Mitsubishi Chemical Corporation

Junji Kanehagi

Tadao Samejima

Yukihiro Mizutori

Yasushi Watanabe

Takayuki Kobayashi

Satoshi Okamoto

Masatoshi Kamata

Provided is a useful improvement in a manufacturing method of a CF-SMC using a partially split continuous carbon fiber bundle. The manufacturing method of an SMC of the present invention includes (i) a step of drawing out a continuous carbon fiber bundle () from a package, the continuous carbon fiber bundle () having a filament number of NK and partially split into n sub-bundles in advance, (ii) a step of chopping the continuous carbon fiber bundle () drawn out from the package with a rotary cutter () into chopped carbon fiber bundles (), and (iii) a step of depositing the chopped carbon fiber bundles () on a carrier film () traveling below the rotary cutter () to form a carbon fiber mat (). In the manufacturing method, due to a fragmentation processing, in which at least some of the chopped carbon fiber bundles before being deposited on the carrier film () are fragmented by being brought into contact with a rotating body, a distribution of the filament number of the chopped carbon fiber bundles in the carbon fiber mat () is made different from that when the fragmentation processing is not performed.

SMC manufacturing method

What is provided is a method for stably producing a fiber-reinforced resin molding material by splitting a fiber bundle such that a split portion becomes long while anon-split portion is shortened. A method for producing a fiber-reinforced resin molding material in which a cut fiber bundle is impregnated with a resin, the method comprising a splitting step of splitting the fiber bundle with a splitting machine at intervals in a longitudinal direction and a cutting step of cutting the fiber bundle at intervals in the longitudinal direction after the splitting step, in which the splitting machine comprises a rotary blade having a releasing section and a spacer member adjacent to the rotary blade.

Method for producing fiber-reinforced resin molding material, and apparatus for producing fiber-reinforced resin molding material

Provided are a method and an apparatus for manufacturing a fiber-reinforced resin molding material by which, when the fiber-reinforced resin molding material is manufactured, separated fiber bundles can be supplied to a cutting machine in stable condition while avoiding the influence of meandering of the fiber bundles or slanting or meandering of filaments occurring in the fiber bundles. A method for manufacturing a sheet-shaped fiber-reinforced resin molding material in which spaces between filaments of cut-out fiber bundles (CF) are impregnated with resin includes, so that a condition of the following expression (1) is satisfied, intermittently separating fibers of the continuous fiber bundles (CF) in a longitudinal direction by a rotational blade () serving as a fiber separating part and cutting out the fiber bundles with an interval therebetween in a longitudinal direction of a cutting machine (A) to obtain the cut-out fiber bundles (CF). Expression (1): 1≤a/L (where a represents a length of a separated part of the continuous fiber bundles (CF) and L represents an interval when the fiber bundles (CF) are cut out in the longitudinal direction.)

Method and apparatus for producing fiber-reinforced resin molding material

Provided is a fiber-reinforced resin material molding in which fluctuations of the dispersion state of the fiber bundle in the molding is small, the generation of a resin pool is suppressed, and fluctuations in physical properties such as tensile strength and modulus of elasticity are suppressed; a method for manufacturing the same, and a method for manufacturing a fiber-reinforced resin material. Provided is a fiber-reinforced resin material molding comprising: a fiber bundle comprising a plurality of reinforcing fibers; and a matrix resin, wherein a coefficient of variation in fiber content of the reinforcing fibers per unit zone of 0.1 mm square on a cut face along a thickness direction is 40% or less.

Fiber-reinforced resin material molding, method for manufacturing fiber-reinforced resin material molding, and method for manufacturing fiber-reinforced resin material

A method for manufacturing a fiber-reinforced resin molding material having a cut fiber tow impregnated with a resin includes a separation step of intermittently separating a fiber tow and forming at least two separation-processed lines arranged side by side in a width direction of the fiber tow and a cutting step of cutting the fiber tow at an interval in the longitudinal direction, and the separation step and the cutting step are carried out to satisfy (1) to (3). (1) 1&#x2264;c/L&#x2264;50 (2) c&#x3c;a (3) b/L&#x3c;1 'c' is an overlapping length of separated parts when one separation-processed line is projected to another separation-processed line adjacent thereto in the width direction, 'L' is the interval in the cutting step, &#x201c;a&#x201d; is a length of the separated part in the separation-processed line, and &#x201c;b&#x201d; is a length of an unseparated part in the separation-processed line.

Method and device for manufacturing fiber-reinforced resin molding material

Provided are a method and an apparatus for manufacturing a fiber-reinforced resin molding material by which, when the fiber-reinforced resin molding material is manufactured, separated fiber bundles can be supplied to a cutting machine in stable condition while avoiding the influence of meandering of the fiber bundles or slanting or meandering of filaments occurring in the fiber bundles. A method for manufacturing a sheet-shaped fiber-reinforced resin molding material in which spaces between filaments of cut-out fiber bundles (CF) are impregnated with resin includes, so that a condition of the following expression (1) is satisfied, intermittently separating fibers of the continuous fiber bundles (CF) in a longitudinal direction by a rotational blade () serving as a fiber separating part and cutting out the fiber bundles with an interval therebetween in a longitudinal direction of a cutting machine (A) to obtain the cut-out fiber bundles (CF). Expression (1): 1&#x2264;a/L (where a represents a length of a separated part of the continuous fiber bundles (CF) and L represents an interval when the fiber bundles (CF) are cut out in the longitudinal direction.)

Provided is a fiber-reinforced resin material molding in which fluctuations of the dispersion state of the fiber bundle in the molding is small, the generation of a resin pool is suppressed, and fluctuations in physical properties such as tensile strength and modulus of elasticity are suppressed; a method for manufacturing the same; and a method for manufacturing a fiber-reinforced resin material. Provided is a fiber-reinforced resin material molding comprising: a fiber bundle comprising a plurality of reinforcing fibers; and a matrix resin, wherein a coefficient of variation in fiber content of the reinforcing fibers per unit zone of 0.1 mm square on a cut face along a thickness direction is 40% or less.

Provided is a method for manufacturing a fiber-reinforced resin molding material having excellent productivity at low cost for manufacturing a fiber-reinforced resin molded article having excellent strength properties. Provided is a method for manufacturing a sheet-shaped fiber-reinforced resin molding material containing a plurality of cut fiber bundles and a resin impregnated between filaments of the cut fiber bundles, the method comprising an integrated material manufacturing step for obtaining an integrated material by collecting a sheet-shaped fiber bundle aggregate obtained by arranging and spreading a plurality of consecutive fiber bundles in a width direction.

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Tokyo, Japan

Junji Kanehagi