JP2014205287A - Method for manufacturing seat molding compound and impregnation machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing an SMC (seat molding compound) capable of effectively de-foaming residual bubble in SMC, and enhancing content of reinforcement fiber material.SOLUTION: SMC material 5 continuously transported and comprising a resin compound 1 and reinforcement fiber material 2 is applied with pressure from both face sides of the SMC material 5 from an upstream to a downstream in a transportation direction in this order from the center of a width direction toward the outside of the width direction of the SMC material 5.

Description

  The present invention relates to a method for manufacturing a sheet molding compound and an impregnation machine.

  A sheet molding compound (hereinafter referred to as SMC) having a resin compound and a reinforcing fiber material such as glass fiber is manufactured, for example, as shown in FIG. 4 (see, for example, Patent Document 1).

  Long films 82 and 83 are supplied from two unwinding rolls 80 and 81, respectively, and a paste-like resin compound 84 is supplied and applied on each of the films 82 and 83. The reinforcing fiber material 85 is sprayed on the resin compound 84 of one film 82, and the application surface of the resin compound 84 of the other film 83 is aligned thereon. As a result, a long SMC sheet 87 in which the SMC material 86 having the resin compound 84 and the reinforcing fiber material 85 is sandwiched between the two films 82 and 83 is obtained. Next, the SMC sheet 87 is conveyed to the impregnation machine 90, the residual bubbles in the SMC material 86 are defoamed, and the resin compound 84 is impregnated between the reinforcing fiber materials 85. In this way, SMC is manufactured.

  The defoaming of residual bubbles in the SMC material 86 by the impregnation machine 90 is performed by passing the SMC sheets 87 through the gaps between the pressure rolls 91 arranged alternately above and below the SMC sheets 87 as shown in FIGS. Done. More specifically, the residual in the SMC material 86 as shown in FIG. 6 due to the sliding pressure resulting from the linear pressure of the entire length in the width direction of the SMC sheet 87 and the thickness difference in the SMC sheet conveyance direction by the pressure roll 91 of the impregnation machine 90. The bubble A is moved outward in the width direction. Defoaming is performed by the residual bubbles A escaping to the outside of the SMC material 86.

JP-A-8-66930

  In the impregnation machine 90, the defoaming effect of the residual bubbles A in the SMC material 86 by the pressure roll 91 arranged on the most upstream side in the SMC sheet conveying direction is great. However, in the pressure roll 91 arranged on the downstream side in the SMC sheet conveyance direction, even if a linear pressure is applied to the SMC sheet 87, the remaining bubbles A in the SMC material 86 are difficult to escape to the outside of the SMC material 86. There is. This is because the SMC sheet 87 is pressurized by the pressure roll 91 disposed on the upstream side, and the SMC material 86 and the films 82 and 83 are more firmly adhered to each other. When the residual bubbles A in the SMC material 86 cannot be escaped from the SMC material 86, the resin compound 84 cannot be effectively impregnated between the reinforcing fiber materials 85. As a result, the content of the reinforcing fiber material 85 in the SMC material 86 cannot be increased, and the strength of the molded body manufactured using the SMC material 86 cannot be increased.

  The present invention has been made in view of the circumstances as described above, and it is possible to more effectively degas the residual bubbles in the SMC material and to increase the content of the reinforcing fiber material. It is an object to provide a manufacturing method and an impregnation machine.

  In order to solve the above-described problem, the SMC manufacturing method of the present invention includes a SMC material having a resin compound and a reinforcing fiber material that are continuously conveyed, the center in the width direction of the SMC material from upstream to downstream in the conveyance direction. A sheet molding compound is obtained by pressing from both sides of the SMC material in order toward the outer side in the width direction and impregnating the resin compound between the reinforcing fiber materials.

  In this SMC manufacturing method, the SMC material is compressed before, after, or before and after pressurizing the SMC material from the upstream to the downstream in the transport direction from the center in the width direction toward the outside in the width direction. It is preferable to apply linear pressure to the entire length in the width direction from both sides of the material.

