JP6874876B2 - Seat molding compound - Google Patents

Description

The present invention relates to a seat molding compound.

Conventionally, there has been known a method for producing a sheet molding compound which is lightweight, thin, and has excellent smoothness on at least one side while having predetermined mechanical properties (see Patent Document 1 below). In the conventional production method described in Patent Document 1, first, a curable resin composition containing a low shrinkage agent is uniformly applied to one side of a separate film to form a resin layer, and then chopped reinforcing fibers are formed on the resin layer. Is sprayed. Next, a curable resin composition substantially free of a low shrinkage agent was uniformly applied to one side of another separate film to form a resin layer, and the surface of the resin layer to which chopped reinforcing fibers were sprayed and the latter resin layer. Overlay with the surface. Then, pressure is applied from the outside to press the two together, and the resin composition is impregnated into the chopped reinforcing fibers.

Japanese Unexamined Patent Publication No. 2004-35714

In the conventional method for producing a sheet molding compound, a curable resin composition containing a low shrinkage agent is applied to one side of a separate film to form a resin layer. Therefore, the low shrinkage agent contained in the curable resin composition may be separated or condensed due to factors such as the difference in specific gravity between the curable resin composition and the low shrinkage agent and compatibility.

The present invention has been made in view of the above problems, and is a sheet molding compound capable of suppressing shrinkage of a thermosetting resin and reducing warpage without adding a low shrinkage agent to the thermosetting resin. SMC) is intended to be provided.

In order to achieve the above object, the method for producing a sheet molding compound of the present invention includes a first fiber spraying step of spraying a first reinforcing fiber cut on a first paste of a thermosetting resin, and the first paste. A method for producing a sheet molding compound, which comprises a first resin impregnation step of impregnating the first reinforcing fiber with a resin, and a resin curing step of heating and curing the first paste impregnated with the first reinforcing fiber. Therefore, it is characterized by having a low shrinkage material laminating step of laminating a film-like low shrinkage material on the first paste before the first resin impregnation step.

The first fiber spraying step is, for example, a step of spraying the first reinforcing fiber cut to a predetermined length on the first paste of the thermosetting resin. The present manufacturing method may include a first mold release material supply step and a first resin laminating step before the first fiber spraying step. The first fiber spraying step can be performed on the first paste laminated on the first mold release material through, for example, the first mold release agent supply step and the first resin laminating step. ..

The first release material supply step is, for example, a step of supplying the first release material by unwinding the film-shaped first release material wound in a roll shape and transporting it by a roller. The first resin laminating step is, for example, a step of laminating the first paste on the first mold release material. More specifically, the first resin laminating step is a first resin coating step of applying the first paste on the first mold release material.

The first resin impregnation step is, for example, a step of impregnating the first reinforcing fiber with the first paste by applying pressure to the first paste with an impregnation roll. The impregnating rolls are arranged, for example, facing each other on both sides in the thickness direction of the laminate of the materials constituting the sheet molding compound containing the first paste. The impregnation roll applies pressure to the first paste to impregnate the first reinforcing fibers by sandwiching the laminate from both sides in the thickness direction while rotating to feed the laminate in the feed direction, for example. .. This makes it possible to manufacture a sheet molding compound.

The resin curing step is a step of heating and curing the first paste impregnated in the first reinforcing fiber. This resin curing step is, for example, a step of hot press molding the sheet molding compound obtained by the first resin impregnation step. In this case, one sheet molding compound may be hot press molded, or a plurality of sheet molding compounds may be laminated and hot press molded. The first paste of the thermosetting resin heated in this resin curing step tends to cure and shrink. In the present manufacturing method, this resin curing step is performed after the low shrinkage material laminating step.

The low shrinkage material laminating step is, for example, a step of laminating a film-like low shrinkage material on the first paste before the first resin impregnation step. In this low shrinkage material laminating step, for example, a film-like low shrinkage material wound in a roll shape is unwound and conveyed by a roller to supply the low shrinkage material and laminate it on the first paste. It is a process to do.

The low shrinkage material laminating step can be performed, for example, before or after the first fiber spraying step. When this low shrinkage material laminating step is a pre-step of the first fiber spraying step, the low shrinkage material is directly laminated on the first paste. When the low shrinkage material laminating step is a subsequent step of the first fiber spraying step, the low shrinkage material is laminated on the first paste via the first reinforcing fiber.

