WO2017111056A1 - 繊維強化樹脂成形材料の製造方法、及び繊維強化樹脂成形材料の製造装置 - Google Patents

繊維強化樹脂成形材料の製造方法、及び繊維強化樹脂成形材料の製造装置 Download PDF

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Publication number
WO2017111056A1
WO2017111056A1 PCT/JP2016/088441 JP2016088441W WO2017111056A1 WO 2017111056 A1 WO2017111056 A1 WO 2017111056A1 JP 2016088441 W JP2016088441 W JP 2016088441W WO 2017111056 A1 WO2017111056 A1 WO 2017111056A1
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WIPO (PCT)
Prior art keywords
fiber
fiber bundle
molding material
sheet
reinforced resin
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/JP2016/088441
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English (en)
French (fr)
Japanese (ja)
Inventor
鮫島　禎雄
由貴廣 水鳥
康 渡邊
惇二 金羽木
正俊 鎌田
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Mitsubishi Chemical Corp
Original Assignee
Mitsubishi Chemical Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Mitsubishi Chemical Corp filed Critical Mitsubishi Chemical Corp
Priority to JP2017501414A priority Critical patent/JP6369622B2/ja
Priority to EP16878942.8A priority patent/EP3395526B1/en
Priority to CN201680074834.4A priority patent/CN108367461B/zh
Publication of WO2017111056A1 publication Critical patent/WO2017111056A1/ja
Priority to US15/970,935 priority patent/US10889025B2/en
Anticipated expiration legal-status Critical
Priority to US17/113,446 priority patent/US20210086404A1/en
Ceased legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • B29C70/504—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC] using rollers or pressure bands
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
    • B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
    • B29B15/10—Coating or impregnating independently of the moulding or shaping step
    • B29B15/12—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length
    • B29B15/122—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length with a matrix in liquid form, e.g. as melt, solution or latex
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/081—Combinations of fibres of continuous or substantial length and short fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/12—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of short length, e.g. in the form of a mat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • B29C70/502—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC] by first forming a mat composed of short fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
    • C08J5/241—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres
    • C08J5/243—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres using carbon fibres
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D11/00—Other features of manufacture
    • D01D11/02—Opening bundles to space the threads or filaments from one another
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02J—FINISHING OR DRESSING OF FILAMENTS, YARNS, THREADS, CORDS, ROPES OR THE LIKE
    • D02J1/00—Modifying the structure or properties resulting from a particular structure; Modifying, retaining, or restoring the physical form or cross-sectional shape, e.g. by use of dies or squeeze rollers
    • D02J1/18—Separating or spreading
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02J—FINISHING OR DRESSING OF FILAMENTS, YARNS, THREADS, CORDS, ROPES OR THE LIKE
    • D02J3/00—Modifying the surface
    • D02J3/02—Modifying the surface by abrading, scraping, scuffing, cutting, or nicking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2063/00—Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2307/00—Use of elements other than metals as reinforcement
    • B29K2307/04—Carbon
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D04H1/4218—Glass fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D04H1/4242—Carbon fibres
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2101/00—Inorganic fibres
    • D10B2101/02—Inorganic fibres based on oxides or oxide ceramics, e.g. silicates
    • D10B2101/06—Glass
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2101/00—Inorganic fibres
    • D10B2101/10—Inorganic fibres based on non-oxides other than metals
    • D10B2101/12—Carbon; Pitch

Definitions

  • the present invention relates to a method for manufacturing a fiber-reinforced resin molding material and a device for manufacturing a fiber-reinforced resin molding material.
  • SMC Sheet Molding Compound
  • SMC Sheet Molding Compound
  • SMC is a sheet-like fiber bundle group formed of a plurality of fiber bundles obtained by cutting long reinforcing fibers such as glass fibers and carbon fibers into a predetermined length.
  • SMC is used as an intermediate material for obtaining a molded product, and has a property of easily flowing during molding with a mold. Therefore, SMC is suitably used when forming parts with different thicknesses, ribs, bosses, etc. in the molded product.
  • SMC is manufactured, for example, by the following method.
  • a paste containing a thermosetting resin is applied on a sheet-like carrier conveyed in one direction to form a belt-like resin sheet.
  • On a traveling resin sheet long fiber bundles are cut into a predetermined length and dispersed to form a sheet-like fiber bundle group.
  • a resin sheet is further laminated on the sheet-like fiber bundle group, and the formed laminate is pressed from both sides so that the sheet-like fiber bundle group is impregnated with the resin to form SMC.
  • a fiber bundle having a large number of filaments called large tow is often used for the purpose of reducing the manufacturing cost.
  • the fiber bundle is expanded in the width direction by opening, and then the opened fiber bundle is divided and divided into a plurality of fiber bundles.
  • a method of cutting a bundle is known (for example, Patent Document 1 and Patent Document 2).
  • Patent Document 1 and Patent Document 2 A method of cutting a bundle.
  • the present invention is a method for producing a fiber-reinforced resin molding material that is excellent in strength properties of the obtained fiber-reinforced resin material molded body, which can be suitably applied to a fiber bundle having a large number of filaments called large tow, which is low in cost and excellent in productivity.
  • the purpose is to provide.
  • the present invention has the following configuration.
  • a method for producing a sheet-like fiber reinforced resin molding material containing a plurality of cut fiber bundles and a resin impregnated between filaments of the cut fiber bundles An aggregate manufacturing process for obtaining an aggregate by collecting sheet-like fiber bundle aggregates obtained by expanding a plurality of continuous fiber bundles in parallel in the width direction; A method for producing a fiber-reinforced resin molding material.
  • the fiber bundle aggregate is pulled out from the accumulation, and the cut fiber bundle is obtained by cutting at intervals in the longitudinal direction, and a plurality of the cut pieces are formed on the first resin sheet containing the first resin.
  • a spreading step of spreading the bundle of fibers into a sheet to form a group of sheet-like fiber bundles A second resin sheet containing a second resin is laminated on the sheet-like fiber bundle group and pressed, and the sheet-like fiber bundle group is impregnated with the first resin and the second resin to strengthen the fiber.