  The impregnating machine of the present invention is an impregnating machine for impregnating the resin compound between the reinforcing fiber materials by pressurizing the SMC material having the resin compound and the reinforcing fiber material continuously conveyed from both sides. A pair of upper and lower first pressure rolls sandwiching the conveyed SMC material, the pair of upper and lower first pressure rolls in the width direction, and the plurality of pairs of first pressure rolls are the SMC material. The roll axis of the first pressure roll that is arranged from one end in the width direction to the other end in the width direction and arranged on the end in the width direction of the SMC material is arranged adjacent to the inner side in the width direction. The first pressurizing roll is shifted in the transport direction of the SMC material from the roll axis of the first pressure roll.

  In this impregnation machine, a second pressure roll having at least a length corresponding to the entire length in the width direction of the SMC material is further provided in the front stage, the rear stage, or both of the first pressure roll, The two pressure rolls are preferably arranged on the upper side and the lower side of the SMC material.

  According to the present invention, residual bubbles in the SMC material can be more effectively degassed, and the content of the reinforcing fiber material can be increased.

It is a schematic diagram which shows one Embodiment of the manufacturing process of SMC of this invention. It is a schematic diagram for demonstrating the impregnation of the SMC sheet by an impregnation machine in the manufacturing process of SMC of FIG. It is a schematic diagram for demonstrating defoaming of the residual bubble in SMC material. It is a schematic diagram which shows one Embodiment of the manufacturing process of the conventional SMC. It is a schematic diagram for demonstrating the impregnation of the SMC sheet by an impregnation machine in the manufacturing process of SMC of FIG. It is a schematic diagram for demonstrating defoaming of the residual bubble in SMC material.

  Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a schematic view showing an embodiment of the production process of the SMC of the present invention.

  SMC is manufactured as follows. First, a resin compound 1 and a reinforcing fiber material 2 as raw materials for SMC are prepared.

  The resin compound 1 is obtained as follows. If necessary, add a curing agent, polymerization inhibitor, polymerizable monomer, low shrinkage agent, inorganic filler, internal release agent, etc. to a base resin such as unsaturated polyester, and stir and mix to paste Next, a thickener is added to the resin mixture to obtain a resin compound 1. The obtained resin compound 1 is put into the dip pans 13 and 14.

  Here, the following thermosetting resin is used as the unsaturated polyester as the base resin. For example, it can be obtained by a condensation reaction of an unsaturated or saturated polycarboxylic acid such as an aliphatic unsaturated polycarboxylic acid, aliphatic saturated polycarboxylic acid or aromatic polycarboxylic acid with an organic polyol such as diol, triol or tetraol. Thermosetting resin. This thermosetting resin may have an unsaturated monomer such as a vinyl monomer dissolved therein.

  Examples of the aliphatic unsaturated polycarboxylic acid include (anhydrous) maleic acid and fumaric acid. Examples of the aliphatic saturated carboxylic acid include sepacic acid, (anhydrous) succinic acid, adipic acid and the like. Examples of the aromatic polycarboxylic acid include (anhydrous) phthalic acid, isophthalic acid, terephthalic acid and the like. Examples of organic polyols include aliphatic polyols and aromatic polyols. Examples of the aliphatic polyol include ethylene glycol, propylene glycol, dipropylene glycol, butylene glycol, triethylene glycol, neopentyl glycol, trimethylene glycol, glycerin, hydrogenated bisphenol A, and the like. Examples of the aromatic polyol include bisphenol A and bisphenol S. Two or more of the above-described polycarboxylic acids and organic polyols may be mixed and used.

  As the curing agent, for example, a high temperature curing catalyst for molding SMC under a high temperature and pressure of 100 ° C. or higher can be used. Examples of the high temperature curing catalyst include methyl ethyl ketone peroxide, t-butyl peroxy 2-ethyl hexanate, benzoyl peroxide, di-t-butyl peroxy 3,3,5 trimethylcyclohexane, t-butyl peroxybenzoate, dioctyl Examples thereof include mill peroxide and t-butyl hydroperoxide.

  As the polymerization inhibitor, a quinone polymerization inhibitor can be used. Specific examples include p-benzoquinone, t-butyl p-benzoquinone, naphthoquinone, phenanthraquinone, tolquinone, 2,5-diphenyl-p-benzoquinone, 2,5-diacetoxy p-benzoquinone and the like. Examples also include 2,5-dicaproxy p-benzoquinone, 2,5-diacyloxy p-benzoquinone, and the like.