As described above, by laminating the film-shaped low shrinkage material on the first paste in the low shrinkage material laminating step, the shrinkage of the first paste is suppressed by the low shrinkage material in the resin curing step. Therefore, the warpage of the seat molding compound can be reduced. The heat shrinkage rate of the low shrinkage material is lower than the heat shrinkage rate of the first paste. Here, the heat shrinkage rate means the rate of shrinkage that occurs in a certain object when the temperature of the object rises by 1 ° C.

More specifically, the low shrinkage material heated in the resin curing step does not melt as a whole, but the surface portion melts and becomes compatible with the thermosetting resin and the reinforcing fiber, and the thermosetting resin and the reinforcing fiber are used. The wettability of fibers is improved. Therefore, in the sheet molding compound produced by this production method and its molded product, the curing shrinkage of the thermosetting resin is suppressed over the entire surface due to the presence of the crystal layer of the low shrinkage material, and the warpage is reduced.

The present manufacturing method has, for example, the low shrinkage material laminating step after the first fiber spraying step, and has a second resin laminating step after the low shrinkage material laminating step and before the first resin impregnation step. You may. This second resin laminating step is, for example, a step of laminating a second paste of a thermosetting resin on the low shrinkage material. In this case, the present manufacturing method may include a second mold release material supply step and a second resin coating step before the second resin laminating step.

The second release material supply step is, for example, a step of supplying the second release material by unwinding the film-like second release material wound in a roll shape and transporting it by a roller. The second resin coating step is, for example, a step of applying a second paste of a thermosetting resin on the second mold release material. In this case, the second resin laminating step is, for example, a step of laminating the second mold release material coated with the second paste on the low shrinkage material.

The first resin impregnation step can be provided after the second resin laminating step. This makes it possible to manufacture a sheet molding compound. Here, when the low shrinkage material laminating step is a pre-step of the first fiber spraying step, the first mold release material, the first paste, the low shrinkage material, and the second reinforcing fiber impregnated with the first reinforcing fiber. A sheet molding compound in which the paste and the second release material are laminated in this order can be produced.

On the other hand, when the low shrinkage material laminating step is a subsequent step of the first fiber spraying step, the first mold release material, the first paste impregnated with the first reinforcing fiber, the low shrinkage material, and the second paste. , And the second mold release material can produce a sheet molding compound laminated in this order. Further, by having the resin curing step after the first resin impregnation step, it is possible to manufacture a molded product using one layer of the sheet molding compound or a molded product using the multilayer sheet molding compound.

Further, in the present production method, for example, after the first fiber spraying step, a second resin laminate in which a second paste of a thermosetting resin is laminated on the first paste on which the first reinforcing fiber is sprayed is laminated. It may have a process. More specifically, the second resin laminating step is a second resin coating step of applying a second paste of a thermosetting resin on the first paste on which the first reinforcing fibers are sprayed.

In this case, the present production method may include the low shrinkage material laminating step and the first resin impregnation step after the second resin laminating step. Here, in the first resin impregnation step, for example, by applying pressure to the first paste and the second paste with an impregnation roll, the first paste and the second paste are impregnated into the first reinforcing fiber. It is a process.

The impregnating rolls are arranged, for example, facing each other on both sides in the thickness direction of the laminate of the materials constituting the sheet molding compound containing the first paste and the second paste. The impregnation roll applies pressure to the first paste and the second paste by sandwiching the laminate from both sides in the thickness direction while rotating to feed the laminate in the feed direction, for example, to apply pressure to the laminate. The first reinforcing fiber is impregnated. Thereby, the wettability of the first paste and the second paste with respect to the first reinforcing fiber can be improved.

In this case, in this production method, after the first resin impregnation step and before the resin curing step, a third resin laminating step, a second fiber spraying step, a fourth resin laminating step, and a second resin impregnation are performed. It can have a process and. The third resin laminating step is, for example, a step of laminating a third paste of a thermosetting resin on the low shrinkage material. More specifically, the third resin laminating step is a third resin coating step of applying the third paste on the low shrinkage material.

The second fiber spraying step is, for example, a step of spraying the second reinforcing fiber cut to a predetermined length on the third paste. As described above, when the present manufacturing method has a plurality of fiber spraying steps, the amount of reinforcing fibers per layer can be reduced, and the wettability of the thermosetting resin paste to the reinforcing fibers is improved. be able to.