  • a bonding impregnation step for obtaining a resin molding material The manufacturing method of the fiber reinforced resin molding material as described in [1] which has. [3] The method for producing a fiber-reinforced resin molding material according to [1] or [2], wherein in the aggregate manufacturing process, the fiber bundle aggregate is divided and collected in the width direction by splitting.
  • An apparatus for producing a sheet-like fiber-reinforced resin molding material containing a plurality of cut fiber bundles and a resin impregnated between filaments of the cut fiber bundles A first manufacturing apparatus;
  • the first manufacturing apparatus includes an arrangement unit that arranges a plurality of continuous fiber bundles in the width direction;
  • a stacking unit that collects a sheet-like fiber bundle aggregate obtained from a plurality of the continuous fiber bundles arranged;
  • a second manufacturing apparatus is further provided, The second manufacturing apparatus includes a cutting machine that pulls out the fiber bundle aggregate from the collection obtained in the stacking unit, performs cutting with a gap in the longitudinal direction, and manufactures the cut fiber bundle.
  • a second resin sheet containing a second resin is laminated on a group of sheet-like fiber bundles formed by spreading a plurality of the cut fiber bundles in a sheet shape on a first resin sheet containing a first resin. And impregnating the sheet-like fiber bundle group with the first resin and the second resin to form a fiber-reinforced resin molding material,
  • a fiber reinforced resin molding material can be manufactured at low cost and with high productivity. By opening and dividing into a flat state, there can be obtained a fiber reinforced resin molding material having few uneven portions of the resin and excellent strength properties of the obtained fiber reinforced resin material molding.
  • the method for producing a fiber reinforced resin molding material and the apparatus for producing a fiber reinforced resin molding material of the present invention are particularly useful when a fiber bundle called a large tow having a large number of filaments is used.
  • the method for producing a fiber reinforced resin molding material of the present invention comprises a sheet-like fiber reinforced resin molding material (SMC) containing a plurality of cut fiber bundles and a resin impregnated between the filaments of the cut fiber bundle. ).
  • the manufacturing method of the fiber reinforced resin molding material of this invention has the following integrated-material manufacturing process.
  • the manufacturing method of the fiber reinforced resin molding material of this invention may have the following dispersion
  • the aggregate manufacturing process is a process of collecting a plurality of continuous fiber bundles in parallel in the width direction and collecting sheet-like fiber bundle aggregates obtained by widening to obtain an aggregate.
  • the continuous fiber bundles are widened in the width direction by opening to form a flat sheet-like fiber bundle aggregate.
  • the sheet-like fiber bundle aggregate is collected to obtain an accumulation.
  • a fiber bundle aggregate is drawn from the aggregate obtained by the aggregate manufacturing process, and a cut fiber bundle is obtained by cutting at intervals in the longitudinal direction of the fiber bundle aggregate.
  • This is a step of forming a sheet-like fiber bundle group by spreading a plurality of cut fiber bundles on a first resin sheet containing resin in a sheet form.
  • the fiber bundle aggregate drawn from the accumulation is continuously cut in the width direction with a predetermined interval in the longitudinal direction.
  • the cut fiber bundle obtained by this is spread
  • Bonding impregnation process In the bonding impregnation step, the second resin sheet containing the second resin is laminated and pressed on the sheet-like fiber bundle group obtained by the spreading step, and the first resin sheet is applied to the sheet-like fiber bundle group.
  • This is a step of obtaining a fiber-reinforced resin molding material by impregnating the first resin contained and the second resin contained in the second resin sheet.
  • the second resin sheet is bonded onto the sheet-like fiber bundle group, and the laminate in which the first resin sheet, the sheet-like fiber bundle group, and the second resin sheet are laminated in this order is pressed, whereby the sheet-like fiber
  • the bundle group is impregnated with resin to obtain a fiber-reinforced resin molding material.
  • the manufacturing method of the fiber reinforced resin molding material of this invention has an integrated-material manufacturing process. That is, in the method for producing a fiber-reinforced resin molding material of the present invention, a sheet-like fiber bundle aggregate obtained by expanding a plurality of continuous fiber bundles in parallel in the width direction is once collected to obtain an aggregate. (Aggregate manufacturing process), and a fiber bundle aggregate is drawn out from the obtained aggregate and used.
  • the process speed of the accumulation manufacturing process and the process speed of the spraying process and the bonding impregnation process can be controlled separately. Therefore, the fall of the process speed of a spreading
  • the fiber reinforced resin molding material manufacturing apparatus 100 of the present embodiment includes a first manufacturing apparatus 1 and a second manufacturing apparatus 2.
  • the 1st manufacturing apparatus 1 is provided with the spreading part 10 corresponding to the arrangement
  • the spread fiber part 10 separates the continuous fiber bundle f1 into the spread part 50 that opens the fiber bundle f1 in the width direction (Y-axis direction) and the spread fiber bundle f2 into the split fiber bundle f3.
  • a splitting unit 52 and a collecting unit 54 that collects the split fiber bundle f3 are provided. That is, in the present embodiment, the split fiber bundle f3 is collected as a fiber bundle aggregate in the collecting unit to constitute an accumulation.
  • the opening part 50 includes a plurality of opening bars 17 provided side by side in the X-axis direction with a space therebetween.
  • the plurality of spread bars 17 are continuous by means of heating, rubbing, swinging, etc. by each spread bar 17 when a plurality of continuous fiber bundles f1 pass in a zigzag manner in order above and below each spread bar 17.
  • the fiber bundle f1 is widened in the width direction. By opening the continuous fiber bundle f1, an open, that is, flat, continuous fiber bundle f2 is obtained.
  • the splitting unit 52 includes a plurality of rotary blades 18 and a plurality of godet rolls 19.
  • the plurality of rotary blades 18 are arranged side by side at a predetermined interval in the width direction (Y-axis direction) of the opened fiber bundle f2.
  • Each rotary blade 18 is provided with a plurality of blades 18a arranged in a row in the circumferential direction.
  • the split fiber bundle f3 is not in a completely split state, and is partially a fiber bundle aggregate in an unsplit state (combined state) and is continuous.
  • the fiber bundle is in a state where the fiber bundle is intermittently split at predetermined intervals in the longitudinal direction.
