JP2014018993A - Smc manufacturing method and device - Google Patents

Smc manufacturing method and device Download PDF

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JP2014018993A
JP2014018993A JP2012157506A JP2012157506A JP2014018993A JP 2014018993 A JP2014018993 A JP 2014018993A JP 2012157506 A JP2012157506 A JP 2012157506A JP 2012157506 A JP2012157506 A JP 2012157506A JP 2014018993 A JP2014018993 A JP 2014018993A
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resin
release film
layer
resin layer
molding material
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Satoru Tsuji
哲 辻
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Panasonic Corp
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Abstract

PROBLEM TO BE SOLVED: To provide an SMC manufacturing method and an SMC manufacturing device capable of suppressing protrusion of a resin forming material to the outside of a fiber during stacked pressing of the fiber and the resin forming material which are SMC materials between two films.SOLUTION: A thermosetting lower resin layer is formed on a lower release film 2, a fiber layer is formed with a predetermined width thereon, and a thermosetting upper resin layer is formed on an upper release film 2. Then, second thermosetting resin forming materials 7 are supplied to both ends of the fiber layer in a width direction. The release films 2 and 3 are stacked so that the upper resin layer can brought into contact between both ends of the fiber layer in the width direction. This laminated film is put through a pressing impregnation part 6, and the fiber layer is pressed and impregnated with the upper resin layer and the lower resin layer to manufacture an SMC 1.

Description

本発明は、FRP(繊維強化プラスチック)等の成形に用いられるSMC(シートモールディングコンパウンド)の製造方法及び製造装置に関する。   The present invention relates to a manufacturing method and a manufacturing apparatus for SMC (sheet molding compound) used for molding FRP (fiber reinforced plastic) and the like.

従来より、SMCは、例えば以下のようにして製造される(特許文献1等参照)。   Conventionally, SMC is manufactured as follows, for example (refer patent document 1 etc.).

すなわち、まず、2枚のフィルム2,3のそれぞれ内面に熱硬化性の樹脂層104を形成し、一方のフィルム2の樹脂層104上に、ガラス繊維105を分散させて堆積させる。次いで、2枚のフィルム2,3の内面どうしを重ね合わせ、これを脱泡・含浸ロールによって上下から押圧して、樹脂層104の樹脂をガラス繊維105に含浸させることで、SMC100は製造される(図5参照)。   That is, first, the thermosetting resin layer 104 is formed on the inner surfaces of the two films 2 and 3, and the glass fibers 105 are dispersed and deposited on the resin layer 104 of one film 2. Next, the inner surfaces of the two films 2 and 3 are overlapped with each other, pressed from above and below by a defoaming / impregnation roll, and impregnated into the glass fiber 105 with the resin of the resin layer 104, whereby the SMC 100 is manufactured. (See FIG. 5).

特開平9−155861号公報Japanese Patent Laid-Open No. 9-155861

しかし、上述のようにSMC100を製造する場合、脱泡・含浸ロールによって上下から押圧する際に、樹脂がガラス繊維105に含浸する方向に押されるだけでなく、横方向にも押されてガラス繊維105の堆積範囲の外側に樹脂がはみ出してしまうおそれがある。これでは、SMC100の幅方向の端部に、ガラス繊維105の密度が低くて強度の弱い部位が形成されてしまう。SMC100の強度を全体的に一定に保つためには、この強度の弱い端部を切断し、廃棄しなければならず、製造ロスとなる。   However, when the SMC 100 is manufactured as described above, when pressing from above and below by the defoaming / impregnating roll, not only the resin is pressed in the direction of impregnating the glass fiber 105 but also pressed in the horizontal direction to make the glass fiber There is a possibility that the resin protrudes outside the deposition range 105. In this case, a portion where the density of the glass fiber 105 is low and the strength is low is formed at the end of the SMC 100 in the width direction. In order to keep the strength of the SMC 100 constant as a whole, this weak end portion must be cut and discarded, resulting in a manufacturing loss.

そこで、上記事情を鑑みて、本発明は、2枚のフィルムの間にSMC材料である繊維と樹脂成形材料とを重ねてプレスする際に、樹脂成形材料が繊維の外側にはみ出すことを抑制することができるSMCの製造方法及び製造装置を提案することを課題とする。   Therefore, in view of the above circumstances, the present invention suppresses the resin molding material from protruding outside the fiber when pressing the fiber which is the SMC material and the resin molding material between two films. An object of the present invention is to propose a manufacturing method and a manufacturing apparatus for SMC that can be used.

上記課題を解決するために本発明のSMCの製造方法は、下側に配置される下側離型フィルムと、上側に配置される上側離型フィルムとを連続して送り出し、この下側離型フィルム上には熱硬化性樹脂である樹脂成形材料を供給して下側樹脂層を形成し、この下側樹脂層上に繊維を散布して所定幅の繊維層を形成し、この上側離型フィルム上には熱硬化性樹脂である樹脂成形材料を供給して上側樹脂層を形成し、前記下側離型フィルムと前記上側離型フィルムとを前記上側樹脂層が前記繊維層に接するように重ね、この重ねられた前記上側離型フィルム及び前記下側離型フィルムを押圧含浸部に通して、前記繊維層に前記上側樹脂層及び前記下側樹脂層を押圧含浸させることでSMCを製造するSMCの製造方法であって、前記下側離型フィルムと前記上側離型フィルムとを重ねる前に、前記繊維層の幅方向の両端部上に熱硬化性樹脂である第二樹脂成形材料を供給し、この第二樹脂成形材料を供給した後、前記下側離型フィルムと前記上側離型フィルムとを前記上側樹脂層が前記繊維層の幅方向の両端部の間に接するように重ねることを特徴とする。   In order to solve the above problems, the SMC manufacturing method of the present invention continuously feeds a lower release film disposed on the lower side and an upper release film disposed on the upper side, and this lower release film. A resin molding material that is a thermosetting resin is supplied onto the film to form a lower resin layer, and fibers are spread on the lower resin layer to form a fiber layer having a predetermined width. A resin molding material that is a thermosetting resin is supplied on the film to form an upper resin layer, and the lower resin release film and the upper mold release film are brought into contact with the fiber layer. The SMC is manufactured by stacking, passing the stacked upper release film and the lower release film through a press impregnation unit, and pressing and impregnating the upper resin layer and the lower resin layer in the fiber layer. A method of manufacturing an SMC, wherein the lower mold release film Before the second release film and the upper release film are stacked, after supplying the second resin molding material is a thermosetting resin on both ends in the width direction of the fiber layer, The lower release film and the upper release film are overlapped so that the upper resin layer is in contact between both ends in the width direction of the fiber layer.

