WO2023100702A1 - Procédé de production d'un préimprégné en feuille - Google Patents

Procédé de production d'un préimprégné en feuille Download PDF

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Publication number
WO2023100702A1
WO2023100702A1 PCT/JP2022/042993 JP2022042993W WO2023100702A1 WO 2023100702 A1 WO2023100702 A1 WO 2023100702A1 JP 2022042993 W JP2022042993 W JP 2022042993W WO 2023100702 A1 WO2023100702 A1 WO 2023100702A1
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Prior art keywords
carbon fiber
mat
belt
carrier film
conveyor
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Application number
PCT/JP2022/042993
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English (en)
Japanese (ja)
Inventor
健太郎 小田
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三菱ケミカル株式会社
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Publication of WO2023100702A1 publication Critical patent/WO2023100702A1/fr

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    • 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
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/30—Processes for applying liquids or other fluent materials performed by gravity only, i.e. flow coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/02—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/12—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by mechanical means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/24—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials for applying particular liquids or other fluent materials

Definitions

  • the present invention mainly relates to a method for manufacturing sheet prepreg, and more particularly to a method for manufacturing sheet prepreg using carbon fiber.
  • CFRP Carbon fiber reinforced plastic
  • Patent Document 1 In the method disclosed in Patent Document 1, the carbon fiber bundle is also heated with a far-infrared heater before impregnation. be. Patent Document 1 does not disclose heating the carbon fiber bundle before dropping it onto a carrier film, nor any means therefor.
  • the impregnation failure prevention effect cannot be sufficiently obtained unless the temperature of the short carbon fiber bundles dropped onto the carrier film is raised at the same time. This is because the temperature of the matrix resin is lowered by depositing the carbon fiber mat thereon.
  • the short carbon fiber bundles produced by cutting the continuous carbon fiber bundles with a chopper are dropped directly onto the carrier film, the short carbon fiber bundles are heated during dropping to sufficiently raise the temperature due to the short drop time. is difficult.
  • a main object of the present invention is to provide an improvement in CF-SMC manufacturing technology that can contribute to preventing the impregnation of carbon fiber mats from occurring. Problems that can be solved by each embodiment of the present invention may be disclosed explicitly or implicitly in this specification.
  • One aspect of the method for producing a sheet prepreg of the present invention includes the following. Applying a thermosetting resin paste to each surface of a first carrier film and a second carrier film, and conveying a plurality of short carbon fiber bundles on a belt conveyor and then removing the first carrier film from the discharge end of the belt conveyor depositing a carbon fiber mat on the surface of the first carrier film to which the thermosetting resin paste is applied by dropping it upward; and sandwiching the carbon fiber mat with the second carrier film. Then, the surfaces coated with the thermosetting resin paste are attached to the first carrier film so as to face each other to form a laminate, and the carbon fiber mat is formed by pressing the laminate.
  • a method for manufacturing a sheet prepreg comprising: impregnating with a thermosetting resin paste; and heating the plurality of short carbon fiber bundles with a heater while being conveyed by the belt conveyor.
  • Another aspect of the method for producing a sheet prepreg of the present invention includes the following. preparing a first carrier film and a second carrier film each having a layer of a thermosetting resin composition preliminarily provided on the surface; depositing a carbon fiber mat on the surface of the first carrier film provided with the layer of the thermosetting resin composition by dropping it onto one carrier film; Forming a laminate by laminating to the first carrier film so that the surfaces provided with the layers of the thermosetting resin composition face each other with a fiber mat interposed therebetween; and heating the laminate.
  • Manufacture of a sheet prepreg comprising: impregnating the carbon fiber mat with the thermosetting resin composition by pressing; and heating the plurality of short carbon fiber bundles with a heater while being conveyed by the conveying means.
  • an improvement in CF-SMC manufacturing technology is provided that can contribute to preventing impregnation failure of the carbon fiber mat.
  • FIG. 1 is a schematic diagram of a CF-SMC manufacturing apparatus.
  • FIG. 2 is a schematic diagram showing a pin-roll type distribution roll arranged below the chopper.
  • FIG. 3 is a schematic diagram of a cage-type dispersing roll.
  • FIG. 4 is a schematic diagram of the carbon fiber mat stacking portion and its vicinity as viewed from the conveying direction of the belt conveyor.
  • FIG. 5 is a schematic view of the carbon fiber mat depositing portion and its neighborhood viewed from a direction orthogonal to the conveying direction of the belt conveyor.