  As the polymerizable monomer, an unsaturated monomer that can be cross-linked with a resin can be used as long as the effects of the present invention are not impaired. When an unsaturated polyester is used as the base resin, examples of the polymerizable monomer include styrene, vinyl toluene, vinyl acetate, diallyl phthalate, triallyl cyanurate, and methyl acrylate. Examples include methyl acrylate, methacrylic acid ester, methyl methacrylate, ethyl methacrylate and the like. These polymerizable monomers can be used in combination.

  The low shrinkage agent is used for the purpose of reducing cure shrinkage of the base resin. Generally, a thermoplastic resin is used. For example, polystyrene, polyethylene, polymethyl methacrylate, saturated polyester, polyvinyl acetate, polystyrene, polyvinyl acetate copolymer, polystyrene-modified copolymer and the like are exemplified.

  Examples of the inorganic filler include calcium carbonate, aluminum hydroxide, silica, and alumina. The addition amount of the inorganic filler is preferably 100 to 300 parts by mass when the mixture of the base resin, the polymerizable monomer and the low shrinkage agent is 100 parts by mass. By making the addition amount of the inorganic filler 100 parts by mass or more, the reinforcing fiber material can be more uniformly dispersed, and the strength variation of the molded body can be reduced. By making the addition amount 300 parts by mass or less, an increase in the viscosity of the resin compound can be suppressed, the resin impregnation into the reinforcing fiber material can be improved, and the strength of the molded body can be further increased.

The inorganic filler is preferably surface-treated with a fatty acid, a coupling agent, or the like. As the fatty acid, those represented by the general formula C _n H _m COOH can be used (n and m are integers of 1 or more), and both saturated fatty acids and unsaturated fatty acids can be used. Examples of saturated fatty acids include butyric acid, valeric acid, caproic acid, caprylic acid, capric acid, lauric acid, myristic acid, palmitic acid, stearic acid, arachidic acid, behenic acid, lignoceric acid and the like. Unsaturated fatty acids include α-linolenic acid, stearidonic acid, eicosapentaenoic acid, docosahexaenoic acid, linoleic acid, γ-linolenic acid, dihomo-γ-linolenic acid, arachidonic acid, oleic acid, elaidic acid, erucic acid, nerbon An acid etc. are illustrated. As the coupling agent, a silane coupling agent represented by the general formula R—Si (OR ′) ₃ can be used. Here, R is a functional group such as an aminopropyl group, a glycidoxy group, a methacryloxy group, an N-phenylaminopropyl group, a mercato group, or a vinyl group. R ′ is a methyl group or an ethyl group.

  Examples of the internal mold release agent include stearic acid.

  The thickener is added so that the SMC has a viscosity suitable for the molding process. Examples of the thickener include magnesium oxide, magnesium hydroxide, calcium hydroxide and the like.

  In this embodiment, glass fiber is used as the reinforcing fiber material 2. Such a reinforcing fiber material 2 can be obtained by cutting the glass roving 7 drawn from the roll 15 into a certain size with the roving cutter 12. The reinforcing fiber material 2 may be a continuous body in a strand state that constitutes roving. Further, a glass fiber substitute can be used as the reinforcing fiber material 2. For example, carbon fiber, metal fiber, vinylon fiber, aramid fiber, polyester fiber and the like. The content of the reinforcing fiber material 2 can be, for example, in the range of 10 to 50% by mass in the SMC material 5 having the resin compound 1 and the reinforcing fiber material 2. When the content of the reinforcing fiber material 2 exceeds 25 mass%, the resin compound 1 may not be satisfactorily impregnated between the reinforcing fiber materials 2 by the conventional method. In the present embodiment, the resin compound 1 can be satisfactorily impregnated between the reinforcing fiber materials 2 even when the content of the reinforcing fiber materials 2 exceeds 25 mass%.

  Using the resin compound 1 and the reinforcing fiber material 2 obtained, SMC is manufactured as follows.

  Two long films 3 and 4 having releasability are continuously supplied from the unwinding rolls 10 and 11, and the paste-like resin compound 1 is supplied from the dip pans 13 and 14 onto the films 3 and 4. Apply.