また、前記繊維層は、その幅方向の両端部がそれぞれ、前記下側樹脂層の幅方向の両端部よりも外側に位置するように形成されることが好ましい。   Moreover, it is preferable that the said fiber layer is formed so that the both ends of the width direction may each be located outside the both ends of the width direction of the said lower side resin layer.

また、上記課題を解決するために本発明のSMCの製造装置は、下側に配置される下側離型フィルムを連続して送り出す第一送出部と、この下側離型フィルム上に熱硬化性樹脂である樹脂成形材料を供給して下側樹脂層を形成する第一樹脂供給部と、この下側樹脂層上に繊維を散布して所定幅の繊維層を形成する繊維散布部と、上側に配置される上側離型フィルムを連続して送り出す第二送出部と、この上側離型フィルム上に熱硬化性樹脂である樹脂成形材料を供給して上側樹脂層を形成する第二樹脂供給部と、前記下側離型フィルムと前記上側離型フィルムとを前記上側樹脂層が前記繊維層に接するように重ねて送り出す積層送出部と、この重ねられた前記上側離型フィルム及び前記下側離型フィルムを上下から押圧して前記繊維層に前記上側樹脂層及び前記下側樹脂層を含浸させる押圧含浸部と、を備え、前記繊維層に前記上側樹脂層及び前記下側樹脂層を含浸させることでSMCを製造するSMCの製造装置において、前記下側離型フィルムと前記上側離型フィルムとを重ねる前に前記繊維層の幅方向の両端部上に熱硬化性樹脂である第二樹脂成形材料を供給する端部樹脂供給部を備え、前記積層送出部は、前記下側離型フィルムと前記上側離型フィルムとを前記上側樹脂層が前記繊維層の幅方向の両端部の間に接するように重ねて送り出すことを特徴とする。   In order to solve the above problems, the SMC manufacturing apparatus of the present invention includes a first delivery unit that continuously feeds the lower release film disposed on the lower side, and thermosetting on the lower release film. A first resin supply part that forms a lower resin layer by supplying a resin molding material that is a functional resin, and a fiber dispersion part that forms fibers of a predetermined width by dispersing fibers on the lower resin layer; A second delivery unit for continuously feeding the upper release film disposed on the upper side, and a second resin supply for forming an upper resin layer by supplying a resin molding material that is a thermosetting resin on the upper release film A laminate delivery section that sends out the upper part release film and the upper release film so that the upper resin layer is in contact with the fiber layer, and the upper release film and the lower Press the release film from above and below to the fiber layer A press impregnation unit that impregnates the side resin layer and the lower resin layer, and an SMC manufacturing apparatus that manufactures SMC by impregnating the upper resin layer and the lower resin layer into the fiber layer, An end resin supply unit that supplies a second resin molding material that is a thermosetting resin on both ends in the width direction of the fiber layer before the lower release film and the upper release film are stacked; The laminate delivery section is characterized in that the lower release film and the upper release film are delivered in such a manner that the upper resin layer is in contact with both ends of the fiber layer in the width direction.

本発明では、繊維層に含浸させる上側樹脂層を、繊維層のうち幅方向の両端部の間の部位に重ねるようにしたことで、押圧含浸部によって押圧された上側樹脂層が、繊維層の幅方向の外側にはみ出すことを抑制できる。また、繊維層に上側樹脂層を重ねる前に、繊維層の幅方向の両端部上に第二樹脂成形材料を供給することで、押圧含浸部によって押圧されるまでに、繊維層の幅方向の両端部に第二樹脂成形材料を一部または全部含浸させることができる。これにより、押圧含浸部によって押圧される際に、繊維層の幅方向の両端部上に第二樹脂成形材料が残りにくくなる。そのため、この両端部上に残った第二樹脂成形材料が、押圧含浸部によって横方向に押圧されて、繊維層の幅方向の外側にはみ出すことを抑制できる。したがって、本発明では、2枚の離型フィルムの間にSMC材料である繊維と樹脂成形材料及び第二樹脂成形材料とを重ねてプレスする際に、樹脂成形材料及び第二樹脂成形材料が繊維の外側にはみ出すことを抑制できる。その結果、本発明では、SMCの幅方向の両端部に、繊維の密度の低い強度の弱い部位が形成されることを抑制できる。   In the present invention, the upper resin layer impregnated in the fiber layer is overlapped on the portion between both end portions in the width direction of the fiber layer, so that the upper resin layer pressed by the press impregnation portion is Protruding to the outside in the width direction can be suppressed. Further, before the upper resin layer is stacked on the fiber layer, the second resin molding material is supplied onto both end portions in the width direction of the fiber layer, so that the fiber layer is pressed in the width direction until pressed by the press impregnation portion. Both or both ends can be impregnated with part or all of the second resin molding material. This makes it difficult for the second resin molding material to remain on both end portions in the width direction of the fiber layer when pressed by the pressing impregnation portion. Therefore, it can suppress that the 2nd resin molding material which remained on this both ends is pressed by the press impregnation part by the horizontal direction, and protrudes to the outer side of the width direction of a fiber layer. Therefore, in the present invention, when the fiber, which is an SMC material, and the resin molding material and the second resin molding material are stacked and pressed between two release films, the resin molding material and the second resin molding material are fibers. Can be prevented from protruding outside. As a result, in the present invention, it is possible to suppress the formation of weak and low-strength portions with low fiber density at both ends in the width direction of the SMC.