  • the plurality of godet rolls 19 guide the separated fiber bundle f3 to the collecting unit 54.
  • the collecting unit 54 can wind the separated fiber bundle f3, which is a sheet-like fiber bundle aggregate, around the bobbin B2 and collect it as an accumulation.
  • the second manufacturing apparatus 2 includes a first carrier sheet supply unit 11, a first transport unit 20, a first coating unit 12, a cutting machine 13, a second carrier sheet supply unit 14, 2 transport units 28, a second coating unit 15, and an impregnation unit 16.
  • the first carrier sheet supply unit 11 supplies the first carrier sheet C1 that is long, that is, continuous, drawn from the first raw roll R1 to the first transport unit 20.
  • the 1st conveyance part 20 is provided with the conveyor 23 which multiplied the endless belt 22 between a pair of pulleys 21a and 21b.
  • the conveyor 23 rotates the endless belt 22 by rotating the pair of pulleys 21a and 21b in the same direction, and conveys the first carrier sheet C1 toward the right side in the X-axis direction on the surface of the endless belt 22.
  • the first coating unit 12 is located immediately above the pulley 21a side in the first transport unit 20, and includes a coater 24 that supplies a paste P containing a thermosetting resin that is a first resin. .
  • the paste P has a predetermined thickness (0.05 mm to 0.8 mm, preferably 0.1 mm to 0.7 mm, on the surface of the first carrier sheet C1. More preferably, the first resin sheet S1 containing the first resin is formed by coating at 0.15 mm to 0.6 mm). The first resin sheet S1 travels along with the conveyance of the first carrier sheet C1.
  • the cutting machine 13 is positioned above the first carrier sheet C1 at a later stage in the transport direction than the first coating unit 12.
  • a guide roll 38 is provided for guiding the divided fiber bundles f3 drawn from the collected material collected around the bobbin B2 to the cutting machine 13.
  • a fiber bundle aggregate (divided fiber bundle f3) may be drawn from each accumulation and guided to the cutting machine 13. In this case, it is preferable to install and extract each accumulated product on individual rolls, rather than installing them on the same roll.
  • the bobbins B2 may be installed on individual rolls to draw the separated fiber bundles f3. preferable. Thereby, even if the length of the fiber bundle in each accumulation
  • the cutting machine 13 cuts the separated fiber bundles f3 that have been once wound around the bobbin B2 and collected from the collected material, with an interval in the longitudinal direction of the fiber bundle assembly (separated fiber bundles f3).
  • the fiber bundle is cut into a predetermined length and a cut fiber bundle is manufactured, and includes a guide roll 25, a pinch roll 26, and a cutter roll 27.
  • the guide roll 25 guides the supplied separated fiber bundle f3 downward while rotating.
  • the pinch roll 26 rotates in the direction opposite to that of the guide roll 25 while sandwiching the fiber bundle f ⁇ b> 3 separated between the pinch roll 25 and the guide roll 25.
  • the cutter roll 27 cuts the fiber bundle f3 divided while rotating so that the fiber bundle aggregate (fiber bundle f3 divided) is spaced apart in the longitudinal direction.
  • the fiber bundle f4 cut to a predetermined length by the cutting machine 13 falls and is spread on the first resin sheet S1 containing the first resin, and the sheet-like fiber bundle group F is formed on the first resin sheet. It is formed.
  • the second carrier sheet supply unit 14 supplies the second carrier sheet C2 that is long, that is, continuous, drawn from the second raw roll R2 to the second transport unit 28.
  • the second transport unit 28 is located above the first carrier sheet C ⁇ b> 1 transported by the conveyor 23 and includes a plurality of guide rolls 29.
  • the second transport unit 28 transports the second carrier sheet C2 supplied from the second carrier sheet supply unit 14 in the direction opposite to the first carrier sheet C1 (left side in the X-axis direction).
  • the conveying direction is reversed by the plurality of guide rolls 29 in the same direction as the first carrier sheet C1.
  • the 2nd coating part 15 is located directly on the 2nd carrier sheet C2 currently conveyed in the direction opposite to the 1st carrier sheet C1, and is the paste P containing the thermosetting resin which is 2nd resin.
  • the coater 30 is provided. By passing the second carrier sheet C2 through the coater 30, the paste P has a predetermined thickness (0.05 mm to 0.8 mm, preferably 0.1 mm to 0.7 mm, on the surface of the second carrier sheet C2. More preferably, the second resin sheet S2 containing the second resin is formed by coating at 0.15 mm to 0.6 mm. The second resin sheet S2 travels with the conveyance of the second carrier sheet C2. Note that the first resin and the second resin may be the same or different, and are preferably the same.
  • the impregnation part 16 is located in the back
  • the pasting mechanism 31 is located above the pulley 21b of the conveyor 23 and includes a plurality of pasting rolls 33.
  • the some bonding roll 33 is arrange
  • the first carrier sheet C1 and the second carrier sheet C2 are overlapped with the first resin sheet S1, the sheet-like fiber bundle group F, and the second resin sheet S2 sandwiched therebetween, It is conveyed while being pasted together. Thereby, the laminated body which laminated
  • what bonded the 1st carrier sheet C1 and the 2nd carrier sheet C2 in the state where the 1st resin sheet S1, sheet-like fiber bundle group F, and the 2nd resin sheet S2 were inserted was pasted sheet S3.
  • the pressurizing mechanism 32 is located at the subsequent stage of the bonding mechanism 31, and includes a lower conveyor 36A in which an endless belt 35a is hung between a pair of pulleys 34a and 34b, and an endless belt 35b between the pair of pulleys 34c and 34d. And an upper conveyor 36B.
  • the lower conveyor 36A and the upper conveyor 36B are arranged to face each other in a state where the endless belts 35a and 35b are abutted with each other.
  • the pair of pulleys 34a and 34b of the lower conveyor 36A are rotated in the same direction, whereby the endless belt 35a is circulated.
  • the pair of pulleys 34c and 34d of the upper conveyor 36B are rotated in the same direction, whereby the endless belt 35b is rotated in the reverse direction at the same speed as the endless belt 35a.
  • interposed between the endless belts 35a and 35b is conveyed by the right side of a X-axis direction.