  • thermosetting resin paste to each surface of the first carrier film and the second carrier film.
  • the thermosetting resin paste of the first carrier film is applied by dropping a plurality of short carbon fiber bundles on the first carrier film from the discharge end of the belt conveyor after being conveyed by the belt conveyor. depositing a carbon fiber mat on the surface.
  • the second carrier film is laminated to the first carrier film with the carbon fiber mat sandwiched therebetween so that the surfaces coated with the thermosetting resin paste face each other to form a laminate. to do.
  • impregnating the carbon fiber mat with the thermosetting resin paste by pressing the laminate;
  • FIG. 1 shows a conceptual diagram of a CF-SMC manufacturing apparatus that can be preferably used when manufacturing CF-SMC using the manufacturing method according to the embodiment.
  • the CF-SMC manufacturing apparatus 100 has a first coating machine 110, a second coating machine 120, a chopper 130, a belt conveyor 140, a heater 150 and an impregnator 160.
  • the first coating machine 110 is used to apply the first resin paste 51 to the first carrier film 41 to form the first resin paste layer 51L on one surface of the first carrier film 41 .
  • the second coating machine 120 is used to apply the second resin paste 52 to the second carrier film 42 to form the second resin paste layer 52L on one surface of the second carrier film 42 .
  • the chopper 130 is of a type that is also used in conventional CF-SMC manufacturing equipment, and includes a cutter roll 131 , a receiving roll (rubber roll) 132 and a guide roll 133 .
  • the rotating shafts of the cutter roll 131 , the receiving roll 132 and the guide roll 133 are all parallel to the T direction of the belt conveyor 140 .
  • the T direction is the width direction of the conveying path of the belt conveyor 140, that is, the width direction of the conveying belt 141 that constitutes the conveying path, and is generally horizontal.
  • the chopper 130 is arranged above the conveying path of the belt conveyor 140 .
  • a dispersing roll 134 for dispersing the short carbon fiber bundles 20 (chopped carbon fiber bundles) falling from the chopper 130 may be arranged below the chopper.
  • the rotation axis of the distribution roll 134 is parallel to the T direction of the belt conveyor 140 .
  • the structure and number of distribution rolls 134 are not limited to those shown.
  • the distribution roll 134 shown in FIG. 2 is of the pin roll type, it may be of the cage type shown in FIG.
  • the pin roll type distribution roll has a cylinder and a plurality of pins arranged on the peripheral surface of the cylinder.
  • the 3 has a structure in which a plurality of wires or rods 134c are bridged between a pair of discs 134b sharing a rotating shaft 134a.
  • the number of distribution rolls is not limited to one, and may be two or more.
  • the distribution roll is generally rigid and preferably made of metal (including alloys).
  • a portion of the short carbon fiber bundles 20 is split into smaller bundle size carbon fiber bundles by contact with the distribution roll 134 . It is well known to those skilled in the art that the smaller the bundle size of short carbon fiber bundles contained in CF-SMC, the higher the strength of CFRP products molded from CF-SMC. By bundle size is meant the number of carbon fiber filaments per bundle.
  • the short carbon fiber bundles 20 fall onto the conveying path of the belt conveyor 140 below the chopper 130 and are conveyed by the conveying belt 141 toward its discharge end.
  • a discharge end of the belt conveyor 140 is arranged above the running path of the first carrier film 41 .
  • the T direction of the belt conveyor 140 and the width direction of the first carrier film 41 running on the running path are parallel to each other.
  • the running direction of the first carrier film 41 is horizontal below the discharge end of the belt conveyor 140 .
  • the upper surface of the first carrier film 41 is preferably kept horizontal.
  • a bonding machine 170 is arranged to gradually bring the first carrier film 41 and the second carrier film 42 closer together and bond them together.
  • the laminate 60 is formed by bonding the first carrier film 41 and the second carrier film 42 together by the bonding machine 170 .
  • the first resin paste layer 51L, the carbon fiber mat 30, and the second resin paste layer 52L are sandwiched between the first carrier film 41 and the second carrier film .
  • the impregnation machine 160 is equipped with two upper and lower belt conveyors in order to sandwich and convey the laminate 60 from above and below with two conveyor belts, and also has rolls for sandwiching and pressurizing the laminate 60 together with the conveyor belts. ing.
