fabric is less bulky than the wet method or airlaid method (because the bulk density is high), so the effect is not significant, but its usefulness is clear. I can say that. From another viewpoint, when a carding type or airlaid type non-woven fabric is used, there is a feature that the basis weight (weight per unit area) of the carbon fiber can be made relatively larger than that of the wet type. Such a high-weight nonwoven fabric can be said to be one of the other most preferable modes that can maximize the effects of the packing form and the manufacturing method of the packing body of the present invention.

  Examples of the method for cutting the nonwoven fabric 16 of the present invention include, but are not limited to, a guillotine blade, a roller blade, a pulling blade, and a rotary blade. The cutting of the nonwoven fabric 16 of the present invention can be performed by online cutting into a sheet shape in the above-described forming process of the nonwoven fabric 16, or after being wound around a roll once in the above-described forming process of the nonwoven fabric and then cutting into a sheet shape offline. good. Among these, when the nonwoven fabric 16 is thick and wound on a roll and the nonwoven fabric 16 is torn due to a difference in peripheral length between the inner and outer layers, it is preferable to cut the sheet into a sheet 19. Moreover, when the formation speed of the nonwoven fabric 16 is fast and the thickness of the nonwoven fabric is thin, it is preferable that the sheet-like material 19 with good dimensional accuracy can be obtained by winding it once on a roll and then cutting it off-line.

A method of compressing the laminate 1 by, for example, laminating a plurality of sheets 19 of the present invention into a laminate 1 is a method of compressing the laminate 1 by applying a weight, for example, applying a mechanical load to the laminate 1. Examples thereof include a method of compressing, a method of compressing by placing and tying the binding string 4 on the laminate 1, or a method combining these methods, but the bulk density of the laminate 1 is in the range of 7 to 75 kg / m ³ . It is not particularly limited as long as it can be compressed.

  Next, although the Example of this invention is described in detail with a comparative example, this invention is not limited to these Examples.

<Bulk density of discontinuous carbon fiber nonwoven fabric compressed and packed>
Using a ruler, the height of the laminate 1 was measured at three points on each side (12 points in total) at random on the four sides around the package, and the average value was defined as the height H1 (mm) of the package. . The thickness of the protective plate 3 used in the package was randomly measured with calipers at five points, and the average value was defined as the thickness H2 (mm) of the protective plate 3. The number of the protective plates 3 used in the package was counted, and the number of the laminated plates was M2 (sheets). The thickness of the protective sheet 3 used for the package was measured at five random points with a micrometer, and the average value was defined as the thickness H3 (mm) of the protective sheet 3. The number of laminated protective sheets 3 used in the package was counted, and the number of laminated sheets was M3 (sheet).

  Next, the compressed package was unpacked, the packed discontinuous carbon fiber nonwoven fabrics were all removed, and the weight W1 (kg) was measured. Further, the width and length of the discontinuous carbon fiber non-woven fabric packed were measured at a random 5 points each with a ruler, and the average values were defined as width A1 (mm) and length B1 (mm).

The bulk density ρ (kg / m ³ ) was calculated by the following formula using H1, H2, H3, W1, A1, and B1 measured as described above.
・ Height of discontinuous carbon fiber nonwoven fabric H4 (mm) = H1-M2 × H2-M3 × H3
Bulk density ρ (kg / m ³ ) = W1 / (H4 × A1 × B1) × 1,000,000

<Transport efficiency of discontinuous carbon fiber nonwoven fabric>
The width and length of the package were measured at a random 5 points each with a ruler, and the average values were defined as the width A2 (m) and the length B2 (m) of the package. Next, the size of the loading area X of the 10 ton truck is 10 m in length, 2.3 m in width, and 2 m in height, the maximum number N4 of packages that can be loaded therein, and the discontinuous carbon fiber nonwoven fabric The load amount V was calculated by the following formula.
・ The number of loads in the length direction N1 (pieces) = 10 / A2 (rounded down)
・ Width stacking number N2 (pieces) = 10 / B2 (rounded down)
・ Width stacking number N3 (pieces) = 10 / H1 (rounded down to the nearest decimal place)
・ Maximum number of packages N4 (pieces) = N1 x N2 x N3
・ Loading capacity V (kg) = W1 x N4
Based on this load capacity V (kg), the transport efficiency was determined according to the following criteria.
AA: Loading capacity V is 1000 kg or more A: Loading capacity V is 300 kg or more B: Loading capacity V is 150 kg or more C: Loading capacity V is less than 150 kg

