SMC manufacturing method

Abstract

The present invention provides a useful improvement in CF-SMC manufacturing technology, including SMC manufacturing methods using a continuous carbon fiber bundle of a certain number of filaments NK that has been partially split into n sub-bundles in advance. In an SMC manufacturing method according to the present invention, chopped carbon fiber bundles, prior to accumulating on a carrier film, are subjected to fragmentation processing using the fragmentation processing device of (A) as follows. (A) A fragmentation processing device comprising a first pin roller and a second pin roller that each have a rotational axis that is parallel to the rotational axis direction of a rotary cutter, wherein the first pin roller is rotationally driven such that pins on the side facing the second pin roller move from top to bottom, and the second pin roller is rotationally driven such that pins on the side facing the first pin roller move from top to bottom.

Description

[Technical Field]

[0001] The present invention relates to a method for producing SMC (sheet molding compound), and more particularly to a method for producing CF-SMC, which is an SMC using carbon fiber (CF). This application claims priority based on Japanese Patent Application No. 2020-047206, filed on March 18, 2020, the contents of which are incorporated herein by reference. [Background technology]

[0002] BACKGROUND ART In recent years, CFRP (carbon fiber reinforced plastic), a composite material made of carbon fiber and resin, has been widely used in parts for aircraft, automobiles, ships, and various other transportation equipment, as well as sporting goods and leisure goods. Some CFRP products are made from CF-SMC by compression molding. CF-SMC is a type of carbon fiber prepreg and has a structure in which a mat made of chopped carbon fiber bundles (also called chopped carbon fiber tow or chopped carbon fiber strand) is impregnated with a thermosetting resin composition. CFRP has higher strength when reinforced with carbon fiber bundles having a smaller number of filaments, but the production cost of carbon fiber bundles having a smaller number of filaments (smaller tow size) is higher (Patent Document 1). It has been proposed to add a step of partially splitting the continuous carbon fiber bundle unwound from the creel before chopping to the SMC manufacturing method, which continuously performs processes from chopping the continuous carbon fiber bundle to impregnating the carbon fiber mat with resin (Patent Document 2). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] US Patent Application Publication No. 2012 / 0213997 [Patent Document 2] International Publication No. 2017 / 221655 Summary of the Invention [Problem to be solved by the invention]

[0004] Typically, by using a technology that partially splits continuous carbon fiber bundles with a large number of filaments, such as large tow, it is thought that SMC that can give high-strength CFRP molded products can be produced at low cost. Because the process of partially splitting continuous carbon fiber bundles requires various adjustments, it may be possible to achieve higher overall manufacturing efficiency in SMC production by separating this process from subsequent processes. The present invention was made in the course of investigations conducted by the present inventors based on this idea, and its main object is to provide useful improvements in CF-SMC production techniques, including methods for producing CF-SMC using partially split continuous carbon fiber bundles. In this specification, problems that can be solved by each embodiment of the present invention may be explicitly or implicitly disclosed. [Means for solving the problem]

[0005] One aspect of the present invention relates to a method for producing an SMC. SMC manufacturing methods according to preferred embodiments of the present invention include, but are not limited to, the following. [1] (i) drawing from a package a continuous carbon fiber bundle having N K filaments, which has previously been partially split into N sub-bundles; (ii) chopping the continuous carbon fiber bundle drawn from the package with a rotary cutter to form chopped carbon fiber bundles; (iii) depositing the chopped carbon fiber bundles onto a carrier film traveling below the rotary cutter to form a carbon fiber mat; and (iv) impregnating the carbon fiber mat with a thermosetting resin composition; A method for producing an SMC, comprising: subjecting the chopped carbon fiber bundles before being deposited on the carrier film to a fragmentation treatment using a fragmentation treatment device described below in (A): (A) A fragmentation processing device comprising a first pin roller and a second pin roller, each having a rotation axis parallel to the rotation axis direction of the rotary cutter, the first pin roller being driven to rotate so that the pins move from top to bottom on the side facing the second pin roller, and the second pin roller being driven to rotate so that the pins move from top to bottom on the side facing the first pin roller. [2] The manufacturing method described in [1], wherein the sum of the maximum radius of the first pin roller and the maximum radius of the second pin roller is equal to or greater than the distance between the rotation axes of the first pin roller and the second pin roller. [3] The manufacturing method described in [2], wherein the sum of the maximum radius of the first pin roller and the maximum radius of the second pin roller is greater than the distance between the rotation axes of the first pin roller and the second pin roller. [4] The manufacturing method described in [1], wherein the sum of the maximum radius of the first pin roller and the maximum radius of the second pin roller is smaller than the distance between the rotation axes of the first pin roller and the second pin roller, and the difference is 10 mm or less. [5] The manufacturing method according to any one of [1] to [4], wherein the continuous carbon fiber bundles are wound in the package so that there are no gaps between the sub-bundles. [6] The manufacturing method according to any one of [1] to [5], wherein the continuous carbon fiber bundle is wound in the package so that adjacent sub-bundles overlap each other. [7] The method according to any one of [1] to [6], wherein the continuous carbon fiber bundle wound around the package has a total width smaller than the sum of the widths of the sub-bundles. [8] The method according to any one of [1] to [7], wherein N is 15 or more. [9] The manufacturing method according to any one of [1] to [8], wherein the radius of the cylinder of each of the first pin roller and the second pin roller is equal to or greater than half of the maximum radius.

[10] The manufacturing method according to any one of [1] to [9], wherein the peripheral speed at the pin tips of the first pin roller is equal to the peripheral speed at the pin tips of the second pin roller.

[11] The method according to any one of [1] to

[10] , wherein the carbon fiber mat contains 99% by weight or more of carbon fiber bundles having a filament count of more than 0.5K.

[12] The manufacturing method according to any one of [1] to

[11] , wherein the fragmentation treatment reduces the number of chopped carbon fiber bundles having a filament number greater than {(N / n)+0.5}K contained in a unit weight of the carbon fiber mat.