  After the resin compound 1 is applied, the reinforcing fiber material 2 is supplied onto the resin compound 1 of the film 4 by a method such as spraying, and the application surface of the resin compound 1 on the film 3 is further aligned thereon. Thus, a long SMC sheet 6 is obtained in which the SMC material 5 in which the resin compound 1 and the reinforcing fiber material 2 are laminated is sandwiched from above and below by the two films 3 and 4. The width of the films 3 and 4 (the length in the short direction) is such that the SMC material 5 does not protrude from the width direction ends of the films 3 and 4 even after the SMC sheet 6 is pressed by the impregnation machine 20 described later. In addition, it is set longer than the width of the SMC material 5.

  Next, the SMC sheet 6 is conveyed to the impregnation machine 20 and the impregnation operation is performed.

  As shown in FIG. 2, the impregnation machine 20 includes a pair of upper and lower first pressure rolls 30 that sandwich the SMC material 5 from both upper and lower sides of the SMC material 5, and pressurizes the SMC sheet 6 through a mesh belt. It is made possible. The mesh belt is formed to be bendable in the transport direction and the width direction of the SMC material 5, and is preferably made of rubber. A fine mesh metal mesh belt can also be used.

  There are a plurality of pairs of upper and lower first pressure rolls 30, and these first pressure rolls 30 are arranged from one end in the width direction to the other end in the width direction of the SMC material 5. In other words, the entire length in the width direction of the SMC material 5 is arranged so as to be substantially pressurized by a plurality of pairs of first pressure rolls 30. Among the plurality of pairs of first pressure rolls 30, the first pressure roll 31 disposed at the center in the width direction of the SMC material 5 is disposed so as to be located at the most upstream in the transport direction. The other first pressure rolls 32 are arranged such that their roll axes are shifted from the first pressure roll 31 in the transport direction of the SMC material 5. That is, the roll axis of the first pressure roll 30 disposed on the width direction end portion side of the SMC material 5 is more SMC material than the roll axis of the first pressure roll 30 disposed adjacent to the width direction inner side. 5 is shifted in the transport direction. Therefore, as the SMC material 5 is disposed from the width direction center portion to the width direction end portion side, the deviation in the transport direction from the first pressure roll 31 disposed at the width direction center portion increases.

  The plurality of pairs of first pressure rolls 30 may be rolls having the same diameter, or rolls having different diameters may be used. The roll width is not particularly limited. For example, a roll having a width of about 1/15 to 1/3 of the width of the SMC material 5 can be used. The deviation in the transport direction between the first pressure rolls 30 adjacent to each other in the width direction can be, for example, in a range from a length corresponding to the roll radius to a length corresponding to the roll diameter. By setting it within this range, residual bubbles in the SMC material 5 can be more effectively degassed. What is necessary is just to set the space | interval of the width direction between the 1st pressurization rolls 30 and 30 adjacent to the width direction to such an extent that the 1st pressurization roll 30 can rotate. As the material of the first pressure roll 30, a material having high rigidity such as iron is used to press the mesh belt.

  By passing the SMC sheet 6 through the gap between the upper roll and the lower roll of the first pressure roll 30, the SMC material 5 can be pressed from both the upper and lower sides of the SMC material 5. The SMC sheet 6 passing through the gap between the upper and lower first pressure rolls 30 is first pressed by the first pressure roll 31 disposed at the center in the width direction. As a result, as shown in FIG. 3, the residual bubbles A contained in the portion located at the center in the width direction of the SMC material 5 move from the center in the width direction toward the outer side in the width direction (the end in the width direction). The SMC sheet 6 passing through the gap between the upper and lower first pressure rolls 30 is pressed by the first pressure roll 31 disposed at the center in the width direction, and is then disposed adjacent to the outside in the width direction. The first pressure roll 30 is pressed. As a result, the residual bubbles A included in the portion of the SMC material 5 corresponding to the first pressure roll 30 further move outward in the width direction.

  After being pressurized by the first pressure roll 30, it is further pressurized by the first pressure roll 30 disposed adjacent to the outside in the width direction. Thus, as the SMC sheet 6 passes through the gap between the upper and lower first pressure rolls 30, the SMC sheet 5 is pressed from both sides from the center in the width direction toward the outer side in the width direction from upstream to downstream in the transport direction. Corresponding to the pressurization of the first pressure roll 30, the residual bubbles A in the SMC material 5 move from the center in the width direction toward the outer side in the transport direction from the upstream to the downstream in the transport direction, and finally The residual bubbles A in the SMC material 5 are reduced by escaping to the outside of the width direction end.