The fourth resin laminating step is, for example, a step of laminating a fourth paste of a thermosetting resin on the third paste on which the second reinforcing fiber is sprayed. In this case, the present manufacturing method may include a second mold release material supply step and a fourth resin coating step before the fourth resin laminating step.

The second release material supply step is, for example, a step of supplying the second release material by unwinding the film-like second release material wound in a roll shape and transporting it by a roller. The fourth resin coating step is, for example, a step of applying a fourth paste of a thermosetting resin onto the second mold release material. In this case, the fourth resin laminating step is, for example, a step of laminating the second mold release material coated with the fourth paste on the third paste on which the second reinforcing fiber is sprayed.

The second resin impregnation step can be provided after the fourth resin laminating step. Here, in the second resin impregnation step, for example, by applying pressure to the third paste and the fourth paste with an impregnation roll, the third paste and the fourth paste are impregnated into the second reinforcing fiber. It is a process. The impregnating rolls are arranged, for example, facing each other on both sides in the thickness direction of a laminate of materials constituting the sheet molding compound containing the third paste and the fourth paste.

The impregnation roll applies pressure to the third paste and the fourth paste by sandwiching the laminate from both sides in the thickness direction while rotating to feed the laminate in the feed direction, for example. The second reinforcing fiber is impregnated. In the second resin impregnation step, pressure can also be applied to the first paste and the second paste to further advance the impregnation of the first paste and the second paste into the first reinforcing fiber. ..

This makes it possible to manufacture a sheet molding compound. The sheet molding compound thus produced is impregnated with the first mold release material, the first paste and the second paste impregnated with the first reinforcing fiber, the low shrinkage material, and the second reinforcing fiber. The third paste, the fourth paste, and the second release material are laminated in this order to form a laminated body. By having the resin impregnation steps a plurality of times in this way, the impregnation property of the thermosetting resin with respect to the reinforcing fibers can be improved, and delamination can be prevented.

Further, by having the resin curing step after the second resin impregnation step, it is possible to manufacture a molded product using the single layer of the sheet molding compound or a molded product using the multi-layered sheet molding compound. At this time, as described above, by laminating the low shrinkage material in the low shrinkage material laminating step, the shrinkage from the first paste to the fourth paste is suppressed by the low shrinkage material, and the sheet molding compound. Warpage can be reduced. Further, in the low shrinkage material laminating step, since the low shrinkage material is laminated on the sheet molding compound, it is necessary to add a low shrinkage agent to the thermosetting resin paste laminated in each resin laminating step. Absent.

The method for producing a sheet molding compound of the present invention includes a low shrinkage material laminating step of laminating a film-like low shrinkage material on a heat-curable resin paste or reinforcing fibers sprayed on the paste. .. Therefore, in the curing step of heating and curing the paste of the thermosetting resin, the film-like low shrinkage material suppresses the curing shrinkage of the thermosetting resin without adding a low shrinkage agent to the thermocurable resin. , The warp of the seat molding compound can be reduced.

FIG. 6 is a schematic cross-sectional view showing an example of a seat molding compound (SMC). The flow chart which shows the manufacturing method of SMC which concerns on Embodiment 1 of this invention. The schematic which shows an example of the manufacturing apparatus for carrying out the manufacturing method of SMC shown in FIG. Schematic cross-sectional view showing an example of SMC. The flow chart which shows the manufacturing method of SMC which concerns on Embodiment 2 of this invention. The schematic which shows an example of the manufacturing apparatus for carrying out the manufacturing method of SMC shown in FIG.

Hereinafter, embodiments of the method for producing the sheet molding compound of the present invention will be described with reference to the drawings. Hereinafter, the seat molding compound is abbreviated as "SMC".

[Embodiment 1]
FIG. 1 is a schematic cross-sectional view showing an example of SMC 10 manufactured by the method for manufacturing SMC according to the first embodiment of the present invention. SMC10 is, for example, a molding material obtained by impregnating reinforcing fibers with a paste of a thermosetting resin as a matrix and molding the reinforcing fibers into a sheet having a thickness of about several mm. The SMC 10 includes, for example, a first mold release material 11, a first paste 13 of a thermosetting resin impregnated in a first reinforcing fiber 12, a low shrinkage material 14, a second paste 15 of a thermosetting resin, and a second paste. The 2 release material 16 is a laminated body laminated in this order.