[13] The manufacturing method according to any one of [1] to

[12] , wherein the carbon fiber mat is pressed together with the thermosetting resin composition to impregnate the carbon fiber mat with the thermosetting resin composition.

[14] The manufacturing method according to any one of [1] to

[13] , wherein at least a portion of the thermosetting resin composition is applied to the upper surface of the carrier film before the step (iii).

[0006] Another aspect of the present invention relates to a method for treating carbon fiber bundles. The carbon fiber bundle processing method according to a preferred embodiment of the present invention includes, but is not limited to:

[15] A method for treating a carbon fiber bundle, comprising fragmenting a carbon fiber bundle having a fiber length of 60 mm or less using the following fragmentation treatment device (A): (A) A fragmentation processing device comprising a first pin roller and a second pin roller having rotation axes parallel to each other, the first pin roller being driven to rotate so that the pins move from top to bottom on the side facing the second pin roller, and the second pin roller being driven to rotate so that the pins move from top to bottom on the side facing the first pin roller.

[16] The processing method described in

[15] , wherein the sum of the maximum radius of the first pin roller and the maximum radius of the second pin roller is equal to or greater than the distance between the rotation axes of the first pin roller and the second pin roller.

[17] The processing method described in

[16] , wherein the sum of the maximum radius of the first pin roller and the maximum radius of the second pin roller is greater than the distance between the rotation axes of the first pin roller and the second pin roller.

[18] The processing method described in

[15] , wherein the sum of the maximum radius of the first pin roller and the maximum radius of the second pin roller is smaller than the distance between the rotation axes of the first pin roller and the second pin roller, and the difference is 10 mm or less.

[19] The processing method according to any one of

[15] to

[18] , wherein the radius of the cylinder of each of the first pin roller and the second pin roller is equal to or greater than half of the maximum radius.

[20] The processing method according to any one of

[15] to

[19] , wherein the peripheral speed at the pin tips of the first pin roller and the second pin roller are equal to each other.

[0007] Yet another aspect of the present invention relates to an apparatus for fragmenting carbon fiber bundles. The carbon fiber bundle fragmentation processing device according to the preferred embodiment of the present invention includes, but is not limited to:

[21] A carbon fiber bundle fragmentation treatment device comprising: a first pin roller and a second pin roller having rotation axes parallel to each other; the first pin roller can be driven to rotate so that the pins move from top to bottom on the side facing the second pin roller; and the second pin roller can be driven to rotate so that the pins move from top to bottom on the side facing the first pin roller.

[22] The fragmentation processing device described in

[21] , wherein the sum of the maximum radius of the first pin roller and the maximum radius of the second pin roller is equal to or greater than the distance between the rotation axes of the first pin roller and the second pin roller.

[23] The fragmentation processing device according to

[22] , wherein the sum of the maximum radius of the first pin roller and the maximum radius of the second pin roller is greater than the distance between the rotation axes of the first pin roller and the second pin roller.

[24] The fragmentation processing device described in

[21] , wherein the sum of the maximum radius of the first pin roller and the maximum radius of the second pin roller is smaller than the distance between the rotation axes of the first pin roller and the second pin roller, and the difference is 10 mm or less.

[25] The fragmentation processing device according to any one of

[21] to

[24] , wherein the radius of the cylinder of each of the first pin roller and the second pin roller is equal to or greater than half of the maximum radius.

[0008] Yet another aspect of the present invention relates to the use of a fragmentation processing device. Uses of the fragmentation processor according to preferred embodiments of the present invention include, but are not limited to:

[26] In a method for producing an SMC, the method comprises depositing chopped carbon fiber bundles on a carrier film to form a carbon fiber mat, and impregnating the carbon fiber mat with a thermosetting resin composition, wherein the chopped carbon fiber bundles are subjected to a fragmentation treatment before being deposited on the carrier film, and the method comprises using the following fragmentation treatment device: A fragmentation processing device comprising a first pin roller and a second pin roller having rotation axes parallel to each other, wherein the first pin roller can be driven to rotate so that the pins move from top to bottom on the side facing the second pin roller, and the second pin roller can be driven to rotate so that the pins move from top to bottom on the side facing the first pin roller.

[27] The use according to

[26] , wherein the sum of the maximum radius of the first pin roller and the maximum radius of the second pin roller is equal to or greater than the distance between the rotation axes of the first pin roller and the second pin roller.

[28] The use according to

[27] , wherein the sum of the maximum radius of the first pin roller and the maximum radius of the second pin roller is greater than the distance between the rotation axes of the first pin roller and the second pin roller.

[29] The use described in

[26] , wherein the sum of the maximum radius of the first pin roller and the maximum radius of the second pin roller is smaller than the distance between the rotation axes of the first pin roller and the second pin roller, and the difference is 10 mm or less.

[30] The use according to any one of

[26] to

[29] , wherein the radius of the cylinder of each of the first pin roller and the second pin roller is equal to or greater than half of the maximum radius.

[31] Use of the following fragmentation processing device in fragmenting carbon fiber bundles with a fiber length of 60 mm or less: A fragmentation processing device comprising a first pin roller and a second pin roller having rotation axes parallel to each other, wherein the first pin roller can be driven to rotate so that the pins move from top to bottom on the side facing the second pin roller, and the second pin roller can be driven to rotate so that the pins move from top to bottom on the side facing the first pin roller.

[32] The use according to

[31] , wherein the sum of the maximum radius of the first pin roller and the maximum radius of the second pin roller is equal to or greater than the distance between the rotation axes of the first pin roller and the second pin roller.

[33] The use according to

[32] , wherein the sum of the maximum radius of the first pin roller and the maximum radius of the second pin roller is greater than the distance between the rotation axes of the first pin roller and the second pin roller.

[34] The use described in

[31] , wherein the sum of the maximum radius of the first pin roller and the maximum radius of the second pin roller is smaller than the distance between the rotation axes of the first pin roller and the second pin roller, and the difference is 10 mm or less.