  • the heater 150 heats the short carbon fiber bundles 20 conveyed by the conveyor belt 141 of the belt conveyor 140 .
  • the heater is arranged above the conveying path to heat the conveyed short carbon fiber bundles 20 from above.
  • the short carbon fiber bundles 20 to be conveyed may be heated from above and below by being arranged above and below the conveying path.
  • a heating method of the heater 150 is not particularly limited, but a hot air heater, an infrared heater, and the like are exemplified. Heaters 150 having different heating methods may be used together. For example, as the heater 150, a hot air heater and an infrared heater can be used together and arranged appropriately.
  • the conveying belt 141 of the belt conveyor 140 When the conveying belt 141 of the belt conveyor 140 has a mesh structure, the short carbon fiber bundles 20 on the conveying belt can be directly heated from below the conveying path by a heater. The carbon fiber hank can be sucked onto the conveyor belt.
  • the conveying belt 141 When the short carbon fiber bundles on the conveying path are heated by the heater arranged below the conveying path, the conveying belt 141 preferably has a mesh structure, but it is not essential.
  • the transfer belt may be heated by a heater, and the short carbon fiber bundles may be heated by contact heat transfer from the transfer belt.
  • Method for producing CF-SMC The procedure for producing CF-SMC using the production method according to the embodiment is described in 1. above.
  • An example of using the CF-SMC manufacturing apparatus described in 1. is as follows. First, a long carbon fiber bundle 10 is pulled out from a fiber package prepared in advance. The long carbon fiber bundles 10 may be drawn outside from a bobbin package attached to a creel, or may be drawn inside from a package from which the bobbins have been removed. The long carbon fiber bundle 10 may be partially split into a plurality of sub-bundles in advance.
  • a plurality of long carbon fiber bundles 10 are arranged parallel to each other and supplied to a chopper 130 .
  • the chopper 130 cuts the long carbon fiber bundle 10 into a predetermined length to form the short carbon fiber bundle 20 .
  • the predetermined length is preferably in the range of 10-60 mm, typically 0.5 inches (about 1.3 cm), 1 inch (about 2.5 cm), 2 inches (about 5.1 cm), etc. can be, but is not limited to.
  • the short carbon fiber bundles 20 fall onto the conveyor belt 141 of the belt conveyor 140 passing below the chopper 130 and are conveyed toward the discharge end of the belt conveyor 140 .
  • the short carbon fiber bundles 20 are heated by the heater 150 while being conveyed by the belt conveyor 140 .
  • the temperature of the heated short carbon fiber bundles 20 may be 40°C or higher and lower than 120°C, may be 50°C or higher and lower than 110°C, or may be 60°C or higher and lower than 100°C.
  • the above upper and lower limits can be arbitrarily combined to form a preferred temperature range.
  • the temperature of the short carbon fiber bundles 20 dropped onto the belt conveyor 140 and heated can be measured with, for example, a thermocouple or a radiation thermometer.
  • the temperature of the short carbon fiber bundles 20 can be controlled by the output of the heater 150, the heating time, and the density of the short carbon fiber bundles 20 on the belt conveyor 140.
  • the heating time is the time required for each short carbon fiber bundle 20 to pass through the area heated by the heater 150, and is determined by the length of the area along the conveying direction of the belt conveyor and the conveying speed. When the space in which the belt conveyor 140 can be installed is narrow, a sufficient heating time can be ensured even if the conveying path is short by lowering the conveying speed.
  • a mat temporary mat in which the short carbon fiber bundles 20 are stacked on the transport belt 141. 31 is deposited.
  • the running speed of the conveyor belt 141 is equal to or less than the running speed of the first carrier film 41
  • the thickness of the mat 31 is equal to or greater than the thickness of the carbon fiber mat 30 deposited on the first carrier film 41 .
  • a suction nozzle is installed so that the lower side of the conveying path is decompressed, and the mat 31 is made to stick to the conveying belt 141, thereby preventing the short carbon fiber bundles from flying around while allowing the heater wire to move along the conveying path. may be placed above the mat to blow hot air onto the mat from above.
  • the short carbon fiber bundles 20 contained in the mat are brought into close contact with each other, so that the contact thermal resistance between the short carbon fiber bundles is reduced and the heating of the entire mat 31 is promoted. . Therefore, even when the mat 31 is heated by the infrared heater, it is useful to cause the mat 31 to stick to the conveying belt 141 by suction.