As the first paste 13 and the second paste 15 which are thermosetting resin pastes, for example, a low shrinkage agent is not added, or the amount of the low shrinkage agent added is significantly reduced as compared with the conventional case. Unsaturated polyester resin or the like can be used. The first paste 13 and the second paste 15 can contain various additives such as a curing agent, a curing catalyst, a mold release agent, a thickener, a coloring agent, and a filler.

As the first reinforcing fiber 12 which is a reinforcing fiber, for example, carbon fiber, graphite fiber, boron fiber, glass fiber or the like cut to a predetermined length can be used. Since carbon fiber is lighter than other fibers, it is most suitable as a reinforcing fiber for producing a thin and lightweight SMC. As the first reinforcing fiber 12, for example, one cut to a length of about 1 [in] can be used.

As the first release material 11 and the second release material 16, for example, a resin film such as a PET film laminated with silicone, a fluororesin film, or a polyolefin resin film, or a resin film coated with a polyolefin-based coating agent is used. Can be done.

As the film-shaped low shrinkage material 14, a stretched film is suitable because it is heat-fixed and crystallized and has a small heat shrinkage. As the material of the low shrinkage material 14, a polyolefin resin or a polyester resin can be used. As the polyolefin resin, for example, polyethylene (PE), polypropylene (PP) and the like can be used, and as the polyester resin, for example, polyethylene terephthalate (PET), polylactic acid (PLA resin) and the like can be used. ..

FIG. 2 is a flow chart of the SMC manufacturing method S100 of the present embodiment. FIG. 3 is a schematic view showing an example of a manufacturing apparatus E1 for carrying out the SMC manufacturing method S100 shown in FIG. The SMC manufacturing method S100 of the present embodiment includes a first fiber spraying step S103, a first resin impregnation step S108, and a resin curing step S109, and a low shrinkage material laminating step before the first resin impregnation step S108. It is characterized by having S104.

Further, the SMC manufacturing method S100 of the present embodiment includes a first mold release material supply step S101 and a first resin laminating step S102 before the first fiber spraying step S103, and after the first fiber spraying step S103. , Has a low shrinkage material laminating step S104. Further, after the low shrinkage material laminating step S104, the second resin laminating step S107 is provided before the first resin impregnating step S108, and before the second resin laminating step S107, the second mold release material supplying step S105 and It has a second resin coating step S106. Hereinafter, each of these steps will be described in detail.

In the first release material supply step S101, as shown in FIG. 3, for example, the first release material 11 in the form of a film wound in a roll shape is unwound and conveyed by a roller (not shown). This is a step of supplying the release material 11. As shown in FIG. 2, the first resin laminating step S102 is performed after the first mold release material supply step S101.

In the first resin laminating step S102, as shown in FIG. 3, for example, the above-mentioned first paste 13 of the heat-curable resin is laminated on the first demolding material 11 supplied in the first demolding material supply step S101. It is a process to do. More specifically, the first resin laminating step S102 is a first resin coating step of applying the first paste 13 on the film-shaped first mold release material 11. The first paste 13 is uniformly applied onto the first mold release material 11 by, for example, a doctor blade (not shown). As shown in FIG. 2, the first fiber spraying step S103 is performed after the first resin laminating step S102.

In the first fiber spraying step S103, as shown in FIG. 3, for example, the first reinforcing fiber cut to a predetermined length by a cutting device such as a roving cutter C on the first paste 13 of the thermosetting resin. 12 is a step of spraying. As described above, in the SMC manufacturing method of the present embodiment, the first fiber spraying step S103 is laminated on the first mold release material 11 through the first mold release material supply step S101 and the first resin laminating step S102. This is done for the first paste 13. As shown in FIG. 2, the low shrinkage material laminating step S104 is performed after the first fiber spraying step S103.

As shown in FIG. 3, the low shrinkage material laminating step S104 is, for example, a step of laminating a film-shaped low shrinkage material 14 on the first paste 13 on which the first reinforcing fibers 12 are sprayed. More specifically, in the low shrinkage material laminating step S104, for example, the low shrinkage material 14 is unwound in a roll shape and conveyed by a roller (not shown). This is a step of supplying and laminating on the first paste 13 on which the first reinforcing fiber 12 is sprayed.