  In this way, the SMC sheet 6 is passed through the gap between the upper and lower first pressure rolls 30, and the SMC material 5 is pressed from both sides from the center in the width direction toward the outer side in the width direction from upstream to downstream in the transport direction. Thus, the residual bubbles A in the SMC material 5 can be degassed more effectively. Further, the resin compound 1 can be effectively impregnated between the reinforcing fiber materials 2 in the SMC material 5. As a result, the content of the reinforcing fiber material 2 in the SMC material 5 can be increased, and the strength of the molded body produced using the SMC material 5 can be increased. Further, since the total amount of bubbles in the SMC material 5 can be reduced, the thickness (weight per unit area) of the SMC material 5 can be increased, which is also beneficial for improving productivity.

  In the present embodiment, in addition to the first pressure roll 30, a second pressure roll 40 having at least a length (width) corresponding to the entire length in the width direction of the SMC material 5 is provided. The second pressure roll 40 is disposed on the upper side and the lower side of the SMC material 5. By passing the SMC sheet 6 between the upper and lower second pressure rolls 40, linear pressure can be applied to the entire length in the width direction from both sides of the SMC material 5 by line contact.

  As long as the second pressure roll 40 can apply a linear pressure to the SMC material 5, the roll axes of the upper and lower rolls may be arranged so as to be displaced from each other in the transport direction of the SMC material 5. A plurality of pairs of the second pressure rolls 40 may be provided.

  The 2nd pressurization roll 40 can use what is used by the conventional method. Such a second pressure roll 40 is, in the impregnation machine 20, a front stage of the first pressure roll 30 (upstream side in the transport direction of the SMC material 5) or a rear stage (downstream side in the transport direction of the SMC material 5). Or both. By providing the former stage and the latter stage as in the present embodiment, the remaining bubbles in the SMC material 5 can be more effectively defoamed.

  While the present invention has been described based on the embodiments, the present invention is not limited to the above-described embodiments, and various modifications can be made without departing from the scope of the invention.

  EXAMPLES Hereinafter, although an Example demonstrates this invention further in detail, this invention is not limited to these Examples at all.

<Example>
SMC was manufactured as follows according to the manufacturing process of SMC shown in FIG.

  80 parts by weight of unsaturated polyester resin as base resin, 20 parts by weight of polymerizable monomer, 5 parts by weight of low shrinkage agent, 1 part by weight of curing agent, 0.05 part by weight of polymerization inhibitor, 150 parts by weight of inorganic filler, and 5 parts by mass of a release agent was mixed with stirring to obtain a paste-like resin mixture. Next, 1 part by mass of a thickener was added to obtain a resin compound 1, which was put into dip pans 13 and 14.

The material components of the resin compound 1 were as follows.
Unsaturated polyester resin: M-580 manufactured by Showa Denko KK
・ Polymerizable monomer: Styrene (Mitsubishi Chemical Corporation CAS (100-42-5) compliant styrene monomer)
・ Low shrinkage agent: Polystyrene (GPPS manufactured by PS Japan)
Curing agent: t-butyl peroxybenzoate (Nippon Yushi Co., Ltd., Perbutyl Z)
-Polymerization inhibitor: p-benzoquinone (Wako Pure Chemical Industries, Ltd.)
・ Inorganic filler: Calcium carbonate (White White SB Blue, manufactured by Shiroishi Kogyo Co., Ltd.)
-Mold release agent: Zinc stearate (manufactured by Kawamura Chemical)
・ Thickener: Magnesium oxide (Kyowa Chemical Co., Ltd. Kyowa Mug # 40)
Further, the glass roving 7 was pulled out from the roll 15 and cut into a certain size with the roving cutter 12 to obtain the reinforcing fiber material 2. As the glass roving 7, RS480PB-549 manufactured by Nittobo Co., Ltd. was used.