  • the infrared heater can be arranged below the conveying path even in a mode in which the lower side of the conveying path is decompressed.
  • the short carbon fiber bundles 20 can be sufficiently heated with the heater 150 installed only above.
  • the heater 150 may be an infrared heater, a hot air heater, or both.
  • a hot air heater it is preferable to use a mesh belt as the conveying belt 141 and blow hot air from the upper surface side of the conveying belt.
  • the transport belt 141 is a mesh belt, and the lower side of the transport path is decompressed to cause the short carbon fiber bundles 20 to stick to the transport belt 141, thereby preventing the short carbon fiber bundles from flying. good too.
  • the short carbon fiber bundles 20 fall from the discharge end of the belt conveyor 140, and the carbon fiber mat 30 made of the short carbon fiber bundles 20 is placed on the first carrier film 41 running below the discharge end. accumulate.
  • a space (inside the dashed line in FIG. 5) including at least the discharge end X of the belt conveyor 140 and the carbon fiber mat deposition portion Y where the carbon fiber mat 30 is deposited on the first carrier film 41. is maintained at a higher temperature than its surroundings. By doing so, it is possible to prevent the temperature of the short carbon fiber bundles 20 from being cooled too much during the fall.
  • This space may be extended to include the heater 150 and the area where the short carbon fiber bundles 20 on the belt conveyor 140 are heated by the heater 150 .
  • the first resin paste 51 is applied to one side of the first carrier film 41 pulled out from the roll using the first coating machine 110 .
  • the first resin paste 51 is a thermosetting resin composition, and its base resin is not limited, but may be, for example, vinyl ester resin (also called epoxy acrylate resin), unsaturated polyester resin, epoxy resin, polyimide resin, Maleimide resin or phenolic resin.
  • a mixed resin of a vinyl ester resin and an unsaturated polyester resin may be used as the base resin.
  • the first resin paste 51 contains a curing agent and, if necessary, a polymerization inhibitor, a thickener, a reactive diluent, a low shrinkage agent, a flame retardant, an antibacterial agent, and the like.
  • the viscosity of the first resin paste 51 may be 0.3 to 20 Pa ⁇ s at 25°C. A resin paste having such viscosity characteristics can be used even at room temperature, but by heating to lower the viscosity, it becomes easier to penetrate into the carbon fiber mat. In another example, the viscosity of the first resin paste 51 may be 5-20 Pa ⁇ s at a certain temperature in the range of 40-80°C. A resin paste having such viscosity characteristics can be used for impregnating the carbon fiber mat by heating, even if it is difficult to penetrate the carbon fiber mat at room temperature.
  • a second coating machine 120 is used to apply a second resin paste 52 made of a thermosetting resin composition having the same composition as the first resin paste 51 to one side of the second carrier film 42 .
  • the second carrier film 42 is laminated on the first carrier film 41 with the carbon fiber mat 30 placed thereon by the laminator 170, with the surface on which the second resin paste layer 52L is formed facing down.
  • the laminate 60 thus formed is pressurized by the impregnator 160 to impregnate the carbon fiber mat 30 with the first resin paste 51 and the second resin paste 52 to form a resin-impregnated carbon fiber mat.
  • the temperature of the short carbon fiber bundles 20 dropped onto the first resin paste layer 51L may be 40°C or higher and lower than 120°C, may be 50°C or higher and lower than 110°C, or may be 60°C or higher and lower than 100°C.
  • the above upper and lower limits can be arbitrarily combined to form a preferred temperature range.
  • the temperature can be measured using non-contact measurement methods such as radiation thermometers.
  • the first resin paste layer 51L and the second resin paste layer 52L may be heated by a heater (not shown) before they come into contact with the short carbon fiber bundles 20.
  • a heater not shown
  • the temperature drop of the first resin paste 51 and the second resin paste 52 due to contact with the short carbon fiber bundles 20 and the accompanying increase in viscosity are prevented or suppressed by heating the short carbon fiber bundles 20 by the heater 150. be.
  • the resin-impregnated carbon fiber mat is wound around a bobbin while being sandwiched between the first carrier film 41 and the second carrier film 42 .
  • the resin-impregnated carbon fiber mat wound on a bobbin is thickened as necessary and shipped as CF-SMC.
  • the resin impregnated carbon fiber mat may be folded and stored in a container instead of being wound on a bobbin.