As a result, the first reinforcing fiber 12 and the first paste 13 are sandwiched between the first mold release material 11 and the low shrinkage material 14. As shown in FIG. 2, the second resin laminating step S107 is performed after the low shrinkage material laminating step S104, but in the SMC manufacturing method S100 of the present embodiment, the second release material supplying step is performed before that. S105 and the second resin coating step S106 are performed.

As shown in FIG. 3, in the second mold release material supply step S105, for example, similarly to the first mold release material 11 described above, the film-shaped second mold release material 16 wound in a roll shape is unwound and the roller R This is a step of supplying the second mold release material 16 by transporting the film. In the second resin coating step S106, as shown in FIG. 3, for example, the second paste 15 of the thermosetting resin is placed on the second mold release material 16 in the same manner as the first paste 13 of the thermosetting resin described above. Is the process of applying.

As shown in FIG. 2, the second mold release material supply step S105 and the second resin coating step S106 can be performed in parallel with the above-mentioned first mold release material supply step S101 to the low shrinkage material laminating step S104. This makes it possible to shorten the manufacturing process and the manufacturing line. After the low shrinkage material laminating step S104 and the second resin coating step S106, the second resin laminating step S107 is performed.

As shown in FIG. 3, the second resin laminating step S107 is, for example, a step of laminating the second paste 15 of the thermosetting resin on the low shrinkage material 14. More specifically, in the SMC manufacturing method S100 of the present embodiment, in the second resin laminating step S107, for example, the second mold release material 16 coated with the second paste 15 is laminated on the low shrinkage material 14. It is a process. As a result, the second paste 15 and the second mold release material 16 can be laminated on the low shrinkage material 14 at the same time. As shown in FIG. 2, the first resin impregnation step S108 is performed after the second resin laminating step S107.

In the first resin impregnation step S108, as shown in FIG. 3, for example, by applying pressure to the first paste 13 by the impregnation roll IR, the first paste 13 is sandwiched between the first mold release material 11 and the low shrinkage material 14. Is a step of impregnating the first reinforcing fiber 12. The impregnated roll IR is arranged, for example, facing each other on both sides in the thickness direction of the laminated body 10a of the materials constituting the SMC 10 containing the first paste 13.

The impregnation roll IR applies pressure to the first paste 13 by sandwiching the laminate 10a from both sides in the thickness direction while rotating the laminate 10a to feed it in the feed direction F, for example, to apply pressure to the first reinforcing fiber. 12 is impregnated. As a result, the SMC 10 shown in FIG. 1 can be manufactured. As shown in FIG. 2, the resin curing step S109 is performed after the first resin impregnation step S108.

The resin curing step S109 is a step of heating and curing the first paste 13 impregnated in the first reinforcing fiber 12. This resin curing step S109 is, for example, a step of hot press molding the SMC 10 obtained by the first resin impregnation step S108. In this case, one SMC 10 may be hot press molded, or a plurality of SMC 10s may be laminated and hot press molded. The first paste 13 and the second paste 15 of the thermosetting resin heated in the resin curing step S109 cure and tend to shrink.

However, in the SMC manufacturing method S100 of the present embodiment, as described above, in the low shrinkage material laminating step S104, the film-like low shrinkage material 14 is laminated on the first paste 13. Therefore, in the resin curing step S109, the shrinkage of the first paste 13 is suppressed by the low shrinkage material 14, and the warp of the SMC 10 can be reduced. The heat shrinkage rate of the low shrinkage material 14 is lower than the heat shrinkage rate of the first paste 13 and the second paste 15 of the thermosetting resin. Here, the heat shrinkage rate means the rate of shrinkage that occurs in an object when the temperature of the object rises by 1 ° C.

More specifically, the low shrinkage material 14 heated in the resin curing step S109 does not melt as a whole, but the surface portion melts and is compatible with the thermosetting resin and the reinforcing fiber, so that the thermosetting resin and the reinforcing fiber are reinforced. The wettability of fibers is improved. Therefore, in the SMC 10 and its molded product manufactured by the SMC manufacturing method S100 of the present embodiment, the curing shrinkage of the thermosetting resin is suppressed on the entire surface due to the presence of the crystal layer of the low shrinkage material 14, and the warpage is reduced. Will be done.

In the resin curing step S109, by hot-press molding one layer of SMC10, a molded product made of one layer of SMC10 can be molded. Further, in the resin curing step S109, a molded product composed of a multi-layered SMC 10 can be molded by laminating a plurality of SMC 10s and hot press molding. In either case, since the crystal layer of the low shrinkage material 14 is present, the curing of the thermosetting resin is suppressed over the entire shrinkage surface, and the warpage of the molded product is reduced.