[35] The use according to any one of

[31] to

[34] , wherein the radius of the cylinder of each of the first pin roller and the second pin roller is equal to or greater than half of the maximum radius. [Effects of the Invention]

[0009] The present invention provides a useful improvement in the technology for producing CF-SMC, including a method for producing SMC using partially split continuous carbon fiber bundles. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 1 is a schematic diagram of a fiber package manufacturing apparatus. [Figure 2A]FIG. 2A is a plan view of a continuous carbon fiber bundle immediately after being partially split into five fibers, as viewed in the thickness direction. [Figure 2B] FIG. 2B is a cross-sectional view showing a cross section perpendicular to the fiber direction of a continuous carbon fiber bundle immediately after it has been partially split into five fibers. [Figure 3] FIG. 1 is a schematic diagram showing a cross section perpendicular to the fiber direction of a continuous carbon fiber bundle that has been partially split into five fibers and then wound around a bobbin. [Figure 4] FIG. 4 is a schematic diagram of an SMC manufacturing device. [Figure 5] FIG. 5 is a schematic diagram of a rotary cutter. [Figure 6] FIG. 6 is a schematic diagram of a fragmentation processing device. [Figure 7] FIG. 7 is a schematic diagram of a pin roller provided in the fragmentation processing device. [Figure 8] FIG. 8 shows a part of the cylindrical surface of the pin roller developed in a plane. [Figure 9] FIG. 9 is a schematic diagram showing the positional relationship between two pin rollers provided in the fragmentation processing device. [Figure 10] FIG. 10 is a histogram showing the filament number distribution of chopped carbon fiber bundles in a carbon fiber mat. [Figure 11] FIG. 11 is a histogram showing the filament number distribution of chopped carbon fiber bundles in a carbon fiber mat. [Figure 12] FIG. 12 is a histogram showing the filament number distribution of chopped carbon fiber bundles in a carbon fiber mat. [Figure 13] FIG. 13 is a histogram showing the filament number distribution of chopped carbon fiber bundles in a carbon fiber mat. [Figure 14] FIG. 14 is a plan view of a continuous carbon fiber bundle immediately after being partially split into five fibers, as viewed in the thickness direction. [Figure 15] FIG. 15 is a histogram showing the filament number distribution of chopped carbon fiber bundles in a carbon fiber mat. DETAILED DESCRIPTION OF THE INVENTION

[0011] 1. SMC manufacturing method SMC is a sheet-like carbon fiber prepreg obtained by impregnating a carbon fiber mat made of chopped carbon fiber bundles with a thermosetting resin composition. One embodiment of the present invention is a method for producing an SMC comprising the following steps (i) to (iv). (i) A step of drawing from a package a continuous carbon fiber bundle having NK filaments, which has previously been partially split into n sub-bundles. (ii) A step of chopping the continuous carbon fiber bundle drawn from the package with a rotary cutter to form chopped carbon fiber bundles. (iii) depositing the chopped carbon fiber bundles onto a carrier film running below a rotary cutter to form a carbon fiber mat; (iv) impregnating the carbon fiber mat with a thermosetting resin composition. In the SMC production method of this embodiment, a fragmentation treatment is performed in which at least a portion of the chopped carbon fiber bundles before being deposited on the carrier film is brought into contact with a rotating body to fragment them. This fragmentation treatment makes the filament number distribution of the chopped carbon fiber bundles contained in the carbon fiber mat formed in the above step (iii) different from that when this fragmentation treatment is not performed. If necessary, a step of thickening the thermosetting resin composition may be further carried out after the step (iv).

[0012] 1.1. Continuous carbon fiber bundle The SMC manufacturing method of this embodiment uses a pre-prepared package of continuous carbon fiber bundles, which has N K filaments and is partially split into n sub-bundles. NK means N x 1000. For example, a carbon fiber bundle consisting of 3000 single fibers has 3K filaments, and a carbon fiber bundle consisting of 12000 single fibers has 12K filaments. N is usually 12 or more, preferably 15 or more, and may be, but is not limited to, for example, 18, 24, 36, 48, or 50.

[0013] A continuous carbon fiber bundle being partially split into n sub-bundles means that the continuous carbon fiber bundle is partially divided into n parts. Each of the n fiber bundles formed by dividing into n parts is called a sub-bundle. The package of partially split continuous carbon fiber bundles can be produced using, but is not limited to, a fiber package production apparatus the schematic diagram of which is shown in FIG.

[0014] Referring to FIG. 1, a fiber package manufacturing apparatus 100 includes a spreading section 110, a splitting section 120, and a winding section . The starting material, a continuous carbon fiber bundle 10 having an NK filament count, is drawn from a supply bobbin B1. The continuous carbon fiber bundle 10 before splitting that is drawn from the supply bobbin B1 is first spread in the spreading section 110. The spreader bar 111 provided in the spreading section 110 may be heated or may be reciprocated in the width direction of the continuous carbon fiber bundle 10, and a known technique can be used as a reference for the mechanism for this purpose. The continuous carbon fiber bundle 10 originally has a flat shape, and its width is further expanded and its thickness is further reduced by rubbing against the spreader bar 111. The thickness of the continuous carbon fiber bundle 10 after passing through the spreading section 110 is not limited to, but may be typically 0.05 to 0.2 mm. When the continuous carbon fiber bundle 10 is sufficiently flat when supplied from the supply bobbin B1, the spreading section 110 can be omitted. For example, a carbon fiber bundle whose bundle width is 50 times or more its average thickness can be said to be sufficiently flat.