本発明の第一実施形態のSMCの製造装置を示す概略正面図である。It is a schematic front view which shows the manufacturing apparatus of SMC of 1st embodiment of this invention. 同上の製造装置のうち端部樹脂供給部を示す概略説明図であり、搬送方向から視た図である。It is a schematic explanatory drawing which shows an edge part resin supply part among the manufacturing apparatuses same as the above, and is the figure seen from the conveyance direction. 同上の製造装置のうち押圧含浸部によって押圧される樹脂成形材料の繊維層への含浸の様子を示す概略説明図であり、搬送方向から視た図である。It is the schematic explanatory drawing which shows the mode of the impregnation to the fiber layer of the resin molding material pressed by the press impregnation part among the manufacturing apparatuses same as the above, and is the figure seen from the conveyance direction. 本発明の第二実施形態のSMCの製造装置のうち端部樹脂供給部を示す概略説明図であり、搬送方向から視た図である。It is a schematic explanatory drawing which shows the edge part resin supply part among the manufacturing apparatuses of SMC of 2nd embodiment of this invention, and is the figure seen from the conveyance direction. 従来のSMCの製造装置のうち脱泡・含浸ロールによって押圧される樹脂のガラス繊維への含浸の様子を示す概略説明図であり、搬送方向から視た図である。It is the schematic explanatory drawing which shows the mode of the impregnation to the glass fiber of the resin pressed by the defoaming and impregnation roll among the conventional SMC manufacturing apparatuses, and is the figure seen from the conveyance direction.

本発明を添付図面に示す実施形態に基づいて説明する。   The present invention will be described based on embodiments shown in the accompanying drawings.

本発明の第一実施形態の製造装置10は、FRP(繊維強化プラスチック)製品の成形材料となる熱硬化性のSMC(シートモールディングコンパウンド)1を製造する装置である。SMC1は、下側に配置される下側離型フィルム2と上側に配置される上側離型フィルム3との間に、熱硬化性樹脂である樹脂成形材料4,7と、ガラス繊維等の繊維5とを挟んで含浸させて増強した薄板状の成形材料である。樹脂成形材料4,7としては、フェノール樹脂やメラミン樹脂、不飽和ポリエステル樹脂などの熱硬化性樹脂を使用することができる。また、樹脂成形材料4,7としては、製造のスピードアップを考慮すれば硬化の速い材料を選択するのが好ましく、熱硬化性樹脂に炭酸カルシウムや水酸化アルミニウム等を混合したものを用いることができる。   The manufacturing apparatus 10 of the first embodiment of the present invention is an apparatus that manufactures a thermosetting SMC (sheet molding compound) 1 that is a molding material for FRP (fiber reinforced plastic) products. SMC 1 includes resin molding materials 4 and 7 that are thermosetting resins and fibers such as glass fibers between a lower release film 2 disposed on the lower side and an upper release film 3 disposed on the upper side. 5 is a thin plate-shaped molding material strengthened by impregnating 5. As the resin molding materials 4 and 7, thermosetting resins such as phenol resin, melamine resin, and unsaturated polyester resin can be used. In addition, as the resin molding materials 4 and 7, it is preferable to select a material that cures quickly in consideration of the speed of production, and it is preferable to use a thermosetting resin mixed with calcium carbonate, aluminum hydroxide, or the like. it can.

図1には、本実施形態のSMC1の製造装置10の概略正面図を示している。   In FIG. 1, the schematic front view of the manufacturing apparatus 10 of SMC1 of this embodiment is shown.

製造装置10は、第一送出部11、第一樹脂供給部12、繊維散布部13、第二送出部14、第二樹脂供給部15、積層送出部16、押圧含浸部6、及びタンク47を備え、さらに端部樹脂供給部17を備える。   The manufacturing apparatus 10 includes a first delivery unit 11, a first resin supply unit 12, a fiber dispersion unit 13, a second delivery unit 14, a second resin supply unit 15, a laminate delivery unit 16, a press impregnation unit 6, and a tank 47. And an end resin supply unit 17.

第一送出部11は、ロール状に巻いた長尺の下側離型フィルム2を連続して送り出す。また、第二送出部14は、ロール状に巻いた長尺の上側離型フィルム3を連続して送り出す。以下、この離型フィルム2,3の送り出し方向に対して平面視にて直交する方向を幅方向として、各構成の説明を行う。   The 1st sending-out part 11 sends out the elongate lower side release film 2 wound by roll shape continuously. Moreover, the 2nd sending part 14 sends out the elongate upper side release film 3 wound by roll shape continuously. Hereinafter, each configuration will be described with a direction perpendicular to the feeding direction of the release films 2 and 3 in a plan view as a width direction.

下側離型フィルム2と上側離型フィルム3とは、略同幅である(図3参照)。両離型フィルム2,3は、樹脂成形材料4,7から剥離しやすい素材で形成されており、例えばポロプロピレンフィルムである。   The lower release film 2 and the upper release film 3 have substantially the same width (see FIG. 3). Both release films 2 and 3 are formed of a material that is easily peeled from the resin molding materials 4 and 7, and are, for example, polypropylene films.

第一樹脂供給部12は、第一送出部11によって送り出された下側離型フィルム2の幅方向の中央部上に樹脂成形材料4を連続して供給して、所定幅L1の下側樹脂層40を形成する。第一樹脂供給部12には、タンク47に溜められた樹脂成形材料4が供給される。そして、繊維散布部13は、形成された下側樹脂層40上に繊維5を連続して散布して所定幅L2の繊維層50を形成する。繊維散布部13は、図2に示すように、繊維層50の幅方向の両端部51が、下側樹脂層40の幅方向の両端部よりも外側に位置するように、繊維5を下側樹脂層40上と、下側樹脂層40の幅方向の両外側の下側離型フィルム2上とに散布する。繊維散布部13は、ガラスロービングGを切断して得られる多数の細かいガラス繊維である繊維5を散布する。本実施形態では繊維5としてガラス繊維を用いるが、繊維5はガラス繊維に限定されるものではない。なお、図2には概略的に繊維層50を示しており、繊維層50は断面矩形状をなすように形成されるとは限らない。   The first resin supply unit 12 continuously supplies the resin molding material 4 onto the central portion in the width direction of the lower release film 2 delivered by the first delivery unit 11, and lower resin of a predetermined width L <b> 1. Layer 40 is formed. The resin molding material 4 stored in the tank 47 is supplied to the first resin supply unit 12. And the fiber spreading | diffusion part 13 spreads | distributes the fiber 5 continuously on the formed lower side resin layer 40, and forms the fiber layer 50 of the predetermined width L2. As shown in FIG. 2, the fiber spreading unit 13 places the fibers 5 on the lower side so that both end portions 51 in the width direction of the fiber layer 50 are located outside both end portions in the width direction of the lower resin layer 40. It spreads on the resin layer 40 and the lower release film 2 on both outer sides in the width direction of the lower resin layer 40. The fiber spreading part 13 spreads the fiber 5 which is many fine glass fibers obtained by cutting the glass roving G. Although glass fiber is used as the fiber 5 in this embodiment, the fiber 5 is not limited to glass fiber. FIG. 2 schematically shows the fiber layer 50, and the fiber layer 50 is not necessarily formed to have a rectangular cross section.