Further, in the resin curing step S109, the difference in the amount of material shrinkage between the front surface side and the back surface side of the molded product due to the temperature difference between the upper mold and the lower mold of the press molding die is reduced by the low shrinkage material 14, and the molding is performed. It is possible to suppress in-plane waviness and warpage of the entire molded product. Further, in the resin curing step S109, the shrinkage difference generated in the cooling process due to the difference in the coefficient of linear expansion between the thermosetting resin and the reinforcing fiber is reduced by the low shrinkage material 14 to suppress warpage and deformation of the molded product. be able to.

As described above, the SMC manufacturing method S100 of the present embodiment is a low shrinkage material in which a film-like low shrinkage material 14 is laminated on a thermosetting resin paste or reinforcing fibers sprayed on the paste. It has a laminating step S104. Therefore, in the curing step of heating and curing the paste of the thermosetting resin, the curing shrinkage of the thermosetting resin is suppressed by the film-shaped low shrinkage material 14, and the low shrinkage agent is added to the thermocurable resin. It is possible to reduce the warp of the SMC 10.

In the SMC manufacturing method S100 of the present embodiment, an example in which the low shrinkage material laminating step S104 is performed after the first fiber spraying step S103 has been described, but the low shrinkage material laminating step S104 is the first fiber spraying step S103. You may go ahead. In this case, in the low shrinkage material laminating step S104, the low shrinkage material 14 is directly laminated on the first paste 13, and then the first fiber spraying step S103 is performed to perform the first on the low shrinkage material 14. The reinforcing fiber 12 can be sprayed, and then the second resin laminating step S107 can be performed.

Alternatively, after the second resin coating step S106, the first fiber spraying step S103 may be performed to spray the first reinforcing fiber 12 on the second paste 15, and then the second resin laminating step S107 may be performed. .. As described above, when the low shrinkage material laminating step S104 is performed before the first fiber spraying step S103, the first mold release material 11, the first paste 13, the low shrinkage material 14, and the first reinforcing fiber 12 are impregnated with the second. An SMC in which the paste 15 and the second release material 16 are laminated in this order can be produced.

[Embodiment 2]
Next, the second embodiment of the method for producing SMC of the present invention will be described. FIG. 4 is a schematic cross-sectional view showing an example of SMC 20 manufactured by the method for manufacturing SMC according to the second embodiment of the present invention. The SMC 20 is applied to, for example, the first mold release material 21, the first paste 23 and the second paste 24 of the thermosetting resin impregnated in the first reinforcing fiber 22, the low shrinkage material 25, and the second reinforcing fiber 26. The third paste 27 and the fourth paste 28 of the impregnated thermosetting resin and the second mold release material 29 are laminated in this order.

In the SMC 20 shown in FIG. 4, the first mold release material 21 and the second mold release material 29, the first reinforcing fiber 22 and the second reinforcing fiber 26, the first paste 23 to the fourth paste 28 of the thermosetting resin, and the low shrinkage material 25 is the first mold release material 11, the second mold release material 16, the first reinforcing fiber 12, the first paste 13 and the second paste 15 of the thermosetting resin, and the low shrinkage material 14 in the SMC 10 shown in FIG. 1, respectively. The same as the above can be used.

FIG. 5 is a flow chart of the SMC manufacturing method S200 of the present embodiment. FIG. 6 is a schematic view showing an example of the manufacturing apparatus E2 for carrying out the SMC manufacturing method S200 shown in FIG. The SMC manufacturing method S200 of the present embodiment has a first fiber spraying step S203, a first resin impregnation step S206, and a resin curing step S213, similarly to the SMC manufacturing method S100 of the first embodiment described above. It is characterized by having a low shrinkage material laminating step S205 before the first resin impregnation step S206.

Further, as shown in FIG. 5, in the SMC manufacturing method S200 of the present embodiment, for example, before the first fiber spraying step S203, the first mold release material supply step S201 and the first mold release material supply step S201 and the same as in the above-described first embodiment 1 It has a resin laminating step S202. Similar to the first embodiment, the first mold release material supply step S201 is a step of supplying the first mold release material 21 shown in FIG. 6, and the first resin lamination step S202 is on the first mold release material 21. This is a step of laminating the first paste 23 of the thermoplastic resin. Further, the first fiber spraying step S203 is a step of spraying the cut first reinforcing fiber 22 on the first paste 23.