  • the pressurizing mechanism 32 is further provided with a plurality of lower rolls 37a and a plurality of upper rolls 37b.
  • the plurality of lower rolls 37a are arranged side by side in the transport direction in contact with the back surface of the butted portion of the endless belt 35a.
  • the plurality of upper rolls 37b are arranged side by side in the transport direction in contact with the back surface of the butted portion of the endless belt 35b.
  • the some lower side roll 37a and the some upper side roll 37b are arrange
  • the pressurizing mechanism 32 the first resin sheet S1 sandwiched between the first carrier sheet C1 and the second carrier sheet C2 while the bonding sheet S3 passes between the endless belts 35a and 35b.
  • the sheet-like fiber bundle group F and the second resin sheet S2 are pressed by a plurality of lower rolls 37a and a plurality of upper rolls 37b.
  • the sheet-like fiber bundle group F is impregnated with the first resin contained in the first resin sheet S1 and the second resin contained in the second resin sheet S2.
  • the raw fabric R of the fiber reinforced resin molding material is obtained.
  • the original fabric R can be cut into a predetermined length and used for molding.
  • the first carrier sheet C1 and the second carrier sheet C2 are peeled from the fiber reinforced resin molding material before molding the fiber reinforced resin molding material.
  • the continuous fiber bundle f1 is pulled out from the bobbin B1, and in the fiber opening unit 50, the continuous fiber bundle f1 is passed in a zigzag manner up and down each opening bar 17 in the width direction by the fiber opening.
  • the spread fiber bundle f2 is widened and flattened continuously.
  • the fiber bundle f2 that has been opened is passed while rotating the plurality of rotary blades 18 in the fiber separation unit 52, the plurality of blades 18a are pierced intermittently, and the fiber bundle f2 that has been opened is divided in the width direction to obtain a plurality of pieces.
  • the split fiber bundle f3 is not in a completely split state, and is a fiber bundle aggregate that is partially unsplit (combined), and is continuous. In this state, the fiber bundles are intermittently split at a predetermined interval in the longitudinal direction. Next, the divided fiber bundle f3 is guided to the bobbin B2 by a plurality of godet rolls 19, and wound and collected.
  • the fiber bundle aggregate is partially unseparated, so that even when a fiber bundle in which skew or meander is present in some filaments is used as the continuous fiber bundle f1, the fiber bundle is separated. Thereby, the cutting
  • a is the length of the division part in the continuous fiber bundle (divided fiber bundle f3)
  • L is the space
  • a / L is set to 1 or more, undivided undivided parts in each cut fiber bundle f4 are reduced, so that the reinforcement during the production of the fiber reinforced resin molding material is performed. This is because the fiber dispersibility tends to be good and the quality of the fiber reinforced resin molding material tends to be good.
  • the value of a / L is preferably 1.05 or more, and more preferably 1.1 or more.
  • the symbols in the formula (2) have the same meaning as the symbols in the formula (1). This is because when the value of a / L is set to 10 or less, even if the filaments in the continuous fiber bundle f1 to be divided are skewed or meandered, the cut fiber bundle This is because the generation of f4 fluff and the occurrence of process troubles due to fluff tend to be suppressed.
  • the value of a / L is preferably 8 or less, and more preferably 5 or less.
  • the value of a / L is preferably 1 to 10, more preferably 1.05 to 8, and further preferably 1.1 to 5.
  • intermittent splitting in the longitudinal direction of continuous fiber bundles is performed so as to satisfy the condition of the following expression (3). It is preferable to obtain a fiber bundle f4 which is cut by performing fiber separation and cutting the continuous fiber bundles at intervals in the longitudinal direction. 0.9 ⁇ a / (a + b) ⁇ 1 (3)
  • a is the length of the division part in the continuous fiber bundle (divided fiber bundle f3)
  • b is in the continuous fiber bundle (divided fiber bundle f3). This is the length between intermittent splitting portions, that is, the length of unsplit portions existing between intermittent splitting portions in a continuous fiber bundle.
  • a / (a + b) is set to 0.9 or more, undivided undivided portions in each cut fiber bundle are reduced. This is because the dispersibility of the reinforcing fibers in the resin tends to be good, and the quality of the fiber-reinforced resin molding material tends to be good.
  • the value of a / (a + b) is preferably 0.92 or more.
  • a / (a + b) is preferably 0.99 or less, and more preferably 0.98 or less.
  • the value of a / (a + b) is preferably from 0.9 to less than 1, more preferably from 0.9 to 0.99, and even more preferably from 0.92 to 0.98.
  • a carbon fiber bundle is preferably used as a continuous fiber bundle used in the method for producing a fiber-reinforced resin molding material of the present invention.
  • a glass fiber bundle may be used as the continuous fiber bundle.
  • the fiber bundle which consists of a filament with 3,000 or more fibers can be used, for example, it is preferable to use a fiber bundle with 12,000 or more filaments. it can.
  • a fiber bundle composed of 48,000 or more filaments called large tow can also be used.
  • the average thickness of the fiber bundle aggregate collected as an aggregate is preferably 0.01 mm to 0.3 mm, more preferably 0.02 mm to 0.2 mm, and 0.025 mm to 0.15 mm is more preferable. If the average thickness of the fiber bundle aggregate is equal to or greater than the lower limit value, the fiber bundle aggregate can be stably opened. If the average thickness is equal to or less than the upper limit value, the fiber-reinforced resin molding material has high strength. The physical properties become. The average thickness of the fiber bundle assembly is measured with a micro gauge.
  • the width of the fiber bundle aggregate collected as the aggregate is preferably 0.5 mm to 50 mm, more preferably 1 mm to 40 mm, and further preferably 2 mm to 25 mm. If the width of the fiber bundle aggregate is not less than the lower limit, the fluidity of the fiber reinforced resin molding material is good, and if it is not more than the upper limit, the fiber reinforced resin molding material has high strength properties.
  • the first carrier sheet supply unit 11 pulls out a long, ie, continuous, first carrier sheet C 1 from the first original fabric roll R 1 and supplies it to the first transport unit 20. Then, the first coating unit 12 applies the paste P containing the first resin with a predetermined thickness to form the first resin sheet S1 containing the first resin. By transporting the first carrier sheet C1 by the first transport unit 20, the first resin sheet S1 on the first carrier sheet C1 is caused to travel.