  • the first resin paste 51 and the second resin paste 52 respectively stored in the first coating machine 110 and the second coating machine 120 are heated or kept warm, and the laminate 60 conveyed by the impregnation machine 160 is Heating or keeping warm can be appropriately performed as needed. Heating or keeping the temperature of the first resin paste 51 and the second resin paste 52 before they are supplied to the coating machine can also be performed by an appropriate method as necessary.
  • the laminate 60 (the resin-impregnated carbon fiber mat sandwiched between the first carrier film 41 and the second carrier film 42) may be cooled before being wound onto a bobbin or folded and stored in a container. .
  • the initiation of the curing reaction of the first resin paste and the second resin paste which are thermosetting resin compositions, can be prevented. Since the viscosity of the first resin paste and the second resin paste present in the gap between them increases, it becomes difficult to squeeze them out of the carbon fiber mat 30 .
  • Cooling may be performed until the temperature of the laminate 60 drops to room temperature, but is not limited, and may be performed to the extent that the above purpose can be achieved. Examples of the cooling method include, but are not limited to, forced air cooling using a fan and contact with a cooling roll. Forced air cooling and cooling rolls may be used in combination.
  • the long carbon fiber bundles 10 fed toward the chopper 130 may additionally be heated. However, if the sizing agent is heated until it softens, the short carbon fiber bundles 20 stick to the rubber roll of the chopper 130, so it is necessary to pay attention to the temperature of the short carbon fiber bundles 20 after heating.
  • a method of cutting the long carbon fiber bundles into short carbon fiber bundles instead of cutting the long carbon fiber bundles into short carbon fiber bundles by cutting the long carbon fiber bundles with a chopper provided in the CF-SMC manufacturing apparatus, a method of cutting the long carbon fiber bundles in a separate process in advance or other methods. The short carbon fiber bundles made by the method may be supplied onto the conveying path of the belt conveyor.
  • conveying means other than a belt conveyor may be used to convey a plurality of short carbon fiber bundles from where they are produced and then drop them onto the first carrier film.
  • transport means include a container capable of storing short carbon fiber bundles and equipped with a heater for heating the stored short carbon fibers, and a transporter for transporting the container. .
  • this modified embodiment has in common with the embodiment using a belt conveyor as the transportation means.
  • thermosetting paste that does not have fluidity at room temperature and has a viscosity of preferably 20 Pa s or less is obtained only by heating.
  • a flexible resin composition can be used.
  • the thermosetting resin composition instead of applying the thermosetting resin composition to the first carrier film and the second carrier film using the first coating machine and the second coating machine, the first carrier film and the second carrier film are separately applied in advance. It can be applied to the film.
  • Embodiments of the present invention include, but are not limited to, the following.
  • a thermosetting resin paste is applied to each surface of the first carrier film and the second carrier film, and after conveying a plurality of short carbon fiber bundles by a belt conveyor, from the discharge end of the belt conveyor depositing a carbon fiber mat on the surface of the first carrier film coated with the thermosetting resin paste by dropping it onto the first carrier film;
  • a laminate is formed by pasting the mat to the first carrier film so that the surfaces coated with the thermosetting resin paste face each other with a mat interposed therebetween, and pressing the laminate by pressing the laminate.
  • a method for producing a sheet prepreg comprising: impregnating a carbon fiber mat with the thermosetting resin paste; and heating the plurality of short carbon fiber bundles with a heater while being conveyed by the belt conveyor.
  • [Embodiment 2] A space including at least the discharge end of the belt conveyor and a carbon fiber mat depositing portion where the carbon fiber mat is deposited on the first carrier film is maintained at a higher temperature than the surroundings. 2.
  • Embodiment 4 The method according to Embodiment 3, wherein the plurality of short carbon fiber bundles are dispersed by a dispersion roll arranged below the chopper before dropping onto the conveying path.
  • Embodiment 5. The method of any of Embodiments 1-4, wherein the heater comprises a hot air heater and/or an infrared heater.
  • the heaters are arranged respectively above and below the transport belt of the belt conveyor.
  • the conveyor belt of the belt conveyor has a mesh structure.
  • Embodiment 8 The method according to Embodiment 7, comprising attracting the plurality of short carbon fiber bundles to the conveyor belt by suction.
  • Embodiment 9 The method according to any one of Embodiments 1 to 8, wherein the running speed of the transport belt of the belt conveyor is higher than the running speed of the first carrier film.