Further, as shown in FIG. 5, the SMC manufacturing method S200 of the present embodiment has, for example, a second resin laminating step S204 after the first fiber spraying step S203. As shown in FIG. 6, the second resin laminating step S204 is a step of laminating the second paste 24 of the thermosetting resin on the first paste 23 on which the first reinforcing fiber 22 is sprayed. More specifically, the second resin laminating step S204 is a second resin coating step of applying the second paste 24 of the thermosetting resin onto the first paste 23 on which the first reinforcing fiber 22 is sprayed. ..

Further, as shown in FIG. 5, the SMC manufacturing method S200 of the present embodiment includes a low shrinkage material laminating step S205 and a first resin impregnating step S206 after the second resin laminating step S204. The low shrinkage material laminating step S205 is a step of supplying the low shrinkage material 25 and laminating it on the second paste 24 in the same manner as in the SMC manufacturing method S100 of the first embodiment described above. In the first resin impregnation step S206, as shown in FIG. 6, for example, the first paste 23 and the second paste 24 are first strengthened by applying pressure to the first paste 23 and the second paste 24 by the impregnation roll IR1. This is a step of impregnating the fiber 22.

The impregnating roll IR1 is arranged so as to face each other on both sides in the thickness direction of the laminated body 20a of the materials constituting the SMC 20 including the first paste 23 and the second paste 24, for example. The impregnation roll IR1 applies pressure to the first paste 23 and the second paste 24 by sandwiching the laminate 20a from both sides in the thickness direction while rotating the laminate 20a to feed the laminate 20a in the feed direction F, for example. Is impregnated into the first reinforcing fiber 22. Thereby, the wettability of the first paste 23 and the second paste 24 with respect to the first reinforcing fiber 22 can be improved.

Further, as shown in FIG. 5, the SMC manufacturing method S200 of the present embodiment includes a third resin lamination step S207 and a second fiber spraying step after the first resin impregnation step S206 and before the resin curing step S213. It has S208, a fourth resin laminating step S211 and a second resin impregnating step S212. As shown in FIG. 6, the third resin laminating step S207 is a step of laminating, for example, the third paste 27 of the thermosetting resin on the low shrinkage material 25. More specifically, the third resin laminating step S207 is a third resin coating step of applying the third paste 27 on the low shrinkage material 25.

As shown in FIG. 6, the second fiber spraying step S208 is, for example, a step of spraying the second reinforcing fiber 26 cut to a predetermined length on the third paste 27. As described above, when the fiber spraying step is performed a plurality of times, the amount of reinforcing fibers per layer can be reduced, and the wettability of the thermosetting resin paste to the reinforcing fibers can be improved.

As shown in FIG. 6, the fourth resin laminating step S211 is a step of laminating the fourth paste 28 of the thermosetting resin on, for example, the third paste 27 on which the second reinforcing fiber 26 is sprayed. Here, as shown in FIG. 5, the SMC manufacturing method S200 of the present embodiment includes the second mold release material supply step S209 and the fourth resin coating step S210 before the fourth resin laminating step S211. There is.

In the second mold release material supply step S209, as shown in FIG. 6, for example, a film-shaped second mold release material 29 wound in a roll shape is wound in the same manner as in the SMC manufacturing method S100 of the first embodiment described above. This is a step of supplying the second mold release material 29 by taking it out and transporting it by the roller R. As shown in FIG. 6, the fourth resin coating step S210 is a step of coating, for example, the fourth paste 28 of the thermosetting resin on the second mold release material 29.

As shown in FIG. 5, the second mold release material supply step S209 and the fourth resin coating step S210 may be performed in parallel with the steps from the first mold release material supply step S201 to the second fiber spraying step S208 described above. it can. This makes it possible to shorten the manufacturing process and shorten the manufacturing line. After the second fiber spraying step S208 and the fourth resin coating step S210, the fourth resin laminating step S211 is performed.

In the SMC manufacturing method S200 of the present embodiment, in the fourth resin lamination step S211 as shown in FIG. 6, for example, the fourth paste 28 is formed on the third paste 27 on which the second reinforcing fiber 26 is sprayed. This is a step of laminating the applied second mold release material 29. As a result, the fourth paste 28 and the second release material 29 can be laminated at the same time on the third paste 27 on which the second reinforcing fiber 26 is sprayed. As shown in FIG. 5, the second resin impregnation step S212 is performed after the fourth resin lamination step S211.

