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公开(公告)号：US11919255B2
公开(公告)日：2024-03-05
申请号：US17978204
申请日：2022-10-31
IPC分类号： B29C70/00 , B29B11/00 , B29B11/02 , B29B15/00 , B29B15/12 , B29C70/10 , B29C70/42 , B65H35/00 , B65H35/08 , D01D11/00 , D01D11/02 , B29K31/00 , B29K307/04
CPC分类号： B29C70/10 , B29B11/02 , B29B15/122 , B29C70/42 , B65H35/0086 , B65H35/08 , D01D11/02 , B29C2793/0081 , B29K2031/00 , B29K2307/04
摘要： 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 (18) serving as a fiber separating part and cutting out the fiber bundles with an interval therebetween in a longitudinal direction of a cutting machine (13A) 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.)
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公开(公告)号：US20230020921A1
公开(公告)日：2023-01-19
申请号：US17945185
申请日：2022-09-15
摘要： Provided is a useful improvement in a CF-SMC manufacturing technique comprising an SMC manufacturing method using a continuous carbon fiber bundle having a filament number of NK and partially split into n sub-bundles in advance. In the SMC manufacturing method according to the present invention, a fragmentation processing using a fragmentation processing apparatus (A) below is performed on chopped carbon fiber bundles before being deposited on a carrier film. The fragmentation processing apparatus (A) comprises a first pin roller and a second pin roller, each of which has a rotation axis parallel to a rotation axis direction of the rotary cutter. The first pin roller is rotationally driven such that its pins move downward from above on its side facing the second pin roller, and the second pin roller is rotationally driven such that its pins move downward from above on its side facing the first pin roller.
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公开(公告)号：US20220347890A1
公开(公告)日：2022-11-03
申请号：US17865288
申请日：2022-07-14
IPC分类号： B29B15/10
摘要： 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 (10) from a package, the continuous carbon fiber bundle (10) 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 (10) drawn out from the package with a rotary cutter (234) into chopped carbon fiber bundles (20), and (iii) a step of depositing the chopped carbon fiber bundles (20) on a carrier film (41) traveling below the rotary cutter (234) to form a carbon fiber mat (30). 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 (41) 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 (30) is made different from that when the fragmentation processing is not performed.
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公开(公告)号：US20180250849A1
公开(公告)日：2018-09-06
申请号：US15970935
申请日：2018-05-04
CPC分类号： B29B15/122 , B29K2063/00 , B29K2307/04 , D02J1/18 , D02J3/02 , D10B2101/06 , D10B2101/12
摘要： 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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5.发明公开公开(公告)号：US20240181678A1
公开(公告)日：2024-06-06
申请号：US18407539
申请日：2024-01-09
CPC分类号： B29B11/16 , B29B11/12 , B29B13/10 , B29B15/105
摘要： A method of manufacturing a sheet molding compound, comprises (i) allowing short fiber bundles to fall onto a travelling carrier film, while dispersing the short fiber bundles using a dispersion roller device, thereby depositing a fiber mat on the carrier film, and (ii) impregnating the fiber mat with a thermosetting resin composition, wherein the dispersion roller device has a rotationally driven dispersion roll, bearings, a first side cover, and a second side cover, wherein the dispersion roll comprises a roll body and roll body-adjoining parts, and an inner circumferential surface of a circular opening provided in each of the first and second side covers and a cylindrical circumferential surface of each of the roll body-adjoining parts face each other.
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公开(公告)号：US20240141569A1
公开(公告)日：2024-05-02
申请号：US18404652
申请日：2024-01-04
摘要： A method of manufacturing a sheet molding compound (SMC) according to an aspect of the present invention comprises: (i) drawing out a carrier film from a roll to travel on a conveyance path such that the surface of the carrier film is horizontal; (ii) cutting a continuous carbon fiber bundle into short carbon fiber bundles with a chopper disposed above the conveyance path; (iii) allowing the short carbon fiber bundles to fall onto the carrier film traveling on the conveyance path while dispersing them using a dispersing roll disposed below the chopper to deposit a carbon fiber mat on the carrier film; (iv) impregnating the carbon fiber mat with a thermosetting resin composition to obtain a resin-impregnated carbon fiber mat; and v) concurrently with the deposition of the carbon fiber mat, removing fiber dust generated from the short carbon fiber bundles due to contact with the dispersing roll using a dust collector.
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公开(公告)号：US11660783B2
公开(公告)日：2023-05-30
申请号：US17108230
申请日：2020-12-01
CPC分类号： B29B15/122 , B29C70/06 , B29C70/12 , B29C70/504 , C08J5/04 , C08J5/042 , B29K2063/00 , B29K2307/04 , C08J2363/00
摘要： 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.
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公开(公告)号：US10604871B2
公开(公告)日：2020-03-31
申请号：US14900459
申请日：2014-06-17
发明人： Akishige Tada , Yukihiro Mizutori
IPC分类号： D02J1/22 , B29C55/00 , D01F6/38 , D01D11/02 , D02J1/18 , D01F9/22 , D02J13/00 , D01F9/21 , D01F6/18 , D06B3/04 , D01D5/16 , D06C3/00 , B29K33/00 , B29L31/00
摘要： This process for manufacturing a carbon-fiber precursor acrylic fiber bundle and this steam drawing apparatus are characterized in that the drawing of an acrylic fiber bundle with a pressured-steam drawing apparatus is conducted by: opening an acrylic fiber bundle by blowing a fluid thereto; supplying humidifying steam to the opened acrylic fiber bundle at a fiber temperature of 80 to 130° C. to adjust the water content of the fiber bundle to 3 to 7%; and thereafter drawing the resulting acrylic fiber bundle in a pressurized-steam atmosphere. Thus, the present invention can prevent the breaking of a single fiber, the fluffing of the fiber bundle, and the breaking of the whole of the fiber bundle, though such defects are susceptible to occurring in a case where an acrylic fiber bundle is drawn by steam drawing at a high draw ratio, at a higher speed, or into a fiber having a small denier.
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公开(公告)号：US12023876B2
公开(公告)日：2024-07-02
申请号：US17036333
申请日：2020-09-29
IPC分类号： B29C70/00 , B29C70/12 , B29C70/14 , D01D11/00 , D01D11/02 , D02J1/00 , D02J1/18 , B29K101/10 , B29K105/12 , B29K307/04
CPC分类号： B29C70/14 , B29C70/12 , D01D11/02 , D02J1/18 , B29K2101/10 , B29K2105/12 , B29K2307/04
摘要： 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.
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公开(公告)号：US11518116B2
公开(公告)日：2022-12-06
申请号：US17216294
申请日：2021-03-29
IPC分类号： B29C70/00 , B29B11/00 , B29B15/00 , B65H35/00 , D01D11/00 , B29C70/10 , D01D11/02 , B29B15/12 , B29B11/02 , B29C70/42 , B65H35/08 , B29K31/00 , B29K307/04
摘要： 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 (18) serving as a fiber separating part and cutting out the fiber bundles with an interval therebetween in a longitudinal direction of a cutting machine (13A) 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.)
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