  • thermosetting resin that is the first resin contained in the paste P is not particularly limited, and examples thereof include unsaturated polyester resins.
  • the paste P may contain a filler such as calcium carbonate, a low shrinkage agent, a release agent, a curing initiator, a thickener, and the like.
  • the continuously split fiber bundle f3 is pulled out from the bobbin B2, and the cutting machine 13 performs cutting with an interval in the longitudinal direction so as to have a predetermined length, and the cut fiber bundle f4 is the first. It is dropped and sprayed on the resin sheet S1. As a result, the sheet-like fiber bundle group F in which the plurality of cut fiber bundles f4 are split in the opened state and dispersed in a random fiber orientation is continuously formed on the traveling first resin sheet S1. Formed.
  • the cut fiber bundle f4 is obtained by cutting continuous fiber bundles (divided fiber bundles f3) at intervals in the longitudinal direction.
  • the average length of the cut fiber bundle is preferably 5 to 100 mm, more preferably 10 to 75 mm, and still more preferably 20 to 60 mm. If the average length of the cut fiber bundle is equal to or greater than the lower limit value, a fiber reinforced resin material molded body having excellent physical properties such as tensile strength and elastic modulus can be obtained. Since the reinforced resin molding material becomes easier to flow, molding becomes easier.
  • the second carrier sheet supply unit 14 pulls out a long, ie, continuous, second carrier sheet C2 from the second raw fabric roll R2 and supplies it to the second transport unit 28.
  • the second coating unit 15 applies the paste P containing the second resin with a predetermined thickness on the surface of the second carrier sheet C2 to form the second resin sheet S2 containing the second resin. To do.
  • thermosetting resin that is the second resin contained in the paste P is not particularly limited, and examples thereof include unsaturated polyester resins.
  • the paste P may contain a filler such as calcium carbonate, a low shrinkage agent, a release agent, a curing initiator, a thickener, and the like.
  • the second resin sheet S2 is caused to travel by conveying the second carrier sheet C2, and in the impregnation unit 16, the second resin sheet S2 is laminated on the sheet-like fiber bundle group F by the bonding mechanism 31 and bonded.
  • the pressurization mechanism 32 pressurizes the laminated body including the first resin sheet S1, the sheet-like fiber bundle group F, and the second resin sheet S2, and the first resin and the second resin sheet included in the first resin sheet S1.
  • the sheet-like fiber bundle group F is impregnated with the second resin contained in S2. Thereby, the raw fabric R of the fiber reinforced resin molding material in which the fiber reinforced resin molding material is sandwiched between the first carrier sheet C1 and the second carrier sheet C2 is obtained.
  • the continuous fiber bundle f1 is opened, and the separated fiber bundle f3 (fiber bundle aggregate) is once collected to obtain an accumulation, and then accumulated in the spreading process. Pull out the fiber bundle assembly from the object. Therefore, the process speed of the spraying process and the bonding impregnation process can be controlled regardless of the process speed of the integrated product manufacturing process, and the fiber bundle opening operation becomes rate limiting, and the process of the spraying process and the bonding impregnation process. It can suppress that speed falls. Further, as described above, the cut fiber bundle f4 obtained by cutting the fiber bundle f3 that has been spread and split in a flat state is continuously formed on the first resin sheet S1 with a random fiber orientation. By being dispersed, there can be obtained a fiber reinforced resin molding material having few uneven resin portions and excellent strength properties.
  • the fiber bundle that has been split is put into a bobbin with a godet roll. It is not limited to the mode of guiding.
  • the opened fiber bundle may be guided by a godet roll and then split to obtain a split fiber bundle.
  • the manufacturing method of the fiber-reinforced resin molding material of the present invention is a manufacturing method using a manufacturing apparatus in which the first manufacturing apparatus 1 is changed to the first manufacturing apparatus 1A illustrated in FIG. There may be.
  • the same parts in FIG. 4 as those in FIG. 1 A of 1st manufacturing apparatuses are the same as the 1st manufacturing apparatus 1 except having provided the splitting part 52A instead of the splitting part 52.
  • FIG. The splitting unit 52A is the same as the splitting unit 52 except that the plurality of rotary blades 18 are arranged at the subsequent stage of the plurality of godet rolls 19.
  • the opened fiber bundle f2 is guided to the rotary blade 18 by the godet roll 19, and the opened fiber bundle f2 is divided in the width direction by splitting, The split fiber bundle f3 can be obtained.
  • the fiber bundle aggregates are respectively drawn from the plurality of aggregates obtained in the aggregate production process, and the respective fiber bundle aggregates drawn are overlapped, and the longitudinal direction thereof It is preferable to obtain a fiber bundle that has been cut by cutting with an interval of.
  • FIGS. 1 and 3 As a method for producing the fiber-reinforced resin molding material of the present invention, for example, a method using a fiber-reinforced resin molding material manufacturing apparatus 200 (hereinafter also simply referred to as “manufacturing apparatus 200”) illustrated in FIGS. 1 and 3. Is mentioned. In FIG. 3, the same parts as those in FIG.
  • the manufacturing apparatus 200 includes a first manufacturing apparatus 1 and a second manufacturing apparatus 3. That is, the manufacturing apparatus 200 is the same as the manufacturing apparatus 100 except that the second manufacturing apparatus 3 is provided instead of the second manufacturing apparatus 2.
  • the second manufacturing apparatus 3 pulls out the plurality of separated fiber bundles f3 from the collected material collected in the plurality of bobbins B2, and superimposes each of the extracted fiber bundles f3.
  • the second manufacturing apparatus 2 is the same as the second manufacturing apparatus 2 except that the fiber bundle aggregates are supplied to the cutting machine 13 and simultaneously cut.
  • the accumulation manufacturing process in the second embodiment can be performed in the same manner as the accumulation manufacturing process in the first embodiment. That is, in the present embodiment, the split fiber bundle f3 is collected as a fiber bundle aggregate in the collecting unit to constitute an accumulation.