第二樹脂供給部15は、第二送出部14によって送り出された上側離型フィルム3の幅方向の中央部上に樹脂成形材料4を連続して供給して、所定幅L3の上側樹脂層41を形成する。第二樹脂供給部15は、下側樹脂層40と略同幅の上側樹脂層41を形成する。第二樹脂供給部15には、タンク47に溜められた樹脂成形材料4が供給される。   The second resin supply unit 15 continuously supplies the resin molding material 4 onto the central portion in the width direction of the upper release film 3 delivered by the second delivery unit 14, and the upper resin layer 41 having a predetermined width L3. Form. The second resin supply unit 15 forms an upper resin layer 41 having substantially the same width as the lower resin layer 40. The resin molding material 4 stored in the tank 47 is supplied to the second resin supply unit 15.

第一及び第二樹脂供給部12,15はそれぞれ、所定の厚みの樹脂層40,41を形成する。第一及び第二樹脂供給部12,15としては、従来公知の装置が用いられ、供給する樹脂成形材料4の粘度や供給量(目付け)に応じて、適宜選択することができる。   The first and second resin supply units 12 and 15 form resin layers 40 and 41 having a predetermined thickness, respectively. Conventionally known devices are used as the first and second resin supply units 12 and 15 and can be appropriately selected according to the viscosity and the supply amount (weight) of the resin molding material 4 to be supplied.

積層送出部16は、下側離型フィルム2と上側離型フィルム3とを上側樹脂層41が繊維層50に接するように重ねて送り出す。詳しくは、積層送出部16は、上側樹脂層41が上面に形成された上側離型フィルム3を上下反転させて、この上側樹脂層41を下側離型フィルム2の繊維層50の幅方向の中央部(つまり、両端部51の間の部位)に重ね合わせて、この両離型フィルム2,3を送り出す。   The laminate delivery unit 16 sends out the lower release film 2 and the upper release film 3 so that the upper resin layer 41 is in contact with the fiber layer 50. Specifically, the laminate delivery unit 16 vertically inverts the upper release film 3 having the upper resin layer 41 formed on the upper surface, and the upper resin layer 41 in the width direction of the fiber layer 50 of the lower release film 2. The two release films 2 and 3 are fed out in a superposed manner at the central portion (that is, the portion between both end portions 51).

押圧含浸部6は、この重ねられた状態の両離型フィルム2,3を上下から押圧して繊維層50に上側樹脂層41及び下側樹脂層40を含浸させる。押圧含浸部6は、例えば、上下一対のネットコンベアであり、両離型フィルム2,3を挟んで上下にジグザグに送り出すことで、上下方向だけでなく左右方向にも押圧して繊維層50に樹脂層40,41を含浸させる。   The press impregnation unit 6 presses the two release films 2 and 3 in an overlapped state from above and below to impregnate the fiber layer 50 with the upper resin layer 41 and the lower resin layer 40. The press impregnation unit 6 is, for example, a pair of upper and lower net conveyors, and is pressed not only in the vertical direction but also in the horizontal direction by being fed in a zigzag manner with the two release films 2 and 3 interposed therebetween, thereby forming the fiber layer 50 The resin layers 40 and 41 are impregnated.

端部樹脂供給部17は、積層送出部16によって下側離型フィルム2と上側離型フィルム3とを重ねる前に、繊維層50の幅方向の両端部51上にそれぞれ第二樹脂成形材料7を供給する。本実施形態では、端部樹脂供給部17には、タンク47に溜められた樹脂成形材料4である第二樹脂成形材料7が供給される。端部樹脂供給部17は、図2に示すように、繊維層50の幅方向の両端部51のうち一方の端部51上に第二樹脂成形材料7を供給する塗装ノズル17aと、他方の端部51上に第二樹脂成形材料7を供給する塗装ノズル17bとを備える。塗装ノズル17a,17bは、例えば、スプレー方式で第二樹脂成形材料7を繊維層50の両端部51上に塗装する。   The end resin supply unit 17 is configured so that the second resin molding material 7 is placed on both end portions 51 of the fiber layer 50 in the width direction before the lower release film 2 and the upper release film 3 are stacked by the laminate delivery unit 16. Supply. In the present embodiment, the second resin molding material 7 that is the resin molding material 4 stored in the tank 47 is supplied to the end resin supply unit 17. As shown in FIG. 2, the end resin supply unit 17 includes a coating nozzle 17 a that supplies the second resin molding material 7 on one end 51 of the both ends 51 in the width direction of the fiber layer 50, and the other The coating nozzle 17b which supplies the 2nd resin molding material 7 on the edge part 51 is provided. The coating nozzles 17a and 17b coat the second resin molding material 7 on both end portions 51 of the fiber layer 50 by, for example, a spray method.