As shown in FIG. 6, the second resin impregnation step S212 second-strengthens the third paste 27 and the fourth paste 28 by, for example, applying pressure to the third paste 27 and the fourth paste 28 by the impregnation roll IR2. This is a step of impregnating the fiber 26. The impregnating roll IR2 is arranged, for example, so as to face each other on both sides in the thickness direction of the laminated body 20b of the materials constituting the SMC 20 including the third paste 27 and the fourth paste 28.

The impregnation roll IR2 applies pressure to the third paste 27 and the fourth paste 28 by sandwiching the laminate 20b from both sides in the thickness direction while rotating the laminate 20b to feed the laminate 20b in the feed direction F, for example. Is impregnated in the second reinforcing fiber 26. In the second resin impregnation step S212, pressure may also be applied to the first paste 23 and the second paste 24 to further advance the impregnation of the first paste 23 and the second paste 24 into the first reinforcing fiber 22. it can. As a result, the SMC 20 shown in FIG. 4 can be manufactured. By having the resin impregnation steps a plurality of times in this way, the impregnation property of the thermosetting resin with respect to the reinforcing fibers can be improved, and delamination can be prevented.

Further, as shown in FIG. 5, by having the resin curing step S213 after the second resin impregnation step S212, it is possible to manufacture a molded product using one layer of SMC20 or a molded product using multiple layers of SMC20. .. At this time, as described above, by laminating the low shrinkage material 25 in the low shrinkage material laminating step S205, the shrinkage of the first paste 23, the second paste 24, the third paste 27, and the fourth paste 28 is low shrinkage. It is suppressed by the material 25, and the warp of the SMC 20 can be reduced. Further, since the low shrinkage material 25 is laminated on the SMC 20 in the low shrinkage material laminating step S205, it is not necessary to add a low shrinkage agent to the thermosetting resin paste laminated in each resin laminating step.

As described above, the SMC manufacturing method S200 of the present embodiment is a low shrinkage material in which a film-like low shrinkage material 25 is laminated on a thermosetting resin paste or reinforcing fibers sprayed on the paste. It has a laminating step S205. Therefore, the same effect as that of the SMC manufacturing method S100 of the first embodiment can be obtained.

Although the embodiments of the present invention have been described in detail with reference to the drawings, the specific configuration is not limited to this embodiment, and there are design changes and the like within a range that does not deviate from the gist of the present invention. Also, they are included in the present invention.

10 SMC
12 1st reinforcing fiber 13 1st paste 14 Low shrinkage material 20 SMC
22 1st reinforcing fiber 23 1st paste 25 Low shrinkage material S100 SMC manufacturing method S103 1st fiber spraying step S104 Low shrinkage material laminating step S108 1st resin impregnation step S109 Resin curing step S200 SMC manufacturing method S203 1st fiber spraying Step S205 Low shrinkage material laminating step S206 First resin impregnation step S213 Resin curing step

Claims (5)

A first fiber reinforced resin layer obtained by impregnating a first reinforcing fiber with a heat-curable resin paste and heating and curing the first reinforcing fiber.
A sheet molding compound which is laminated on the paste and has a film-like low shrinkage material whose surface portion is compatible with the first fiber reinforced resin layer by the heating. The sheet molding compound according to claim 1, wherein the thermosetting resin is not added with a low shrinkage agent. The sheet molding compound according to claim 1, wherein the heat shrinkage rate of the low shrinkage material is lower than the heat shrinkage rate of the heat-curable resin. The surface of the low shrinkage material is cured by the heating of the first mold release material, the first fiber reinforced resin layer, the low shrinkage material, and a thermosetting resin paste laminated on the low shrinkage material. The sheet molding compound according to claim 1, wherein the second resin layer that is compatible with the portion and the second mold release material are laminated in this order. The second reinforcing fiber is impregnated with a paste of a thermosetting resin laminated on the first mold release material, the first fiber reinforced resin layer, the low shrinkage material, and the low shrinkage material, and heated to cure. The sheet molding compound according to claim 1, wherein the second fiber reinforced resin layer and the second mold release material, which are compatible with the surface portion of the low shrinkage material, are laminated in this order.

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