  • the first carrier sheet supply unit 11 pulls out the first, continuous, first carrier sheet C1 from the first raw fabric roll R1. 1 to the first conveying unit 20, the first coating unit 12 applies the paste P containing the first resin to a predetermined thickness, and the first resin sheet S1 containing the first resin is applied. Form. By transporting the first carrier sheet C1 by the first transport unit 20, the first resin sheet S1 on the first carrier sheet C1 is caused to travel.
  • a plurality of continuously separated fiber bundles f3 are drawn from a plurality of bobbins B2, and are cut by separating them in the longitudinal direction so as to be a predetermined length in the cutting machine 13 by overlapping them.
  • the bundle of fibers f4 is dropped and sprayed on the first resin sheet S1.
  • the sheet-like fiber bundle group F in which the plurality of cut fiber bundles f4 are split on the traveling first resin sheet S1 and spread in a random fiber orientation is continuously formed. Formed.
  • a plurality of fiber bundle aggregates are obtained.
  • the plurality of fiber bundle assemblies are stacked and cut so that the width directions are shifted.
  • the factors for obtaining such an effect are considered as follows. That is, in a plurality of fiber bundle aggregates separated by the same device, the division positions in the width direction are the same position. Therefore, when the plurality of fiber bundles are overlapped and cut so that the width directions coincide with each other, the division positions in the width direction coincide with each other in the laminated body of the laminated fiber bundles. It tends to occur. On the other hand, in the embodiment in which a plurality of fiber bundles are stacked and cut so that the width direction is shifted, the division position in the width direction in the laminated body of the stacked fiber bundles is also shifted. Unevenness is less likely to occur.
  • the continuous fiber bundle f1 is opened, and the separated fiber bundle f3 is once collected to obtain an integrated product, and then the aggregated fiber bundles are collected from the integrated product in the spraying process. Pull out and use your body. Therefore, the process speed of the spraying process and the bonding impregnation process can be controlled regardless of the process speed of the integrated product manufacturing process, and the fiber bundle opening operation becomes rate limiting, and the process of the spraying process and the bonding impregnation process. It can suppress that speed falls. Further, as described above, the cut fiber bundle f4 obtained by cutting the fiber bundle f3 that has been spread and split in a flat state is continuously formed on the first resin sheet S1 with a random fiber orientation. By being dispersed, a fiber-reinforced resin molding material having few uneven resin portions and excellent strength properties can be obtained, and a fiber-reinforced resin molding material having less unevenness in the basis weight and little variation in physical properties can be obtained.
  • the spread fiber bundle may be guided by a godet roll and then split to obtain a split fiber bundle.
  • the manufacturing method of the fiber-reinforced resin molding material of the present invention is a manufacturing method using a manufacturing apparatus in which the first manufacturing apparatus 1 is changed to the first manufacturing apparatus 1A illustrated in FIG. There may be. Thereby, even if fluffing occurs in the fiber bundle at the time of fiber separation, problems due to winding around the roll are less likely to occur.
  • the fiber bundles opened in the integrated product manufacturing process are collected, and in the spraying process, the collected fiber bundles (integrated product) are drawn and separated. Then, you may cut and spread.
  • the fiber bundles that have been spread are separated in the integrated product manufacturing process, and the fiber bundles that have been separated are collected, but the fiber bundles may be separated in the spraying process. . That is, in the present embodiment, the opened fiber bundle f2 is collected as a fiber bundle aggregate in the collecting unit to constitute an accumulation.
  • the fiber reinforced resin of the present invention that collects the fiber bundles that have been opened in the integrated product manufacturing process, and draws, splits, divides, and cuts / spreads the collected fiber bundles (collected product) in the application process.
  • a method for producing the molding material for example, a method using the fiber-reinforced resin molding material production apparatus 300 illustrated in FIGS. 5 and 6 (hereinafter, also simply referred to as “production apparatus 300”) can be given. 5 and FIG. 6 that are the same as those in FIG. 1 and FIG.
  • the manufacturing apparatus 300 includes a first manufacturing apparatus 4 and a second manufacturing apparatus 5.
  • the first manufacturing apparatus 4 includes an opening unit 50, a guide roll 40, and a collection unit 54.
  • the first manufacturing apparatus 4 is the same as the first manufacturing apparatus 1 except that the guide roll 40 is provided instead of the separating unit 52.
  • a plurality of long, ie, continuous, fiber bundles f1 drawn from the bobbin B1 are opened at the opening portion 50, and the fiber bundle f2 (fiber bundle aggregate) is guided to the collecting portion 54 by the guide roll 40. It is wound around bobbin B2.
  • the second manufacturing apparatus 5 includes a separating unit 52, a first carrier sheet supply unit 11, a first transport unit 20, a first coating unit 12, a cutting machine 13, and a second carrier sheet.
  • a supply unit 14, a second transport unit 28, a second coating unit 15, and an impregnation unit 16 are provided.
  • the second manufacturing apparatus 5 is the same as the second manufacturing apparatus 2 except that it further includes a splitting unit 52.
  • the separating unit 52 is provided in the front stage of the cutting machine 13.
  • the spread fiber bundle f2 (fiber bundle aggregate) drawn from the bobbin B2 is guided to the guide roll 41 and supplied to the splitting section 52, and the fiber bundle f3 split in the splitting section 52 is cut. 13 is supplied.
  • the continuous fiber bundle f1 is pulled out from the bobbin B1, and in the fiber opening unit 50, the continuous fiber bundle f1 is passed in a zigzag manner in the top and bottom of each fiber opening bar 17 in the width direction.
  • the spread fiber bundle f2 is widened and flattened.
  • the opened fiber bundle f2 is guided to the collection unit 54 by the guide roll 40, wound around the bobbin B2, and collected as an accumulation.
  • a plurality of guide rolls 40 may be used.
  • the opened fiber bundle f2 When winding the continuous opened fiber bundle f2 around the bobbin B2, the opened fiber bundle f2 may be wound with a paper or film overlapped. As a result, paper or a film is inserted between the opened fiber bundles f2 wound on the bobbin B2, so that the fibers of the opened fiber bundle f2 to be wound are entangled and difficult to draw out. It becomes easy to be suppressed.
  • the first carrier sheet supply unit 11 pulls out a long, ie, continuous, first carrier sheet C 1 from the first original roll R 1 and supplies it to the first transport unit 20.