タンク47と第一及び第二樹脂供給部12,15との接続構造と、タンク47と端部樹脂供給部17との接続構造についてさらに詳しく説明すると、タンク47には、図2に示すように、樹脂供給管71が接続されている。樹脂供給管71は、下流側で第一乃至第三樹脂供給管71a,71b,71cの3つ供給管に分岐している。この第一乃至第三樹脂供給管71a,71b,71cにはそれぞれ、送液装置P1,P2,P3が配されている。この送液装置P1,P2,P3は、流量計付きのポンプであり、所定量の樹脂成形材料4を安定して供給できる。第一樹脂供給管71aは、第一及び第二樹脂供給部12,15に接続されている。第一樹脂供給管71aは、この第一及び第二樹脂供給部12,15にそれぞれ樹脂成形材料4を供給する。第二樹脂供給管71bは塗装ノズル17aに接続されており、第三樹脂供給管71cは塗装ノズル17bに接続されている。第二及び第三樹脂供給管71a,71bはそれぞれ、塗装ノズル17a,17bに第二樹脂成形材料7(樹脂成形材料4)を供給する。   The connection structure between the tank 47 and the first and second resin supply units 12 and 15 and the connection structure between the tank 47 and the end resin supply unit 17 will be described in more detail. As shown in FIG. The resin supply pipe 71 is connected. The resin supply pipe 71 is branched into three supply pipes of first to third resin supply pipes 71a, 71b, 71c on the downstream side. The first to third resin supply pipes 71a, 71b, 71c are provided with liquid feeding devices P1, P2, P3, respectively. The liquid feeding devices P1, P2, and P3 are pumps with a flow meter, and can stably supply a predetermined amount of the resin molding material 4. The first resin supply pipe 71 a is connected to the first and second resin supply units 12 and 15. The first resin supply pipe 71a supplies the resin molding material 4 to the first and second resin supply units 12 and 15, respectively. The second resin supply pipe 71b is connected to the coating nozzle 17a, and the third resin supply pipe 71c is connected to the coating nozzle 17b. The second and third resin supply pipes 71a and 71b supply the second resin molding material 7 (resin molding material 4) to the coating nozzles 17a and 17b, respectively.

続いて、上述した製造装置10を用いて、SMC1を製造する手順の一例について説明する。   Then, an example of the procedure which manufactures SMC1 using the manufacturing apparatus 10 mentioned above is demonstrated.

まず、第一送出部11によって下側離型フィルム2を連続して送り出し、第二送出部14によって上側離型フィルム3を連続して送り出す。なお、第一送出部11と第二送出部14は、離型フィルム2,3を送り出し始めるタイミングが同じであってもよいし、異なっていてもよい。次いで、第一送出部11によって送り出された下側離型フィルム2の幅方向の中央部上に、第一樹脂供給部12によって樹脂成形材料4を連続して供給して、所定幅L1の下側樹脂層40を形成する。次いで、この下側樹脂層40上及びその幅方向の外側の下側離型フィルム2上に、繊維散布部13によって繊維5を散布して所定幅L2の繊維層50を形成する。繊維層50と下側樹脂層40とは、徐々に含浸していく。   First, the lower release film 2 is continuously sent out by the first delivery unit 11, and the upper release film 3 is sent out continuously by the second delivery unit 14. In addition, the timing with which the 1st sending part 11 and the 2nd sending part 14 start sending out the release films 2 and 3 may be the same, and may differ. Next, the resin molding material 4 is continuously supplied by the first resin supply part 12 onto the center part in the width direction of the lower release film 2 sent out by the first delivery part 11, and below the predetermined width L1. The side resin layer 40 is formed. Next, on the lower resin layer 40 and on the lower release film 2 on the outer side in the width direction, the fiber 5 is spread by the fiber spreading unit 13 to form a fiber layer 50 having a predetermined width L2. The fiber layer 50 and the lower resin layer 40 are gradually impregnated.

次いで、端部樹脂供給部17の塗装ノズル17a,17bによって、繊維層50の幅方向の両端部51上に、樹脂成形材料4と同材料の第二樹脂成形材料7をスプレー方式で供給する。供給された第二樹脂成形材料7は、自重により繊維層50の幅方向の両端部51内に徐々に含浸していく。   Next, the second resin molding material 7 which is the same material as the resin molding material 4 is supplied by the spray method onto both end portions 51 in the width direction of the fiber layer 50 by the coating nozzles 17a and 17b of the end resin supply unit 17. The supplied second resin molding material 7 is gradually impregnated into both end portions 51 in the width direction of the fiber layer 50 by its own weight.

また、第二送出部14によって送り出された上側離型フィルム3の幅方向の中央部上には、第二樹脂供給部15によって樹脂成形材料4を連続して供給して所定幅L3の上側樹脂層41を形成する。   In addition, the resin molding material 4 is continuously supplied by the second resin supply unit 15 onto the central portion in the width direction of the upper release film 3 delivered by the second delivery unit 14, and the upper resin having a predetermined width L3. Layer 41 is formed.

次いで、積層送出部16によって、上側離型フィルム3の上下を反転させ、この上側離型フィルム3上の上側樹脂層41を下側に向けながら、この上側樹脂層41を、下側離型フィルム2上の繊維層50の幅方向の両端部51の間の部位に接するように重ねる。   Next, the upper and lower release films 3 are turned upside down by the laminate delivery section 16, and the upper resin layer 41 is placed on the lower release film while the upper resin layer 41 on the upper release film 3 faces downward. 2 are overlapped so as to be in contact with the portion between both end portions 51 in the width direction of the upper fiber layer 50.

次いで、この重ねた状態の両離型フィルム2,3を押圧含浸部6に通して、繊維層50に上側樹脂層41及び下側樹脂層40を押圧含浸させる。   Next, the two release films 2 and 3 in the stacked state are passed through the press impregnation unit 6, and the fiber layer 50 is press impregnated with the upper resin layer 41 and the lower resin layer 40.

このとき、図3に示すように、上側樹脂層41及び下側樹脂層40は、繊維層50に含浸する方向と、繊維層50の幅方向の外側に拡がる。しかし、本実施形態では、上側樹脂層41及び下側樹脂層40の幅方向の両端部よりも繊維層50の幅方向の両端部51が外側に位置しているため、この上側樹脂層41及び下側樹脂層40が、繊維層50の幅方向の両端部51の外側までは押し出されにくくなっている。   At this time, as shown in FIG. 3, the upper resin layer 41 and the lower resin layer 40 extend in the direction in which the fiber layer 50 is impregnated and outside in the width direction of the fiber layer 50. However, in the present embodiment, since both end portions 51 in the width direction of the fiber layer 50 are located outside the both end portions in the width direction of the upper resin layer 41 and the lower resin layer 40, the upper resin layer 41 and The lower resin layer 40 is difficult to be pushed out to the outside of both end portions 51 in the width direction of the fiber layer 50.