[0015] The continuous carbon fiber bundle 10 is then fed to the splitting section 120 where it is partially split. The split section 120 is provided with a rotary blade 121 for forming slits in the continuous carbon fiber bundle 10 and a plurality of godet rolls 123 for controlling the running speed of the continuous carbon fiber bundle 10 . The rotation axis of the rotary blade 121 is parallel to the width direction of the continuous carbon fiber bundle 10, which runs in the fiber direction. A plurality of blade portions 122 are provided at regular intervals in the circumferential direction on the outer periphery of the rotary blade 121 so that slits of a certain length are formed intermittently at a certain period along the fiber direction of the continuous carbon fiber bundle 10. The slit length and the gap length between the slits can be controlled by adjusting the running speed of the continuous carbon fiber bundle 10, the circumferential speed of the rotary blade 121, and the distance between the blade portions 122.

[0016] The continuous carbon fiber bundle 10 is partially divided into n parts by intermittently forming slits along the fiber direction using (n-1) rotary blades 121 arranged in a direction parallel to the width direction of the running continuous carbon fiber bundle 10. The number n is not limited, but is preferably 3 or more, more preferably 5 or more, and may be 10 or more. As an example, FIGS. 2A and 2B show a continuous carbon fiber bundle 10 immediately after four rotary blades 121 have intermittently formed slits extending in the fiber direction. For convenience, the fiber direction (longitudinal direction) of the continuous carbon fiber bundle 10 is defined as the x direction, the width direction as the y direction, and the thickness direction as the z direction. FIG. 2A is a plan view of the continuous carbon fiber bundle 10 as viewed from the z direction, and FIG. 2B shows a cross section of the continuous carbon fiber bundle 10 perpendicular to the x direction (a cross section when cut on the yz plane).

[0017] As shown in FIG. 2A, the continuous carbon fiber bundle 10 has a first slit row A S1 , second slit row A S2 , third slit row A S3 and the fourth slit row A S4 Four slit rows are formed. First slit row A S1 consists of a plurality of first slits S1 aligned in the x direction. Second slit row A S2consists of a plurality of second slits S2 arranged in the x direction. Third slit row A S3 consists of a plurality of third slits S3 arranged in the x direction. Fourth slit row A S4 consists of a plurality of fourth slits S4 aligned in the x direction. These four slit rows are formed by different rotary blades, and therefore are located at different positions in the y direction.

[0018] Slit length L S and the gap length between the slits L G is constant within any slit row and is common between different slit rows. Slit length L S and the gap length between the slits L G Slit length L for the sum of S The ratio of L S / (L S +L G ) is usually 90% or more, preferably 95% or more, and may be, for example, 99%. Therefore, the continuous carbon fiber bundle 10 is split into five sub-bundles 11 in most parts, as shown in Figure 2B. First slit row A S1 , second slit row A S2 , third slit row A S3 and the fourth slit row A S4 The positions in the y direction are set so that the widths of the five sub-bundles 11 are approximately the same. For example, when the number of filaments in the continuous carbon fiber bundle 10 is 15K, the number of filaments in each sub-bundle 11 is 3K±0.5K.

[0019] Slit length L S Although not limited to, the slit length L is preferably longer than 25 mm, more preferably longer than 50 mm, and even more preferably longer than 500 mm. S The length may be 10 times or more, further 20 times or more, or even 30 times or more the cut length when the continuous carbon fiber bundle 10 is cut to produce the SMC. Slit length L Smay be, for example, greater than 25 mm and less than or equal to 50 mm, greater than 50 mm and less than or equal to 100 mm, greater than 100 mm and less than or equal to 200 mm, greater than 200 mm and less than or equal to 500 mm, greater than 500 mm and less than or equal to 1000 mm, greater than 1000 mm and less than or equal to 1500 mm, greater than 1500 mm and less than or equal to 2000 mm, or greater than 2000 mm and less than or equal to 3000 mm. Slit gap length L G is not limited to, but is, for example, 5 to 10 mm, and may be shorter than 5 mm.

[0020] In the example shown in FIG. 2A, the first slit row A S1 and the second slit row A S2 The gap between the slits G S The position of the second slit row A is shifted in the x direction. S2 and the third slit row A S Between 3 and the third slit row A S3 and the fourth slit row A S4 The same is true between In this way, the gap between adjacent slit rows is G S It is not essential to shift the positions of the slits in the x-direction. In one example, as shown in FIG. 14, the inter-slit gap G S In another example, the positions of the inter-slit gaps G between some of the slit rows may be aligned. S and the gap between the slits G between the other slit rows. S The position of may be shifted in the x direction.

[0021] Slit length L S , gap length between slits L G , slit length L S and the gap length between the slits L G Slit length L for the sum of S The ratio of L S / (L S +L G ), and the gap between the slits G S The above description of the position is not limited to the case where the continuous carbon fiber bundle 10 is partially split into five sub-bundles, but also applies to the case where the continuous carbon fiber bundle 10 is partially split into four or less or six or more sub-bundles. The number of filaments in the sub-bundles formed by splitting the continuous carbon fiber bundle 10 is preferably 5K or less, more preferably 4K or less, and even more preferably 3K or less, regardless of the number n. The number of filaments in the sub-bundles formed by splitting the continuous carbon fiber bundle 10 is preferably more than 0.5K, and more preferably 1K or more, regardless of the number n. When the number of filaments is more than 0.5K, the straightness of the carbon fiber bundle is more easily maintained, and the reinforcing effect tends to be relatively high. The above upper and lower limits can be combined arbitrarily. For example, the number of filaments in the sub-bundles formed by splitting the continuous carbon fiber bundle 10 is preferably 0.5K to 5K, more preferably 0.5K to 4K, and even more preferably 1K to 3K, regardless of the number n.

[0022] Referring again to FIG. 1, the continuous carbon fiber bundle 10 partially split into n fibers in the split section 120 is sent to the winding section 130 and wound onto a winding bobbin B2 to complete a package. The take-up bobbin B2 is, for example, but not limited to, a paper tube. When the package is used, the take-up bobbin B2 can be removed and the continuous carbon fiber bundle can be unwound from the inside. When the continuous carbon fiber bundle 10 is wound, no gaps are formed between the sub-bundles 11. The reason for this is to prevent the sub-bundles 11 from getting caught between the portion wound earlier on the bobbin B2 and the portion wound later on top of that. By winding the sub-bundles 11 so that no gaps are formed between them, it is possible to prevent the continuous carbon fiber bundle 10 from becoming tangled or broken when unwinding by outside take-up or inside take-up.