  • the first coating unit 12 applies the paste P containing the first resin with a predetermined thickness to form the first resin sheet S1 containing the first resin.
  • the first resin sheet S1 on the first carrier sheet C1 is caused to travel.
  • the continuous opened fiber bundle f2 is pulled out from the bobbin B2, and the opened fiber bundle f2 is allowed to pass while rotating the plurality of rotary blades 18 in the separating section 52, and the plurality of blades 18a are intermittently passed.
  • the fiber bundle f2 pierced and opened is divided in the width direction to obtain a continuous fiber bundle f3.
  • the split fiber bundle f ⁇ b> 3 is supplied to the cutting machine 13 by a plurality of godet rolls 19.
  • the continuous split fiber bundle f3 is cut so as to have a predetermined length, with a gap in the longitudinal direction thereof, and the cut fiber bundle f4 is placed on the first resin sheet S1. Drop and spray. As a result, the sheet-like fiber bundle group F in which the plurality of cut fiber bundles f4 are split in the opened state and dispersed in a random fiber orientation is continuously formed on the traveling first resin sheet S1. Formed.
  • the continuous fiber bundle f1 is opened in the integrated product manufacturing process, the opened fiber bundle f2 (fiber bundle aggregate) is once collected, and then opened in the spreading process. (Fiber bundle assembly) is pulled out and used. Therefore, the process speed of the spraying process and the bonding impregnation process can be controlled regardless of the process speed of the integrated product manufacturing process, and the fiber bundle opening operation becomes rate limiting, and the process of the spraying process and the bonding impregnation process. It can suppress that speed falls. Further, as described above, the cut fiber bundle f4 obtained by cutting the fiber bundle f3 that has been spread and split in a flat state is continuously formed on the first resin sheet S1 with a random fiber orientation. By being dispersed, there can be obtained a fiber reinforced resin molding material having few uneven resin portions and excellent strength properties.
  • the split fiber bundle is transferred to a cutting machine with a godet roll.
  • the mode of guidance is not limited.
  • the opened fiber bundle may be guided by a godet roll and then split to obtain a split fiber bundle.
  • the manufacturing method of the fiber reinforced resin molding material of the present invention includes the second manufacturing apparatus 5A illustrated in FIG. 8 except that the splitting part 52 is changed to the splitting part 52A.
  • a method using the manufacturing apparatus 300 ⁇ / b> A having the same mode as the above may be used.
  • the splitting unit 52A is the same as the splitting unit 52 except that the plurality of rotary blades 18 are arranged at the subsequent stage of the plurality of godet rolls 19.
  • the collected opened fiber bundle f2 is drawn out, guided to the rotary blade 18 by a godet roll, and the opened fiber bundle f2 is divided in the width direction by splitting.
  • the divided fiber bundle f3 can be obtained.
  • the fiber of the present invention is obtained by pulling out a fiber bundle aggregate from each of the obtained plurality of aggregates, superimposing the drawn fiber bundle aggregates, and obtaining a fiber bundle cut by cutting at intervals in the longitudinal direction.
  • Examples of the method for producing a reinforced resin molding material include a method using a fiber reinforced resin molding material production apparatus 400 (hereinafter also simply referred to as “production apparatus 400”) illustrated in FIGS. 5 and 7. The same parts in FIG. 7 as those in FIG.
  • the manufacturing apparatus 400 includes a first manufacturing apparatus 4 and a second manufacturing apparatus 6. That is, the manufacturing apparatus 400 is the same as the manufacturing apparatus 300 except that the second manufacturing apparatus 6 is provided instead of the second manufacturing apparatus 5.
  • the second manufacturing apparatus 6 pulls out a plurality of opened fiber bundles f2 from the collected material collected in a plurality of bobbins B2, and superimposes the drawn out fiber bundles f2.
  • the second manufacturing apparatus 5 is the same as the second manufacturing apparatus 5 except that the fiber bundle aggregates are simultaneously cut and supplied to the cutting machine 13.
  • the accumulation manufacturing process in the fourth embodiment can be performed in the same manner as the accumulation manufacturing process in the third embodiment. That is, in the present embodiment, the opened fiber bundle f2 is collected as a fiber bundle aggregate in the collecting unit to constitute an accumulation.
  • the first carrier sheet supply unit 11 pulls out a long, ie, continuous, first carrier sheet C 1 from the first raw roll R 1. 1 to the first conveying unit 20, the first coating unit 12 applies the paste P containing the first resin to a predetermined thickness, and the first resin sheet S1 containing the first resin is applied. Form. By transporting the first carrier sheet C1 by the first transport unit 20, the first resin sheet S1 on the first carrier sheet C1 is caused to travel.
  • a plurality of continuous fiber bundles f2 drawn from the plurality of bobbins B2 are drawn out, separated in the separating unit 52, and overlapped with each other so as to have a predetermined length in the cutting machine 13 in the longitudinal direction.
  • the cut fiber bundle f4 is dropped on the first resin sheet S1 and dispersed.
  • the sheet-like fiber bundle group F in which the plurality of cut fiber bundles f4 are split on the traveling first resin sheet S1 and spread in a random fiber orientation is continuously formed. Formed.
  • a fiber bundle is obtained by stacking a plurality of fiber bundle aggregates drawn from a plurality of aggregates in the spraying step and cutting them at intervals in the longitudinal direction, a plurality of fibers are obtained.
  • the plurality of fiber bundle aggregates are overlapped and cut so that the width direction is shifted.
  • the continuous fiber bundle f1 is opened, and the opened fiber bundle f2 is collected once to obtain an integrated product. Pull out and use your body. Therefore, the process speed of the spraying process and the bonding impregnation process can be controlled regardless of the process speed of the integrated product manufacturing process, and the fiber bundle opening operation becomes rate limiting, and the process of the spraying process and the bonding impregnation process. It can suppress that speed falls.
  • the cut fiber bundle f4 obtained by cutting the fiber bundle f3 that has been spread and split in a flat state is continuously formed on the first resin sheet S1 with random fiber orientation. By being dispersed, it is possible to obtain a fiber reinforced resin molding material having few uneven resin portions and excellent strength properties, and obtaining a fiber reinforced resin molding material having less unevenness per unit area and little variation in physical properties.