また、繊維層50の幅方向の両端部51上に供給された第二樹脂成形材料7は、この押圧含浸部6によって押圧されるまでに、一部または全部がこの両端部51内に含浸する。そのため、押圧含浸部6によって押圧される際には、繊維層50の幅方向の両端部51上に第二樹脂成形材料7が残りにくい。また、繊維層50の幅方向の両端部51上に残った第二樹脂成形材料7が、押圧含浸部6によって押圧されて繊維層50の幅方向の外側へ押し出されたとしても、その量は微量となる。これにより、第二樹脂成形材料7も、繊維層50の幅方向の両端部51の外側へ押し出されにくくなっている。   In addition, the second resin molding material 7 supplied onto both end portions 51 in the width direction of the fiber layer 50 is impregnated partially or entirely in the both end portions 51 before being pressed by the press impregnation portion 6. . Therefore, the second resin molding material 7 hardly remains on both end portions 51 in the width direction of the fiber layer 50 when pressed by the press impregnation portion 6. Further, even if the second resin molding material 7 remaining on both end portions 51 in the width direction of the fiber layer 50 is pressed by the press impregnation portion 6 and pushed out to the outside in the width direction of the fiber layer 50, the amount is Trace amount. Accordingly, the second resin molding material 7 is also difficult to be pushed out of the both end portions 51 in the width direction of the fiber layer 50.

以上のようにして、繊維層50に樹脂成形材料4(上側樹脂層41及び下側樹脂層40)及び第二樹脂成形材料7を含浸させてSMC1を製造する。   As described above, the fiber layer 50 is impregnated with the resin molding material 4 (the upper resin layer 41 and the lower resin layer 40) and the second resin molding material 7, and the SMC 1 is manufactured.

上述した製造装置10で形成されるSMC1は、繊維層50の幅方向の両端部51の外側に、樹脂成形材料4(上側樹脂層41及び下側樹脂層40)及び第二樹脂成形材料7が押し出されにくいものとなっている。なお、繊維層50の幅方向の両端部51には、第二樹脂成形材料7が含浸されている。そのため、本実施形態のSMC1は、幅方向の両端部に繊維5の密度が低く強度の弱くなった部位が形成されにくいものとなっている。その結果、本実施形態のSMC1では、強度の弱くなった端部を切断する必要が低くなり、製造ロスの発生を抑制できるものとなっている
なお、以上のようにして製造されたSMC1は、その後、上方に開口する矩形箱状をしたコンテナ等である収納部8につづら折り状に重ねて収納し、熟成庫(非図示)にて熟成させる。熟成庫で熟成させた後、離型フィルム巻取り装置(非図示)によって離型フィルム2,3を剥がして、この離型フィルム2,3をそれぞれ巻取りロールに巻取る。そして、シート状のSMC1を切断装置にて長手方向に所定の長さに切断する。この所定長となったSMC1を圧縮成形装置に供給して成形を行うことで、FRP製品は製造される。
In the SMC 1 formed by the manufacturing apparatus 10 described above, the resin molding material 4 (the upper resin layer 41 and the lower resin layer 40) and the second resin molding material 7 are disposed outside the both end portions 51 in the width direction of the fiber layer 50. It is hard to be pushed out. Note that both end portions 51 in the width direction of the fiber layer 50 are impregnated with the second resin molding material 7. Therefore, in the SMC 1 of the present embodiment, it is difficult to form portions where the density of the fibers 5 is low and the strength is weak at both ends in the width direction. As a result, in the SMC 1 of the present embodiment, it is less necessary to cut the end portion whose strength has been reduced, and the production loss can be suppressed. The SMC 1 manufactured as described above is Then, it is folded and stored in a storage unit 8 which is a rectangular box-like container or the like that opens upward, and is aged in an aging box (not shown). After aging in an aging box, the release films 2 and 3 are peeled off by a release film winding device (not shown), and the release films 2 and 3 are respectively wound on winding rolls. Then, the sheet-like SMC 1 is cut into a predetermined length in the longitudinal direction by a cutting device. The FRP product is manufactured by supplying the SMC 1 having the predetermined length to the compression molding apparatus and performing molding.

なお、上述した端部樹脂供給部17は、繊維層50上に供給した第二樹脂成形材料7が、押圧含浸部6に至るまでに全て繊維層50内に含浸するように、押圧含浸部6から所定の距離離して配置することが好ましい。   The end resin supply unit 17 described above is configured so that the second resin molding material 7 supplied onto the fiber layer 50 is completely impregnated into the fiber layer 50 before reaching the press impregnation unit 6. It is preferable to arrange them at a predetermined distance from each other.

続いて、図4に示す本発明の第二実施形態のSMC1の製造装置10について説明する。第二実施形態の製造装置10は、第一実施形態の製造装置10とは、端部樹脂供給部17から供給される第二樹脂成形材料7が樹脂成形材料4を希釈したものである点でのみ異なる。第一実施形態の製造装置10と同様の構成については、図中に同じ符号をつけ、異なる構成について詳しく説明する。   Then, the manufacturing apparatus 10 of SMC1 of 2nd embodiment of this invention shown in FIG. 4 is demonstrated. The manufacturing apparatus 10 of the second embodiment is different from the manufacturing apparatus 10 of the first embodiment in that the second resin molding material 7 supplied from the end resin supply unit 17 is a dilution of the resin molding material 4. Only different. About the structure similar to the manufacturing apparatus 10 of 1st embodiment, the same code | symbol is attached | subjected in a figure and a different structure is demonstrated in detail.

第二実施形態のSMC1の製造装置10は、希釈液を溜める希釈液タンク18と、この希釈液を端部樹脂供給部17に供給する希釈液供給管20と、供給された希釈液とタンク47の樹脂成形材料4とを混合する混合部19と、を備える。   The manufacturing apparatus 10 of the SMC 1 according to the second embodiment includes a diluent tank 18 that stores a diluent, a diluent supply pipe 20 that supplies the diluent to the end resin supply unit 17, and a supplied diluent and tank 47. The mixing part 19 which mixes the resin molding material 4 is provided.