  • Embodiment 10 The method of any of Embodiments 1-4, comprising depositing the temporary mat of carbon fiber bundles on a conveyor belt of the belt conveyor.
  • Embodiment 11 The method of embodiment 10, wherein the thickness of the temporary mat is equal to or greater than the thickness of the carbon fiber mat.
  • Embodiment 12 Embodiment 10 or 11, wherein the conveying belt of the belt conveyor has a mesh structure, and hot air is blown onto the temporary mat from both the upper side and the lower side of the conveying belt.
  • method pertaining to [Embodiment 13] The method according to embodiment 12, wherein part of the hot air flows through the interior of the temporary mat in a direction crossing the thickness direction of the temporary mat.
  • Embodiment 14 A method according to embodiment 10 or 11, wherein the conveyor belt of the belt conveyor has a mesh structure and the temporary mat is attracted to the conveyor belt by suction.
  • Embodiment 15 The method of any of Embodiments 1-14, further comprising heating the thermosetting resin paste prior to depositing the carbon fiber mat.
  • Embodiment 16 The method according to any one of Embodiments 1 to 15, wherein the length of the short carbon fiber bundles is within the range of 10 to 60 mm.
  • Embodiment 17 Prepare a first carrier film and a second carrier film each having a layer of a thermosetting resin composition preliminarily provided on the surface thereof, and convey a plurality of short carbon fiber bundles using a conveying means.
  • a method for manufacturing a sheet prepreg comprising: [Embodiment 18] The method according to Embodiment 17, wherein the plurality of short carbon fiber bundles are produced by cutting long carbon fibers with a chopper. Embodiment 19.
  • said conveying means is a belt conveyor.
  • a space containing at least the discharge end of the belt conveyor and the carbon fiber mat depositing portion where the carbon fiber mat is deposited on the first carrier film is maintained at a higher temperature than the surroundings. 20.
  • Embodiment 22 The method according to Embodiment 21, wherein the plurality of short carbon fiber bundles are dispersed by a dispersion roll arranged below the chopper before dropping onto the conveying path.
  • Embodiment 23 The method of any of Embodiments 19-22, wherein the heater comprises a hot air heater and/or an infrared heater.
  • Embodiment 24 The method according to any one of embodiments 19 to 23, wherein the heaters are arranged respectively above and below the transport belt of the belt conveyor.
  • Embodiment 25 The method of any of Embodiments 19-24, wherein the conveyor belt of the belt conveyor has a mesh structure.
  • Embodiment 26 The method of embodiment 25, comprising attracting the plurality of short carbon fiber bundles to the conveyor belt by suction.
  • Embodiment 27 The method according to any one of Embodiments 19 to 26, wherein the running speed of the transport belt of the belt conveyor is greater than the running speed of the first carrier film.
  • Embodiment 28 The method of any of embodiments 19-22, comprising depositing the temporary mat of carbon fiber bundles on a conveyor belt of the belt conveyor.
  • Embodiment 29 The method of embodiment 28, wherein the thickness of the temporary mat is equal to or greater than the thickness of the carbon fiber mat.
  • Embodiment 30 Embodiment 28 or 29, wherein the conveying belt of the belt conveyor has a mesh structure, and hot air is blown onto the temporary mat from both the upper side and the lower side of the conveying belt.
  • method pertaining to [Embodiment 31] A method according to Embodiment 30, wherein a portion of the hot air flows through the interior of the temporary mat in a direction crossing the thickness direction of the temporary mat.
  • Embodiment 32 A method according to embodiment 28 or 29, wherein the conveying belt of the belt conveyor has a mesh structure and the temporary mat is attracted to the conveying belt by suction.
  • Embodiment 33 The method of any of Embodiments 17-32, further comprising heating said thermosetting resin composition prior to depositing said carbon fiber mat.
  • the short carbon fiber bundles have a length in the range of 10-60 mm.
  • the impregnation of the carbon fiber mat is promoted by using the method according to the embodiment, the impregnation time required to prevent impregnation failure is shortened, and the line speed of the CF-SMC production line can be increased. becomes.
  • the viscosity of the matrix resin can be reduced by heating. Therefore, it is possible to use a thermosetting resin composition with a high room temperature viscosity, which was conventionally not suitable for CF-SMC, as the matrix resin. It becomes possible.
  • CFRP carbon fiber reinforced plastic
  • CFRP products that can be manufactured using CF-SMC are diverse, including manned aircraft, unmanned aircraft, parts used in various transportation equipment including automobiles and ships, sporting goods, leisure goods, and the like.