  • the spread fiber bundle may be guided by a godet roll and then split to obtain a split fiber bundle.
  • the method for manufacturing the fiber-reinforced resin molding material of the present invention may be a manufacturing method using a manufacturing apparatus in which the splitting part 52 is changed to the splitting part 52A in the manufacturing apparatus 400.
  • the manufacturing method of the fiber reinforced resin molding material of the present invention from the point that the apparatus configuration becomes simpler, for the opened fiber bundle drawn from the aggregate as in the third and fourth embodiments.
  • the method of collecting the split fiber bundles that have been split after opening as in the first and second embodiments is preferable to the method of splitting.
  • the fiber bundle is once collected after the fiber bundle is opened. It can suppress that process speed of this falls. Further, in the method for producing a fiber-reinforced resin molding material of the present invention, a fiber-reinforced resin molding material can be produced at low cost with high productivity, and the fiber bundle is opened and divided into a flat state. Fiber reinforced resin molding with few uneven parts of resin and excellent strength physical properties by cutting the cut fiber bundle obtained by cutting the fiber bundle continuously onto the first resin sheet with random fiber orientation Material can be obtained.
  • the method for producing a fiber-reinforced resin molding material and the apparatus for producing a fiber-reinforced resin molding material of the present invention are particularly useful when a fiber bundle called a large tow having a large number of filaments is used.
  • the manufacturing method of the fiber reinforced resin molding material of this invention is not limited to an above described method.
  • the method for collecting the fiber bundles opened in the integrated product manufacturing process is not limited to winding, and a known collection method such as transfer may be adopted.
  • Example 1 A carbon fiber bundle (trade name “TRW40 50L”, manufactured by Mitsubishi Rayon Co., Ltd.) was used as a continuous fiber bundle.
  • a phosphoric acid ester derivative composition product
  • modified diphenylmethane diisocyanate product name: Cosmonate LL, manufactured by Mitsui Chemicals
  • 4- benzoquinone Product name: p-benzoquinone, manufactured by Wako Pure Chemical Industries, Ltd.
  • a plurality of continuous fiber bundles drawn from the bobbin B1 in the first manufacturing apparatus 1 are arranged in the width direction, and the fiber bundle width is opened to 25 mm in the fiber opening unit 50.
  • the fiber separation unit 52 a As a result, the fiber bundles were separated so as to be divided into two parts so that the value of / (a + b) was 0.98, and an aggregate collected at the accumulation unit at a speed of 40 m / min was obtained.
  • the paste was applied onto the first carrier sheet being conveyed to form a first resin sheet having a thickness of 0.45 mm.
  • an accumulation (collected carbon fiber bundles having a thickness of 0.1 mm and a width of 12.5 mm which has been opened and separated) collected by the accumulation unit is cut with a cutting machine, and the value of a / L is 1. 1 was dropped as a chopped fiber bundle having an average fiber length of 25.4 mm to form a sheet-like fiber bundle group having a thickness of 1.3 mm.
  • the line speed was 1.5 m / min.
  • Above the first carrier sheet by applying the paste on the second carrier sheet that is conveyed in the opposite direction to the first carrier sheet, to form a second resin sheet having a thickness of 0.45 mm, The second resin sheet was laminated and laminated on the sheet-like fiber bundle group with the conveying direction reversed. Furthermore, the laminated body of the first resin sheet, the sheet-like fiber bundle group, and the second resin sheet was impregnated to obtain a sheet-like fiber-reinforced resin molding material having a thickness of 2 mm.
  • the fiber-reinforced resin molding material obtained is cured for one week, cut into 250 mm x 250 mm, and applied to a panel molding die (300 mm x 300 mm x 2 mm, surface chrome plating finish) having a fitting part at the end. Aligning the conveyance direction (MD direction) of the fiber reinforced resin molding material in the reinforced resin molding material manufacturing apparatus, two sheets were put into the center of the mold to obtain a fiber reinforced resin material molded body (fiber content 53 wt%). . The resulting molded article had a high tensile strength of 150 Mpa.
  • Example 2 A carbon fiber bundle (trade name “TR50S 15L”, manufactured by Mitsubishi Rayon Co., Ltd.) was used as a continuous fiber bundle.
  • the width of the fiber bundle is opened up to 15 mm at the opening portion, and the value of a / (a + b) is 0.92 at the dividing portion so as to be divided into two.
  • the fiber bundle assembly was collected at a speed of 40 m / min.
  • Example 2 The paste obtained in Example 1 was applied on the first carrier sheet being conveyed to form a first resin sheet having a thickness of 0.45 mm.
  • the collection (collected carbon fiber bundles having a thickness of 0.05 mm and a width of 7.5 mm that has been opened and separated) collected by the accumulation unit is cut with a cutting machine, and the value of a / L is 5.
  • a chopped fiber bundle having an average fiber length of 25.4 mm was dropped to form a sheet-like fiber bundle group having a thickness of 1.4 mm.
  • the line speed was 1.5 m / min.
  • Example 2 In the same manner as in Example 1, the second resin sheet was laminated on the sheet-like fiber bundle group and laminated, the laminate was impregnated, and a sheet-like fiber-reinforced resin molding material having a thickness of 2.1 mm was obtained. Obtained.
  • Example 2 Under the same conditions as in Example 1, molding was performed using a fiber reinforced resin molding material obtained after curing for one week to obtain a fiber reinforced resin material molding (fiber content 57 wt%). The resulting molded article had a high tensile strength of 240 MPa.

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PCT/JP2016/088441 2015-12-25 2016-12-22 繊維強化樹脂成形材料の製造方法、及び繊維強化樹脂成形材料の製造装置 Ceased WO2017111056A1 (ja)

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CN201680074834.4A CN108367461B (zh) 2015-12-25 2016-12-22 纤维强化树脂成型材料的制造方法以及纤维强化树脂成型材料的制造装置
US15/970,935 US10889025B2 (en) 2015-12-25 2018-05-04 Method for manufacturing fiber-reinforced resin molding material, and device for manufacturing fiber-reinforced resin molding material
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