詳しくは、希釈液タンク18には、希釈液供給管20が接続されている。この希釈液供給管20は下流側で第一及び第二希釈液供給管20a,20bの2つの供給管に分岐している。この第一及び第二希釈液供給管20a,20bにはそれぞれ送液装置P4,P5が配されている。この送液装置P4,P5は、流量計付きのポンプであり、所定量の希釈液を安定して供給できる。混合部19は、スタティックミキサー等の混合装置である。混合部19は、塗装ノズル17aに接続された第二樹脂供給管71bに配される第一混合部19aと、塗装ノズル17bに接続された第三樹脂供給管71cに配される第二混合部19bとを備える。この第一混合部19aに第一希釈液供給管20aが接続されており、第二混合部19bに第二希釈液供給管20bが接続されている。   Specifically, a diluent supply pipe 20 is connected to the diluent tank 18. This diluent supply pipe 20 is branched downstream into two supply pipes, the first and second diluent supply pipes 20a and 20b. The first and second diluent supply pipes 20a and 20b are provided with liquid feeding devices P4 and P5, respectively. The liquid feeding devices P4 and P5 are pumps with a flow meter, and can stably supply a predetermined amount of diluent. The mixing unit 19 is a mixing device such as a static mixer. The mixing unit 19 includes a first mixing unit 19a disposed in the second resin supply pipe 71b connected to the coating nozzle 17a and a second mixing unit disposed in the third resin supply pipe 71c connected to the coating nozzle 17b. 19b. A first diluent supply pipe 20a is connected to the first mixing section 19a, and a second diluent supply pipe 20b is connected to the second mixing section 19b.

上述した構成の本実施形態の製造装置10では、第一実施形態の製造装置10と略同様の手順で、SMC1が製造される。ここで、第一実施形態の製造装置10による手順と異なる箇所だけ説明する。   In the manufacturing apparatus 10 of the present embodiment configured as described above, the SMC 1 is manufactured in substantially the same procedure as the manufacturing apparatus 10 of the first embodiment. Here, only a different part from the procedure by the manufacturing apparatus 10 of the first embodiment will be described.

上述した本実施形態の製造装置10では、端部樹脂供給部17によって第二樹脂成形材料7を供給する際に、以下のような手順を踏む。   In the manufacturing apparatus 10 of this embodiment mentioned above, when supplying the 2nd resin molding material 7 by the edge part resin supply part 17, the following procedures are followed.

すなわち、まず、送液装置P4,P5を駆動させて、希釈液タンク18内の希釈液を第一及び第二希釈液供給管20a,20bを介して第一及び第二混合部19a,19bに送る。このとき、送液装置P2,P3を駆動させて、タンク47内の樹脂成形材料4を第二及び第三樹脂供給管71b,71cを介して第一及び第二混合部19a,19bに送る。次いで、この送られてきた樹脂成形材料4と希釈液とを、第一及び第二混合部19a,19bで混合する。次いで、この樹脂成形材料4を希釈した第二樹脂成形材料7を、塗装ノズル17a,17bから繊維層50の幅方向の両端部51上に供給する。   That is, first, the liquid feeding devices P4 and P5 are driven, and the diluent in the diluent tank 18 is transferred to the first and second mixing portions 19a and 19b via the first and second diluent supply pipes 20a and 20b. send. At this time, the liquid feeding devices P2 and P3 are driven to send the resin molding material 4 in the tank 47 to the first and second mixing portions 19a and 19b via the second and third resin supply pipes 71b and 71c. Next, the sent resin molding material 4 and the diluent are mixed in the first and second mixing portions 19a and 19b. Next, the second resin molding material 7 obtained by diluting the resin molding material 4 is supplied onto both end portions 51 in the width direction of the fiber layer 50 from the coating nozzles 17a and 17b.

このように端部樹脂供給部17から樹脂成形材料4を希釈した第二樹脂成形材料7を繊維層50の幅方向の両端部51上に供給するようにしたことで、この両端部51への第二樹脂成形材料7の含浸速度を速めることができる。   In this way, the second resin molding material 7 obtained by diluting the resin molding material 4 from the end resin supply unit 17 is supplied onto the both end portions 51 in the width direction of the fiber layer 50, The impregnation speed of the second resin molding material 7 can be increased.

これにより、押圧含浸部6によって下側及び上側樹脂層40,41を繊維層50に含浸させる際には、繊維層50の幅方向の両端部51上には第二樹脂成形材料7が残りにくくなる。したがって、この繊維層50の幅方向の両端部51上に残った第二樹脂成形材料7が押圧含浸部6によって押圧されて繊維層50の幅方向の両端部51の外側に押し出されることを抑制できる。よって、第二実施形態のSMC1では、下側及び上側樹脂層40,41だけでなく、第二樹脂成形材料7も、繊維層50の幅方向の両端部51の外側に押し出されにくくなっている。そのため、第二実施形態のSMC1は、幅方向の両端部に繊維5の密度が低くて強度の弱くなった部位が形成されにくいものとなっている。   Accordingly, when the fiber layer 50 is impregnated with the lower and upper resin layers 40 and 41 by the press impregnation unit 6, the second resin molding material 7 hardly remains on both end portions 51 in the width direction of the fiber layer 50. Become. Therefore, the second resin molding material 7 remaining on both end portions 51 in the width direction of the fiber layer 50 is suppressed from being pushed out by the press impregnating portion 6 and being pushed outside the both end portions 51 in the width direction of the fiber layer 50. it can. Therefore, in the SMC 1 of the second embodiment, not only the lower and upper resin layers 40 and 41 but also the second resin molding material 7 is difficult to be pushed outside the both end portions 51 in the width direction of the fiber layer 50. . Therefore, in the SMC 1 of the second embodiment, it is difficult to form portions where the density of the fibers 5 is low and the strength is weak at both ends in the width direction.

以上、本発明を添付図面に示す実施形態に基づいて説明したが、本発明は上記の各実施形態に限定されるものではなく、本発明の意図する範囲内であれば、適宜の設計変更が可能である。   Although the present invention has been described based on the embodiments shown in the accompanying drawings, the present invention is not limited to the above-described embodiments, and appropriate design changes can be made within the intended scope of the present invention. Is possible.