[0023] In order to wind the continuous carbon fiber bundle 10 around the bobbin without leaving any gaps between the sub-bundles 11, the total width W of the continuous carbon fiber bundle 10 must be set to the sub-bundle width W as shown in FIG. s It is enough to make it narrower than the sum of 3 is a cross-sectional view of a continuous carbon fiber bundle 10 cut perpendicular to the fiber direction, in which the five sub-bundles 11 are aligned in the y direction with no gaps between them. That is, there are no portions where adjacent sub-bundles 11 are separated from each other, and each sub-bundle 11 overlaps with the adjacent sub-bundle 11 at its edge. The width of the carbon fiber bundle can be reduced by guiding the carbon fiber bundle with a narrower guide. Thus, the total width W is multiplied by the sub-bundle width W s To wind the continuous carbon fiber bundle 10 onto the bobbin B2 in a state narrower than the sum of the sub-bundle widths, for example, a grooved roll having a groove width narrower than the sum of the sub-bundle widths may be used to guide the partially split continuous carbon fiber bundle to the winding bobbin. Alternatively, the width of the fiber bundle guide of the traverse device may be narrower than the sum of the sub-bundle widths.

[0024] When the total width of the continuous carbon fiber bundle is narrowed by such a method, not only do the sub-bundles overlap with each other, but some of the sub-bundles may be folded in the width direction. Therefore, the overlapping state between the sub-bundles in the continuous carbon fiber bundle wound on the take-up bobbin is not limited to the state shown in Fig. 3, but may be various. In order to reliably prevent gaps from being formed between the sub-bundles, the total width of the continuous carbon fiber bundle 10 when wound onto the winding bobbin is preferably 90% or less, and more preferably 80% or less, of the sum of the sub-bundle widths. The total width of the continuous carbon fiber bundle when wound onto a take-up bobbin is not limited, but it is preferable not to narrow it so much as to be equivalent to the width of the sub-bundles. In particular, when the number n of sub-bundles is large, if the total width is made too small, the winding tends to collapse.

[0025] The winding section 130 is typically equipped with a traverse device (not shown). When the continuous carbon fiber bundle 10 is traverse wound around the take-up bobbin B2, the helix angle at the start of winding can be, for example, 5 to 30°, and the helix angle at the end of winding can be, for example, 2 to 17°, although this is not limited thereto. The wind ratio indicates how many times the bobbin rotates during one reciprocation of the traverse guide, or it can be said to be the number of turns per traverse cycle. When winding thread onto a bobbin at a constant wind ratio, if the wind ratio is an integer, the thread will be wound in the same position on the bobbin in every traverse cycle, resulting in so-called ribbon winding, which may result in poor unwinding properties. When the decimal fraction of the winding ratio is a multiple of 1 / p (p is an integer greater than or equal to 2), the thread is wound at the same position on the bobbin every p cycles of traverse, so when p is small in particular, unwinding performance may be poor, just as when the winding ratio is an integer. Therefore, when winding the continuous carbon fiber bundle 10 onto the winding bobbin B2, it is normal not to use an integer winding ratio, and furthermore, it is preferable not to use a fractional part of the winding ratio as a multiple of 1 / 2, 1 / 3, 1 / 4, or 1 / 5.

[0026] 1.2.SMC manufacturing equipment FIG. 4 shows a conceptual diagram of an SMC manufacturing apparatus that can be preferably used in the SMC manufacturing method of this embodiment. 4, the SMC manufacturing apparatus 200 includes a first resin coating section 210, a second resin coating section 220, a chopping section 230, a deposition section 240, and an impregnation section 250. A fragmentation treatment device 260 is disposed between the chopping section 230 and the deposition section 240.

[0027] In the first resin coating section 210, a first coater 211 equipped with a doctor blade is arranged to form a first resin layer 51 consisting of a thermosetting resin composition 50 on a first carrier film 41 drawn from a roll. In the second resin coating section 220, a second coater 221 equipped with a doctor blade is arranged to form a second resin layer 52 made of the same thermosetting resin composition 50 on the second carrier film 42 drawn from a roll.

[0028] In the chopping section 230, a rotary cutter 231 is arranged for chopping the continuous carbon fiber bundle 10 drawn out from the package (the bobbin may be removed). 5, the rotary cutter 231 includes a guide roll 232, a pinch roll 233, and a cutter roll 234. A plurality of blades 235 are arranged at regular intervals around the outer periphery of the cutter roll 234, and it is possible to cut out chopped carbon fiber bundles 20 having a constant fiber length one after another from the continuous carbon fiber bundle 10. Usually, a plurality of continuous carbon fiber bundles 10 are simultaneously drawn and aligned parallel to each other in a plane parallel to the direction of the rotation axis of the rotary cutter 231 and supplied to the rotary cutter 231 . The rotation axis direction of the rotary cutter 231 is the direction of the rotation axis of the roll included in the rotary cutter 231, that is, the direction of the rotation axis of the cutter roll 234. The directions of the rotation axes of the guide roll 232 and the pinch roll 233 are also the same as the direction of the rotation axis of the cutter roll 234.

[0029] The deposition section 240 is disposed below the chop section 230. The first carrier film 41 is transported from the first resin coating section 210 through the deposition section 240 to the impregnation section 250. When the first carrier film 41 travels through the deposition section 240, the chopped carbon fiber bundles 20 produced in the chop section 230 fall and deposit on the first resin layer 51 formed on the surface of the first carrier film 41, thereby forming a carbon fiber mat 30.