<Carbon fiber breakage during compression>
The compressed package is unpacked, the sheet 19 of the discontinuous carbon fiber nonwoven fabric 16 packed is taken out, cut into 80 mm squares with a cutter, and a plurality of the cut samples are stacked to obtain a laminate A having a height of 80 ± 10 mm. It was created. Next, the weight W2 (kg) of the laminate A is measured to two digits after the decimal point. Subsequently, the height H5 (m) of the laminate A having the above bulk density ρ (kg / m ³ ) was calculated from the following equation.
・ H5 (m) = W2 / (ρ × 0.08 × 0.08)

Next, in accordance with ASTM-D695 (1997), the laminate A is compressed using two parallel compression platens (φ150 mm), and when the distance between the platens reaches H5 (m), The load was removed and Laminate A was removed from the platen. Thereafter, the platen surface on which the compression test was performed was visually confirmed, and carbon fiber breakage was determined according to the following criteria.
○: Broken carbon fiber cannot be confirmed ×: Broken carbon fiber can be confirmed

<Ease of handling when unpacking>
The handling property when unpacking the compressed package and taking out all the sheet-like materials 19 of the discontinuous carbon fiber nonwoven fabric 16 packed one by one was determined according to the following criteria.
○: No breakage occurs in the sheet-like material 19 of the discontinuous carbon fiber nonwoven fabric 16 ×: Breakage occurs in the sheet-like material 19 of the discontinuous carbon fiber nonwoven fabric 16

(Reference Example 1) Carbon fiber A
Spinning, firing treatment, and surface oxidation treatment were carried out from a copolymer containing polyacrylonitrile as a main component to obtain continuous carbon fibers having a total number of 12,000 single yarns. The characteristics of this continuous carbon fiber were as follows.
Single fiber diameter: 7μm
Mass per unit length: 1.6 g / m
Specific gravity: 1.8
Tensile strength: 4600 MPa
Tensile modulus: 220 GPa.
Tensile elongation: 2.1%

(Reference Example 2) Binder A
As the binder A, a binder (JF-05) manufactured by Nippon Vinegar Poval Co., Ltd. was used.

Example 1
A papermaking substrate was produced using the apparatus shown in FIG. The configuration of the apparatus shown in FIG. 2 was as follows. As the papermaking tank 6, a large square sheet machine (No. 2553-I (trade name) manufactured by Kumagai Riki Kogyo Co., Ltd.) is provided, and the bottom of the papermaking tank 6 has a papermaking surface 9 having a width of 500 mm. 10 was installed. At the end of the papermaking tank 6, a conveyor 12 that conveys the papermaking base material 11 is provided connected to the mesh conveyor 10. A mesh coater 10 is provided with a curtain coat type binder applicator 13 above the conveyor 12 and a dryer 14. It was connected to the conveyor 15. Further, the end point portion of the apparatus was provided with a cutting machine 17 composed of a guillotine blade capable of cutting the nonwoven fabric 16 of the dried papermaking base material, and a nip roller 18 for gripping the papermaking base material.

  The carbon fiber A obtained in Reference Example 1 was cut to 3 mm with a cartridge cutter to obtain discontinuous carbon fibers 7. A dispersion medium 20 having a concentration of 0.1% by mass consisting of water and a surfactant (manufactured by Nacalai Tex Co., Ltd., polyoxyethylene lauryl ether (trade name)) is continuously supplied to the papermaking tank 6 at a feed rate of 1125 kg / min. While being supplied, the discontinuous carbon fiber 7 was continuously charged at a charging rate of 0.225 kg / min, and a slurry having a solid component concentration of 0.02 wt% was adjusted in the papermaking tank 6. Next, the dispersion medium was sucked and removed by the papermaking surface 9 provided in the papermaking tank 6, and was rolled up by the mesh conveyor 10 to obtain a papermaking substrate 11.

  The obtained papermaking substrate 11 was placed on a conveyor 12 and a 3 mass% aqueous solution of binder A (Reference Example 2) was applied at a supply rate of 1.70 kg / min with a binder application device 13. Next, the papermaking base material to which the binder has been applied is passed through the dryer 14 at 200 ° C. by the conveyor 15, and then the non-woven fabric 16 of the papermaking base material is 0.75 m long on-line with a cutting machine comprising a guillotine blade. The laminate 1 was obtained by laminating the sheet-like material 19 that was further cut into layers. The take-up speed at this time was 3 m / min.

The resulting papermaking substrate had a basis weight of 157 g / m ² (carbon fiber basis weight: 150 g / m ² ) and an effective width of 500 mm. 330 sheets of this papermaking substrate were produced and then laminated to obtain a laminate 1.

  Next, the packing method will be described. A protective sheet 2 (manufactured by Tatsuta Chemical Co., Ltd., High Crystal (trade name)) cut into a width of 500 mm, a length of 750 mm, and a thickness of 100 μm is arranged as a protective sheet on the front and back of the obtained laminate 1. A protective plate 3 (manufactured by Okochi Metals Co., Ltd., A2017P-T3 (trade name)) cut to a width of 500 mm, a length of 750 mm, and a thickness of 3 mm was disposed as a protective plate. In addition, the protection board 3 used what processed the corner | angular part of 4 corners so that it might become circular arc shape with a radius of 35 mm.