1 SMC
2 下側離型フィルム
3 上側離型フィルム
4 樹脂成形材料
5 繊維
6 押圧含浸部
7 第二樹脂成形材料
10 製造装置
11 第一送出部
12 第一樹脂供給部
13 繊維散布部
14 第二送出部
15 第二樹脂供給部
16 積層送出部
17 端部樹脂供給部
40 下側樹脂層
41 上側樹脂層
50 繊維層
51 両端部
1 SMC
2 Lower release film 3 Upper release film 4 Resin molding material 5 Fiber 6 Press impregnation part 7 Second resin molding material 10 Manufacturing apparatus 11 First delivery part 12 First resin supply part 13 Fiber dispersion part 14 Second delivery part 15 Second resin supply unit 16 Laminate delivery unit 17 End resin supply unit 40 Lower resin layer 41 Upper resin layer 50 Fiber layer 51 Both ends

Claims (3)

下側に配置される下側離型フィルムと、上側に配置される上側離型フィルムとを連続して送り出し、
この下側離型フィルム上には熱硬化性樹脂である樹脂成形材料を供給して下側樹脂層を形成し、この下側樹脂層上に繊維を散布して所定幅の繊維層を形成し、
この上側離型フィルム上には熱硬化性樹脂である樹脂成形材料を供給して上側樹脂層を形成し、
前記下側離型フィルムと前記上側離型フィルムとを前記上側樹脂層が前記繊維層に接するように重ね、
この重ねられた前記上側離型フィルム及び前記下側離型フィルムを押圧含浸部に通して、前記繊維層に前記上側樹脂層及び前記下側樹脂層を押圧含浸させることでSMCを製造するSMCの製造方法であって、
前記下側離型フィルムと前記上側離型フィルムとを重ねる前に、前記繊維層の幅方向の両端部上に熱硬化性樹脂である第二樹脂成形材料を供給し、
この第二樹脂成形材料を供給した後、前記下側離型フィルムと前記上側離型フィルムとを前記上側樹脂層が前記繊維層の幅方向の両端部の間に接するように重ねることを特徴とするSMCの製造方法。
The lower release film disposed on the lower side and the upper release film disposed on the upper side are continuously sent out,
On this lower release film, a resin molding material that is a thermosetting resin is supplied to form a lower resin layer, and fibers are spread on this lower resin layer to form a fiber layer having a predetermined width. ,
On the upper release film, a resin molding material that is a thermosetting resin is supplied to form an upper resin layer,
The lower release film and the upper release film are stacked so that the upper resin layer is in contact with the fiber layer,
The SMC is manufactured by passing the overlapped upper release film and lower release film through a press-impregnating section, and press-impregnating the upper resin layer and the lower resin layer into the fiber layer. A manufacturing method comprising:
Before stacking the lower release film and the upper release film, supply a second resin molding material that is a thermosetting resin on both ends in the width direction of the fiber layer,
After supplying the second resin molding material, the lower release film and the upper release film are overlapped so that the upper resin layer is in contact between both ends in the width direction of the fiber layer. SMC manufacturing method.
前記繊維層は、その幅方向の両端部がそれぞれ、前記下側樹脂層の幅方向の両端部よりも外側に位置するように形成されることを特徴とする請求項1に記載のSMCの製造方法。   2. The SMC manufacturing according to claim 1, wherein the fiber layer is formed such that both end portions in the width direction are located outside both end portions in the width direction of the lower resin layer. Method. 下側に配置される下側離型フィルムを連続して送り出す第一送出部と、この下側離型フィルム上に熱硬化性樹脂である樹脂成形材料を供給して下側樹脂層を形成する第一樹脂供給部と、この下側樹脂層上に繊維を散布して所定幅の繊維層を形成する繊維散布部と、上側に配置される上側離型フィルムを連続して送り出す第二送出部と、この上側離型フィルム上に熱硬化性樹脂である樹脂成形材料を供給して上側樹脂層を形成する第二樹脂供給部と、前記下側離型フィルムと前記上側離型フィルムとを前記上側樹脂層が前記繊維層に接するように重ねて送り出す積層送出部と、この重ねられた前記上側離型フィルム及び前記下側離型フィルムを上下から押圧して前記繊維層に前記上側樹脂層及び前記下側樹脂層を含浸させる押圧含浸部と、を備え、前記繊維層に前記上側樹脂層及び前記下側樹脂層を含浸させることでSMCを製造するSMCの製造装置において、
前記下側離型フィルムと前記上側離型フィルムとを重ねる前に前記繊維層の幅方向の両端部上に熱硬化性樹脂である第二樹脂成形材料を供給する端部樹脂供給部を備え、
前記積層送出部は、前記下側離型フィルムと前記上側離型フィルムとを前記上側樹脂層が前記繊維層の幅方向の両端部の間に接するように重ねて送り出すことを特徴とするSMCの製造装置。
A first delivery section that continuously feeds the lower release film disposed on the lower side, and a resin molding material that is a thermosetting resin is supplied on the lower release film to form the lower resin layer A first resin supply unit, a fiber distribution unit that forms a fiber layer of a predetermined width by dispersing fibers on the lower resin layer, and a second delivery unit that continuously sends out an upper release film disposed on the upper side. And a second resin supply part for supplying a resin molding material that is a thermosetting resin on the upper release film to form an upper resin layer, the lower release film, and the upper release film. A laminate delivery unit that sends out the upper resin layer so that the upper resin layer is in contact with the fiber layer, and presses the upper release film and the lower release film stacked from above and below to the fiber layer to the upper resin layer and A pressure impregnation part for impregnating the lower resin layer. In the manufacturing apparatus of the SMC to produce a SMC by impregnating the upper resin layer and the lower resin layer on the fiber layer,
An end resin supply part that supplies a second resin molding material that is a thermosetting resin on both ends in the width direction of the fiber layer before the lower release film and the upper release film are stacked;
The laminate delivery section sends out the lower release film and the upper release film so that the upper resin layer is in contact with both ends in the width direction of the fiber layer. manufacturing device.
JP2012157506A 2012-07-13 2012-07-13 Smc manufacturing method and device Pending JP2014018993A (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2015060299A1 (en) * 2013-10-22 2015-04-30 三菱レイヨン株式会社 Prepreg production method

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2015060299A1 (en) * 2013-10-22 2015-04-30 三菱レイヨン株式会社 Prepreg production method
JP5822033B2 (en) * 2013-10-22 2015-11-24 三菱レイヨン株式会社 Manufacturing method of prepreg

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