Mitsubishi Chemical Corporation

Mitsubishi Rayon Company, Limited

Tadao Samejima

Yukihiro Mizutori

Yasushi Watanabe

Junji Kanehagi

Takayuki Kobayashi

Manabu Kaneko

Takuya Teranishi

Masahiro Ichino

Kazuhiro Sumioka

Kiharu Numata

Hiroto Tatsuno

Teppei Miura

Masatoshi Kamata

Hiroshi Iwata

Kazutami Mitani

Ryuichi Ishikawa

Kazuki Koga

Hiroyuki Nakao

Hajime Okutsu

Tetsu Yasunami

Youji Hatanaka

Akira Miyauchi

Masaki Kusumi

Tadanobu Ikeda

Shouhei Mori

A manufacturing method of an SMC of the present invention comprises (i) forming chopped carbon fiber bundles by chopping a continuous carbon fiber bundle having a filament number of NK with a rotary cutter, (ii) fragmentation-processing the chopped carbon fiber bundles by using a fragmentation-processing apparatus comprising a rotating body, (iii) forming a carbon fiber mat by depositing the fragmentation-processed chopped carbon fiber bundles on a carrier film traveling below the rotary cutter, and (iv) impregnating the carbon fiber mat with a thermosetting resin composition, wherein N is 20 or more, and the fragmentation-processing apparatus comprises a first pin roller and a second pin roller which are disposed side by side, each having a rotation axis parallel to a rotation axis direction of the rotary cutter.

Method for manufacturing SMC

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.

One mode of the invention relates to a producing a device for chopped fiber bundles having a chopper unit including a cutting blade for cutting long fiber bundles, a guide for restricting the travel direction of the fiber bundles to be supplied to the cutting means, and a structure, provided between the chopper unit and the guide, that widens the fiber bundles. The invention also relates to method for producing chopped fiber bundles by widening fiber bundles while restricting the travel direction of the long fiber bundles to be supplied to chopper unit by a guide, and obtaining chopped fiber bundles by cutting the fiber bundles with the chopper unit.

Producing device and producing method for chopped fiber bundles, producing device and producing method for fiber-reinforced resin forming materials, cutting blade for carbon fiber bundles, and rotary cutter for carbon fiber bundles

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.

Method for manufacturing fiber-reinforced resin molding material, and device for manufacturing fiber-reinforced resin molding material

This prepreg comprises reinforcing fibers and a matrix resin composition. The matrix resin composition comprises at least an epoxy resin (component (A)), a radical polymerizable unsaturated compound (component (B)), and a polymer formed by radical polymerization of the component (B) (component (E)).

Prepreg and method for producing same

According to the present invention, a porous electrode substrate with greater sheet strength, lower production cost, and excellent gas permeability and conductivity as well as its manufacturing method are provided. Also provided are a precursor sheet for forming such a substrate, and a membrane electrode assembly and a polymer electrolyte fuel cell containing such a substrate. The method for manufacturing such a porous electrode substrate includes the following steps [1]&#x2dc;[3]: [1] a step for manufacturing a sheet material in which short carbon fibers (A) are dispersed; [2] a step for manufacturing a precursor sheet by adding a water-soluble phenolic resin and/or water-dispersible phenolic resin to the sheet material; and [3] a step for carbonizing the precursor sheet at a temperature of 1000&#xb0; C. or higher. The present invention also relates to a porous electrode substrate obtained by such a manufacturing method as well as a precursor sheet to be used for manufacturing the substrate, a membrane electrode assembly and a polymer electrolyte fuel cell.

Porous electrode substrate, method for manufacturing same, precursor sheet, membrane electrode assembly, and polymer electrolyte fuel cell

A carbon-fiber-precursor acrylic fiber bundle which can smoothly pass through a flame-resistance impartation step and a carbonization step. The carbon-fiber-precursor acrylic fiber bundle has a high-density part as a portion thereof, wherein the high-density part satisfies the following requirements (A) and (B). Requirement A: The high-density part has a maximum fiber density &#x3c1;of 1.33 g/cmor higher. Requirement B: The portion extending between an intermediate-density point and a maximum-density-region arrival point has an increase in fiber density of 1.3&#xd7;10g/cmor less per 10 mm of the fiber bundle length.

Carbon fiber precursor acrylic fiber bundle, method for thermally oxidizing part thereof, thermal oxidation oven, and process for producing carbon fiber bundle

The present invention relates to a method for producing a prepreg which contains reinforcing fibers and a matrix resin composition with the weight per square meter of the reinforcing fibers being 250-2,000 g/m. The production method comprises the following steps (1)-(3): (1) a matrix resin composition blending step for obtaining a matrix resin composition by mixing an epoxy resin, a radically polymerizable unsaturated compound, an epoxy resin curing agent and a polymerization initiator that generates radicals, in said step the content of the radically polymerizable unsaturated compound relative to 100% by mass of the total of the epoxy resin and the radically polymerizable unsaturated compound being 10-25% by mass; (2) a matrix resin composition impregnating step; and (3) a surface viscosity increasing step.

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Tokyo, Japan

Tadao Samejima