[0030] A mechanism for gradually bringing the first carrier film 41 and the second carrier film 42 closer to each other is disposed upstream of the impregnation section 250. An impregnation machine 251 is disposed in the main part of the impregnation section 250. In order to sandwich the laminate, in which the carbon fiber mat 30 and the thermosetting resin composition 50 are sandwiched between the first carrier film 41 and the second carrier film 42, between two conveyor belts from above and below and convey the laminate, the impregnation machine 251 is equipped with two belt conveyors, one above the other, and rollers for sandwiching and pressurizing the laminate together with the conveyor belts.

[0031] 6, the fragmentation treatment device 260, which is disposed between the chop section 230 and the deposition section 240, has a cover 261, and a guide plate 262 and a pair of pin rollers (a first pin roller 263a and a second pin roller 263b) disposed inside the cover. The first pin roller 263a and the second pin roller 263b have approximately the same axial length, and their rotation axes are parallel to each other. In the SMC production apparatus 200, the fragmentation processing device 260 is disposed so that the rotation axes of the first pin roller 263a and the second pin roller 263b are parallel to the rotation axis direction of the rotary cutter 231. The fragmentation processing device 260 is preferably located directly below the rotary cutter 231.

[0032] 7, the first pin roller 263a has a cylinder 264a on the surface of which are arranged a plurality of pins 265a, all of which have the same shape and dimensions. Both the cylinder 264a and the pins 265a are rigid bodies, and are made of, for example, metal. The diameter of the cylinder 264a is not limited to, but may be, for example, 60 mm to 150 mm.

[0033] The pin 265a extends perpendicular to the rotation axis of the first pin roller 263a and has, for example, but not limited to, a cylindrical shape. The boundary between the end face and the circumferential surface of the pin 265a may be chamfered. The diameter of the pin 265a is not limited to, but may be, for example, 1 mm to 5 mm. The length of the pin 265a, that is, the distance from the tip to the base of the pin, is not limited to, but may be, for example, 10 mm to 50 mm. It is preferable that the pins 265a have a circular cross section in order to prevent fuzzing of the chopped carbon fiber bundles 20 processed in the fragmentation processing device 260. The pins 265a may have a conical or truncated conical shape with a diameter decreasing toward the tip.

[0034] The arrangement of the pins 265a on the circumferential surface of the cylinder 264a is preferably such that when the pins 265a are shifted axially by 5 mm to 20 mm and circumferentially by 4 mm to 30 mm, they will overlap with their original arrangement. For example, in the case of cylinder 264a shown in Fig. 7, when the peripheral surface is developed into a plane, pins 265a are arranged at each vertex of an equilateral triangle (shown by dashed lines) that fills the plane with one side parallel to the axial direction, as shown in Fig. 8. If the length of one side of this equilateral triangle is, for example, 5 mm, the arrangement of pins 265a shown in Fig. 8 will overlap with the original arrangement when shifted by 2.5 mm in the axial direction and approximately 4.3 mm in the circumferential direction.

[0035] In this specification, the maximum radius of a pin roller is defined as the distance from its rotation axis to the tip of the pin. In the first pin roller 263a, the radius of the cylinder 264a is preferably at least half, and more preferably at least 75%, of the maximum radius of the first pin roller 263a. This is because the higher the ratio of the cylinder radius to the maximum radius of the pin roller, the smaller the difference in peripheral speed between the tip and base of the pin when the pin roller is rotating.

[0036] Everything stated above regarding the first pin roller 263a also applies to the second pin roller 263b. Without being limited thereto, in order to reduce the costs of designing, manufacturing, and maintaining the fragmentation processing device 260, it is preferable to match the design and specifications of the first pin roller 263a and the second pin roller 263b in as many aspects as possible, including maximum radius, cylinder diameter, pin shape, dimensions, number, and arrangement, etc.

[0037] Referring to FIG. 9, in the fragmentation processing device 260, the maximum radius r of the first pin roller 263a M1 and the maximum radius r of the second pin roller 263b M2 The sum of these is the distance d between the rotation axes of these two pin rollers. 12 is greater than. The maximum radius r of the first pin roller 263a M1 and the radius r of the cylinder 264b of the second pin roller C2 The sum of the distance between the rotation axes of the two pin rollers d 12 Similarly, the maximum radius r of the second pin roller 263b is smaller than M2 and the radius r of the cylinder 264a of the first pin roller C1 The sum of the distance between the rotation axes of the two pin rollers d 12 Smaller than. The maximum radius r of the first pin roller 263a M1 and the maximum radius r of the second pin roller 263b M2 and the distance between the rotation axes d 12 The difference between M1 +r M2 )-d 12} is, for example, but not limited to, 20 mm or less, and may be 15 mm or less, 10 mm or less, or 5 mm or less.

[0038] The first pin roller 263a and the second pin roller 263b are rotationally driven by a drive mechanism (not shown). The rotation speeds of the first pin roller 263a and the second pin roller 263b may be independently controllable. The rotation directions of the first pin roller 263a and the second pin roller 263b are as shown by the arrows in Fig. 6. That is, the first pin roller 263a rotates such that the pins move from top to bottom on the side facing the second pin roller 263b, and the second pin roller 263b rotates such that the pins move from top to bottom on the side facing the first pin roller 263a. Rotating both the first pin roller 263a and the second pin roller 263b in this manner is advantageous in preventing the chopped carbon fiber bundles 20 from getting stuck between these two pin rollers.

[0039] Substantially all of the chopped carbon fiber bundles 20 produced in the chop section 230 pass between the cylinder 264a of the first pin roller 263a and the cylinder 264b of the second pin roller 263b and fall into the deposition section. Since the difference in the falling position depending on the bundle size of the chopped carbon fiber bundles 20 is unlikely to occur, there is an advantage that the carbon fiber mat 30 is likely to become homogeneous along the thickness direction even when the bundle size distribution of the chopped carbon fiber bundles 20 is wide.