  Next, a 60 kg weight is placed on the protective plate 3, the laminate 1 is compressed in the height direction, and the laminate 1 having the protective sheet 2 and the protective plate 3 arranged thereon is bound with a binding string 4 (manufactured by Sekisui Resin Co., Ltd., 15.5BX (trade name)) was used to fix the laminate 1 in a compressed state and remove the weight. Subsequently, the entire laminate fixed with the binding string 4 is wrapped with the polyethylene wrapping film 5 (manufactured by Prime Polymer Co., Ltd., Hi-Zex (trade name)), and the non-woven fabric made of discontinuous carbon fibers is packed. I got a thing.

(Example 2)
A non-woven fabric composed of discontinuous carbon fibers in the same manner as in Example 1 except that 250 papermaking base materials were produced to form a laminate 1 and a 6 kg weight was placed on the protective plate 3. I got a package.

(Example 3)
A non-woven fabric composed of discontinuous carbon fibers in the same manner as in Example 1 except that 400 papermaking base materials were manufactured to form a laminate 1 and a weight of 240 kg was placed on the protective plate 3. I got a package.

Example 4
The feed rate of the dispersion medium 20 is 3750 kg / min, the feed rate of the discontinuous carbon fiber 7 is 0.75 kg / min, the feed rate of the 3% by weight aqueous solution of binder A is 5.65 kg / min, and the basis weight is 525 g / m ^2. Constructed from discontinuous carbon fibers in the same manner as in Example 1 except that a papermaking base material (carbon fiber basis weight: 500 g / m2) was obtained and 30 papermaking base materials were produced to form a laminate 1. A non-woven package was obtained.

(Example 5)
A non-woven fabric composed of discontinuous carbon fibers in the same manner as in Example 4 except that 45 papermaking base materials were produced to form a laminate 1 and a 6 kg weight was placed on the protective plate 3. I got a package.

(Example 6)
A non-woven fabric composed of discontinuous carbon fibers in the same manner as in Example 4 except that 65 papermaking base materials were produced to form a laminate 1 and a weight of 240 kg was placed on the protective plate 3. I got a package.

(Example 7)
Except that the dried paper base material was wound up in an 8 inch paper tube (outer diameter 230 mmφ, length 700 mm), and then the wound paper base material was cut into a length of 750 mm with a cutter, as in Example 5. A non-woven package composed of discontinuous carbon fibers was obtained.

(Example 8)
An air laid base material having a carbon fiber basis weight of 150 g / m ² was obtained by the air laid system. The obtained air-laid substrate was placed on the conveyor 12, and a 3 mass% aqueous solution of binder A (Reference Example 2) was applied at a supply rate of 1.70 kg / min. Next, the air-laid base material to which the binder has been applied is passed through the dryer 14 at 200 ° C. by the conveyor 15, and then the air-laid base material 16 of the air-laid base material 16 is 0.75 m on-line with a cutting machine comprising a guillotine blade. The laminate 1 was obtained by laminating the sheet-like material 19 that was further cut into layers. The take-up speed at this time was 3 m / min. The obtained airlaid substrate had a basis weight of 157 g / m ² (carbon fiber basis weight: 150 g / m ² ) and an effective width of 500 mm.

  200 non-woven fabrics of air-laid base materials were packed by the same packing method as in Example 1 to obtain a packed product of non-woven fabric composed of discontinuous carbon fibers.

Example 9
A carding base material having a carbon fiber basis weight of 150 g / m ² was obtained by the carding method. The obtained carding substrate was placed on the conveyor 12, and a 3% by mass aqueous solution of binder A (Reference Example 2) was applied at a supply rate of 1.70 kg / min with a binder application device 13. Next, the carding base material to which the binder has been applied is passed through the dryer 14 at 200 ° C. by the conveyor 15, and then the non-woven fabric 16 of the carding base material has a length of 0 on-line with a cutting machine comprising a guillotine blade. The laminate 1 was obtained by laminating the sheet-like material 19 which was cut to .75 m and further cut. The take-up speed at this time was 3 m / min. The obtained carding substrate had a basis weight of 157 g / m ² (carbon fiber basis weight: 150 g / m ² ) and an effective width of 500 mm.

  400 carded nonwoven fabrics were packed by the same packing method as in Example 1 to obtain a nonwoven fabric package composed of discontinuous carbon fibers.