Next, the obtained resin compound 1 is applied onto the films 3 and 4, the reinforcing fiber material 2 is spread on the resin compound 1 of the film 4, and the application surface of the resin compound 1 on the film 3 is aligned thereon. An SMC sheet 6 was obtained. The reinforcing fiber material 2 was dispersed in the entire SMC material 5 having the resin compound 1 and the reinforcing fiber material 2 so that the content was 30% by mass, 35% by mass, and 40% by mass. The SMC material 5 was manufactured so that the weight per unit area was 3 kg / m ² and the width was 500 mm.

  Subsequently, the impregnation operation was performed with the impregnation machine 20 to evaluate the impregnation property.

  The impregnating machine 20 used was equipped with a first pressure roll 30 (uneven roll) and a second pressure roll 40 disposed in the preceding and subsequent stages.

  As the second pressurizing roll 40 in the previous stage, a roll having a roll diameter of 60 mm and a roll width of 600 mm was used. The second pressure roll 40 at the rear stage also has the same configuration as the pressure roll 40 at the front stage.

As the first pressure roll 30, a roll having a roll diameter of 60 mm and a roll width of 50 mm and having 11 rolls in each of the upper and lower sides was used. The first pressure roll 30 has a roll axis of the first pressure roll 30 disposed on the width direction end side and a roll axis of the first pressure roll 30 disposed adjacent to the width direction inner side. Is also displaced by 30 mm in the transport direction.
<Comparative example>
The impregnation of the SMC sheet 6 is performed in the same manner as in the example except that in the impregnating machine 20 of the example, a roll having the same configuration as the first (or subsequent) second pressure roll 40 is used instead of the first pressure roll 30. Work was performed and the impregnation property was evaluated.
<Evaluation of impregnation>
The SMC material of each SMC sheet obtained in the examples and comparative examples was cut open at the center in the thickness direction, and the impregnation state of the reinforcing fiber material was visually confirmed.

  The results are shown in Table 1.

  From the above results, it was confirmed that the impregnation state of the reinforcing fiber material was good even in the SMC material having a high content of the reinforcing fiber material in the examples. This result means that the residual bubbles in the SMC material are more effectively degassed. In the comparative example, even when the content of the reinforcing fiber material was 30% by mass, a partially unimpregnated portion was observed.

  From the above, the residual bubbles in the SMC material are more effectively degassed by pressurizing the SMC material from both sides of the SMC material from the center in the width direction toward the outer side in the width direction from upstream to downstream in the transport direction. It was confirmed that it was possible. It was also confirmed that the content of the reinforcing fiber material can be increased.

DESCRIPTION OF SYMBOLS 1 Resin compound 2 Reinforcement fiber material 5 SMC material 20 Impregnation machine 30 1st pressurization roll 40 2nd pressurization roll

Claims (4)

  The SMC material having the resin compound and the reinforcing fiber material that are continuously conveyed is pressed from both sides of the SMC material in order from the center in the width direction toward the outer side in the width direction from the upstream to the downstream in the conveying direction. A method for producing a sheet molding compound, wherein the resin compound is impregnated between the reinforcing fiber materials to obtain a sheet molding compound.   The entire length of the SMC material in the width direction from both sides of the SMC material before, after, or before and after pressurizing the SMC material from the upstream to the downstream in the transport direction from the center in the width direction toward the outside in the width direction. The method of manufacturing a sheet molding compound according to claim 1, wherein a linear pressure is applied to the sheet molding.   An impregnator for impregnating the resin compound between the reinforcing fiber materials by pressing an SMC material having a resin compound and a reinforcing fiber material that are continuously conveyed from both sides, the upper and lower sides sandwiching the conveyed SMC material A pair of first pressure rolls are provided, and the pair of upper and lower first pressure rolls has a plurality of pairs in the width direction, and the plurality of pairs of first pressure rolls are arranged in the width direction from one end in the width direction of the SMC material. Of the first pressure roll arranged across the end and the roll axis of the first pressure roll arranged on the width direction end side of the SMC material adjacent to the inner side in the width direction. An impregnation machine characterized by being displaced in the transport direction of the SMC material from the roll axis. Further, the first pressure roll has a second pressure roll having at least a length corresponding to the entire length in the width direction of the SMC material at the front stage, the rear stage, or both of the first pressure roll, 4. The impregnation machine according to claim 3, wherein the impregnation machine is disposed on an upper side and a lower side of the SMC material.

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