[0040] In a modified embodiment, the maximum radius r of the first pin roller 263a in the fragmentation processing device 260 M1 and the maximum radius r of the second pin roller 263b M2 The sum of these is the distance d between the rotation axes of these two pin rollers. 12 may be equal to In another modified embodiment, the maximum radius r of the first pin roller 263a in the fragmentation processing device 260 M1 and the maximum radius r of the second pin roller 263b M2 The sum of these is the distance d between the rotation axes of these two pin rollers. 12 The difference {d 12 -(r M1 +r M2 )} is preferably 10 mm or less, more preferably 5 mm or less.

[0041] 1.3.SMC Manufacturing Method The SMC manufacturing method of this embodiment will be described using the SMC manufacturing apparatus 200 described in 1.2 above as an example. (Pulling process) In the drawing process, a continuous carbon fiber bundle is drawn from a previously prepared package of continuous carbon fiber bundles. This continuous carbon fiber bundle has a filament count of N K and has been partially split into n sub-bundles in advance. In this step, the bobbin package may be attached to a creel and the continuous carbon fiber bundle may be drawn out from the outside, or the continuous carbon fiber bundle may be drawn out from the package from which the bobbin has been removed from the inside. As described above, when a package is manufactured, the continuous carbon fiber bundle is wound around a bobbin with adjacent sub-bundles overlapping each other, and therefore the continuous carbon fiber bundle unwound from the package includes portions where the sub-bundles are adhered to each other while partially overlapping each other.

[0042] (Chopping process) In the chopping step, the drawn continuous carbon fiber bundle 10 is supplied to a chopping section 230 and cut one after another by a rotary cutter 231, thereby producing chopped carbon fiber bundles 20 having a predetermined fiber length. The produced chopped carbon fiber bundles 20 fall toward a fragmentation treatment device 260 installed below the rotary cutter 231. The fiber length of the chopped carbon fiber bundle 20 is not limited, but may be, for example, 5 to 100 mm, preferably 20 to 60 mm, and typically about 13 mm, about 25 mm, or about 50 mm.

[0043] (Fragmentation process) As described above, the continuous carbon fiber bundle drawn out from the package includes portions in which sub-bundles are adhered to each other while partially overlapping each other. The chopped carbon fiber bundles produced in the chopping step contain a certain amount of fiber bundles with a filament count greater than {(N / n)+0.5}K, which are generated by cutting such portions. The purpose of the fragmentation treatment step is to fragment such fiber bundles using a fragmentation treatment device, thereby improving the filament count distribution of the chopped carbon fiber bundles in the carbon fiber mat formed in the deposition step, which will be described later.

[0044] In the fragmentation treatment device 260, at least a part of the chopped carbon fiber bundles 20 dropping from the rotary cutter 231 comes into contact with at least one of the first pin roller 263a and the second pin roller 263b, and is broken into a plurality of fragments by the impact. This fragmentation process is not intended for defibration. That is, it does not loosen the chopped carbon fiber bundles to the point where they become single fibers or a state close to that. In a preferred example, the peripheral speeds at the tips of the pins of the first pin roller 263a and the second pin roller 263b are set so that fiber bundles and single fibers with a filament count of 0.5K or less are not generated by the fragmentation process, or even if they are generated, so that the content of such fiber bundles and single fibers in the carbon fibers deposited on the first carrier film 41 is less than 1% by weight.

[0045] One of the reasons why the rotation directions of the first pin roller 263a and the second pin roller 263b are set so that the pins move from top to bottom on the sides facing each other is to prevent a strong shear force from being applied to the chopped carbon fiber bundle 20 passing between these two pin rollers. A strong shear force is thought to cause fluffing and a decrease in straightness of the carbon fiber bundle. To achieve this objective more effectively, it is preferable to set the rotation speed (rpm) of the first pin roller 263a and the second pin roller 264b so that the peripheral speed at the tip of the former pin 265a is equal to the peripheral speed at the tip of the latter pin 265b.

[0046] (Resin coating process) In the resin coating process, a first resin layer 51 made of a thermosetting resin composition 50 is formed on a first carrier film 41 drawn from a roll using a first coater 211, and a second resin layer 52 made of the same thermosetting resin composition 50 is formed on a second carrier film 42 drawn from another roll using a second coater 221. The thermosetting resin composition 50 is a fluid paste containing a thermosetting resin as the main component, a thickener, and a curing agent, and, if necessary, additives such as a reactive diluent, a low-shrinkage agent, a filler, and a flame retardant. Typical examples of thermosetting resins are epoxy resins, vinyl ester resins, unsaturated polyester resins, polyimide resins, maleimide resins and phenolic resins, and two or more selected from these may be used in combination. Preferred thermosetting resins are epoxy resins, vinyl ester resins and unsaturated polyester resins because they have excellent adhesive properties to carbon fibers. For the specific formulation of the thermosetting resin composition, reference can be made to the prior art as appropriate.

[0047] (deposition process) In the depositing step, the chopped carbon fiber bundles 20 processed by the fragmentation treatment device 260 fall onto the first carrier film 41 carried below the fragmentation treatment device 260. The dropped chopped carbon fiber bundles 20 are deposited on the first resin layer 51 formed on the surface of the first carrier film 41, forming a carbon fiber mat 30.

[0048] (Impregnation process) The first carrier film 41 carrying the carbon fiber mat 30 deposited on the first resin layer 51 is bonded to a second carrier film 42 with the side on which the second resin layer 52 is formed facing downward while being transported toward the impregnation machine 251. The laminate formed by lamination is pressed by the impregnation machine 251 , whereby the carbon fiber mat 30 is impregnated with the thermosetting resin composition 50 . After the impregnation process is completed, the impregnated carbon fiber mat 30 is wound around a bobbin while sandwiched between the first carrier film 41 and the second carrier film 42, and is then subjected to an aging process, which is performed as needed, to become an SMC product. In the aging process, the viscosity of the thermosetting resin composition 50 increases due to the action of the added thickener, and the thermosetting resin composition 50 reaches a semi-cured state.