(Comparative Example 1)
A non-woven fabric package composed of discontinuous carbon fibers was obtained in the same manner as in Example 4 except that 11 papermaking base materials were produced to form the laminate 1 and the packaging process was not performed.

(Comparative Example 2)
The supply rate of the dispersion medium 20 is 60 kg / min, the discontinuous carbon fiber 7 is supplied at a rate of 0.012 kg / min, the feed rate of a 3% by weight aqueous solution of binder A is 0.09 kg / min, and the basis weight is 8.4 g / min. Discontinuous carbon fibers in the same manner as in Example 3 except that a papermaking base material with m ² (carbon fiber basis weight: 8 g / m2) was obtained and 10,000 papermaking base materials were produced to form a laminate 1. A non-woven fabric package comprising:

(Comparative Example 3)
A non-woven fabric composed of discontinuous carbon fibers in the same manner as in Example 1 except that 490 papermaking base materials were manufactured to form a laminate 1 and a weight of 330 kg was placed on the protective plate 3. I got a package.

  Table 1 shows the evaluation results of the non-woven fabric package composed of the discontinuous carbon fibers obtained above.

  As apparent from Table 1, Examples 4 to 6 and Comparative Example 1 revealed that the transport efficiency of the discontinuous carbon fiber nonwoven fabric can be increased by compression packaging.

From Examples 1 to 3 and Comparative Examples 2 and 3, it is clear that by setting the bulk density to 7 to 75 kg / m ³ , there is no fiber breakage during compression or tearing during unpacking, and transport efficiency can be increased. It was.

  From Examples 1 and 7, it has become clear that whether the cutting is performed online or offline, the transportation efficiency can be improved by compressing and packing.

  Non-woven fabric composed of discontinuous carbon fibers obtained in the present invention, as a molding substrate such as carbon fiber reinforced thermoplastic resin, carbon fiber reinforced thermosetting resin or carbon fiber reinforced carbon material, electrical and electronic equipment parts, It can be used for various applications such as civil engineering / architectural parts, automobile / motorcycle parts, aerospace parts, fuel cells and the like.

DESCRIPTION OF SYMBOLS 1 Laminate 2 Protective sheet 3 Protective plate 4 Binding string 5 Wrapping film 6 Papermaking tank 7 Discontinuous carbon fiber 8 Stirrer 9 Papermaking surface 10 Mesh conveyor 11 Papermaking base material 12 Conveyor 13 Binder application device 14 Dryer 15 Conveyor 16 Nonwoven fabric 17 (a) Cutting machine upper blade 17 (b) Cutting machine lower blade 18 Roller 19 Sheeted material 20 of cut nonwoven fabric Dispersion medium

Claims (12)

A package comprising a plurality of sheet-like materials obtained by cutting a nonwoven fabric composed of at least discontinuous carbon fibers, and compressed in a range of 7 to 75 kg / m ^{3 in} bulk density. A protective sheet and / or a protective plate are disposed on both surfaces of the laminate in which a plurality of the sheet-like materials are laminated, and the corners thereof are rounded so as to form an arc shape having a radius of 1 mm or more, or The package according to claim 1, wherein a protective corner cover is disposed at a corner of the laminate. The package according to claim 1 or 2, wherein a release sheet is disposed between the sheet-like materials. The package according to any one of claims 1 to 3, wherein the entire package is fixed with a binding string. The package according to any one of claims 1 to 4, wherein the nonwoven fabric is formed by a papermaking method, an airlaid method, or a carding method. The basis weight of the nonwoven fabric is in the range of 10 to 1000 g / ^{m 2,} the thickness of the no-load is in the range of 0.1~100mm thickness, packing article according to claim 1. A nonwoven fabric composed of at least discontinuous carbon fibers is formed, the nonwoven fabric is cut into a sheet-like material, a plurality of the sheet-like materials are laminated to form a laminate, and a bulk density is 7 to 75 kg / m ³ . A method of manufacturing a package that compresses to be within the range. The method for producing a package according to claim 7, wherein the nonwoven fabric is formed by a papermaking method, an airlaid method, or a carding method, and the nonwoven fabric is cut online in the step. The method for producing a package according to claim 7, wherein the nonwoven fabric is formed by a papermaking method, an airlaid method, or a carding method, wound on the nonwoven fabric roll in the step, and subsequently cut off the nonwoven fabric offline. Protective sheets and / or protective plates are disposed on both surfaces of the laminate, and the corners thereof are rounded so as to form an arc shape having a radius of 1 mm or more, or protective corner covers are provided at the corners of the laminate. The manufacturing method of the package in any one of Claims 7-9 which arrange | positions. The manufacturing method of the package in any one of Claims 7-10 which arrange | positions a release sheet between the said sheet-like objects. The manufacturing method of the package in any one of Claims 7-11 which fixes the whole package with a binding string.

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