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  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Mechanical Engineering (AREA)
  • Reinforced Plastic Materials (AREA)

Abstract

La présente invention concerne une technologie de production de CF-SMC améliorée qui est apte à contribuer à la prévention de l'apparition d'une défaillance d'imprégnation d'un mat de fibres de carbone. Un mode de réalisation d'un procédé de production d'un préimprégné en feuille selon la présente invention comprend : une étape dans laquelle une pâte de résine thermodurcissable est appliquée sur les surfaces de premier et second films de support ; une étape dans laquelle une pluralité de faisceaux de fibres de carbone courtes (20) sont portés par un convoyeur à courroie (140) et sont lâchés sur un premier film de support (41) depuis l'extrémité d'évacuation du transporteur à courroie, de telle sorte qu'un mat de fibres de carbone (30) est déposé sur la surface sur laquelle a été appliquée la pâte de résine thermodurcissable ; une étape dans laquelle un second film de support (42) est lié au premier film de support (41) de telle sorte que les surfaces auxquelles la pâte de résine thermodurcissable a été appliquée se font face avec le mat de fibres de carbone (30) étant interposé entre ces dernières, formant ainsi un corps multicouche (60) ; une étape dans laquelle une pression est appliquée au corps multicouche (60) de façon à imprégner le mat de fibres de carbone (30) avec la pâte de résine thermodurcissable ; et une étape dans laquelle la pluralité de faisceaux de fibres de carbone courtes (20) sont chauffés par un dispositif de chauffage (150), tout en étant portés par le transporteur à courroie (140).
PCT/JP2022/042993 2021-12-01 2022-11-21 Procédé de production d'un préimprégné en feuille WO2023100702A1 (fr)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2024128010A1 (fr) * 2022-12-16 2024-06-20 三菱ケミカル株式会社 Procédé de production de préimprégné en feuille, procédé d'alimentation en matière première fibreuse, et préimprégné en feuille

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JP2008284729A (ja) * 2007-05-16 2008-11-27 Hekisa Chemical:Kk 繊維含有樹脂造粒物及びその製造方法
JP2014030913A (ja) * 2012-08-01 2014-02-20 Teijin Ltd ランダムマットの製造方法
JP2018035274A (ja) * 2016-08-31 2018-03-08 王子ホールディングス株式会社 繊維強化熱可塑性プラスチック作製用プレシートおよびその製造方法、ならびに繊維強化熱可塑性プラスチック成形品
JP2018126975A (ja) * 2017-02-10 2018-08-16 三菱ケミカル株式会社 シートモールディングコンパウンドの製造方法及びシートモールディングコンパウンドの製造装置
WO2021010084A1 (fr) * 2019-07-16 2021-01-21 東レ株式会社 Cabine de pulvérisation de fibres et dispositif de fabrication d'un matelas de fibres renforcées l'utilisant
WO2021106585A1 (fr) * 2019-11-25 2021-06-03 Dic株式会社 Mélange à mouler en feuille, et procédé de fabrication d'article moulé

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2008284729A (ja) * 2007-05-16 2008-11-27 Hekisa Chemical:Kk 繊維含有樹脂造粒物及びその製造方法
JP2014030913A (ja) * 2012-08-01 2014-02-20 Teijin Ltd ランダムマットの製造方法
JP2018035274A (ja) * 2016-08-31 2018-03-08 王子ホールディングス株式会社 繊維強化熱可塑性プラスチック作製用プレシートおよびその製造方法、ならびに繊維強化熱可塑性プラスチック成形品
JP2018126975A (ja) * 2017-02-10 2018-08-16 三菱ケミカル株式会社 シートモールディングコンパウンドの製造方法及びシートモールディングコンパウンドの製造装置
WO2021010084A1 (fr) * 2019-07-16 2021-01-21 東レ株式会社 Cabine de pulvérisation de fibres et dispositif de fabrication d'un matelas de fibres renforcées l'utilisant
WO2021106585A1 (fr) * 2019-11-25 2021-06-03 Dic株式会社 Mélange à mouler en feuille, et procédé de fabrication d'article moulé

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2024128010A1 (fr) * 2022-12-16 2024-06-20 三菱ケミカル株式会社 Procédé de production de préimprégné en feuille, procédé d'alimentation en matière première fibreuse, et préimprégné en feuille

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