[0049] 1.4. SMC Manufacturing Method According to Modified Embodiment The SMC manufacturing method described in Section 1.3 uses as raw material a continuous carbon fiber bundle with NK filaments that has been partially split into n sub-bundles. However, in a modified SMC manufacturing method, a continuous carbon fiber bundle that has not been subjected to partial splitting processing may also be used as raw material.

[0050] Therefore, the following SMC manufacturing method is also included in the embodiments of the present invention.

[36] A method for producing an SMC, comprising chopping continuous carbon fiber bundles with a rotary cutter to form chopped carbon fiber bundles, depositing the chopped carbon fiber bundles on a carrier film traveling below the rotary cutter to form a carbon fiber mat, and impregnating the carbon fiber mat with a thermosetting resin composition, wherein the chopped carbon fiber bundles before being deposited on the carrier film are subjected to a fragmentation treatment using a fragmentation treatment device described below in (A): (A) A fragmentation processing device comprising a first pin roller and a second pin roller, each having a rotation axis parallel to the rotation axis direction of the rotary cutter, the first pin roller being driven to rotate so that the pins move from top to bottom on the side facing the second pin roller, and the second pin roller being driven to rotate so that the pins move from top to bottom on the side facing the first pin roller.

[37] The manufacturing method described in

[36] , wherein the sum of the maximum radius of the first pin roller and the maximum radius of the second pin roller is equal to or greater than the distance between the rotation axes of the first pin roller and the second pin roller.

[38] The manufacturing method described in

[37] , wherein the sum of the maximum radius of the first pin roller and the maximum radius of the second pin roller is greater than the distance between the rotation axes of the first pin roller and the second pin roller.

[39] The manufacturing method described in

[36] , wherein the sum of the maximum radius of the first pin roller and the maximum radius of the second pin roller is smaller than the distance between the rotation axes of the first pin roller and the second pin roller, and the difference is 10 mm or less.

[40] The manufacturing method according to any one of

[36] to

[39] , wherein the radius of the cylinder of each of the first pin roller and the second pin roller is equal to or greater than half of the maximum radius.

[41] The manufacturing method according to any one of

[36] to

[40] , wherein the peripheral speed at the pin tips of the first pin roller and the second pin roller is equal to the peripheral speed at the pin tips of the first pin roller.

[42] The method according to any one of

[36] to

[41] , wherein the carbon fiber mat contains 99% by weight or more of carbon fiber bundles having a filament count of more than 0.5K.

[43] The manufacturing method according to any one of

[36] to

[42] , wherein the carbon fiber mat is pressed together with the thermosetting resin composition to impregnate the carbon fiber mat with the thermosetting resin composition.

[44] The manufacturing method according to any one of

[36] to

[43] , wherein at least a portion of the thermosetting resin composition is applied to the upper surface of the carrier film before the chopped carbon fiber bundles are deposited to form the carbon fiber mat.

[0051] 2. Experimental Results The results of the experiments conducted by the present inventors are described below.

[0052] Experiment 1 (Preparation of Partially Split Continuous Carbon Fiber Bundles) A flat continuous carbon fiber bundle (TR50S15L, manufactured by Mitsubishi Chemical Corporation) with 15,000 filaments, an initial width of 8 mm, and a thickness of 0.1 mm was prepared as the starting material. Using a splitter with four rotary blades, four rows of slits, each 1000 mm long and with a 5 mm gap between the slits, were formed, splitting the continuous carbon fiber bundle into five 1.6 mm-wide sub-bundles. The position of the gap between the slits in the fiber direction was the same for all rows of slits. After partial splitting, the continuous carbon fiber bundle was wound onto a paper bobbin with a diameter of 82 mm and a length of 280 mm at a traverse length of 254 mm to prepare a square-end package. The total width of the continuous carbon fiber bundle during winding was kept to 6 mm or less by adjusting the width of the guide that guides the fiber bundle.

[0053] (Preparation of carbon fiber mats) Using an SMC manufacturing apparatus having the same configuration as the SMC manufacturing apparatus shown in Figure 4 except that it does not have a fragmentation treatment device, a carbon fiber mat was produced from a continuous carbon fiber bundle with 15,000 filaments that was partially split into five sub-bundles, prepared using the procedure described above. A plurality of continuous carbon fiber bundles were arranged in parallel at equal intervals and fed to a rotary cutter, where they were cut into pieces every 25.4 mm. The chopped carbon fiber bundles were dropped onto a carrier film that had not been coated with the thermosetting resin composition and was running below the rotary cutter at a linear speed of 5 m / min, and the dropped chopped carbon fiber bundles were deposited on the carrier film to form a carbon fiber mat.

[0054] (Measurement of filament number distribution) From the carbon fiber mat prepared by the above procedure, an area of approximately 21 cm × 30 cm deposited near the center line of the carrier film was selected, and the weight of all chopped carbon fiber bundles (300 pieces or more) contained in that area was measured. The filament number distribution of the chopped carbon fiber bundles in the carbon fiber mat, calculated by converting the measured weight into the number of filaments, is shown in Figure 10. In the produced carbon fiber mat, the content of carbon fiber bundles having a filament number exceeding 0.5K was 99.9% by weight or more.

[0055] 2.2.Experiment 2 A carbon fiber mat was produced using the same SMC manufacturing equipment as used in Experiment 1 except that it was equipped with a fragmentation treatment device, and its filament number distribution was measured in the same manner as in Experiment 1. The carbon fiber mat production procedure was the same as in Experiment 1, except that the chopped carbon fiber bundles were fragmented using the fragmentation treatment device before being deposited on the carrier film. The configuration of the fragmentation processing device was the same as that of the SMC manufacturing device shown in Figure 4. Both pin rollers were made of metal and had the same configuration. The diameter and length of the pins arranged on the circumferential surface of the cylinder were 3 mm and 20 mm, respectively. The pins on the circumferential surface of each pin roller were arranged periodically, so that when shifted 7.5 mm in the axial direction and 6.5 mm in the circumferential direction, they overlapped with the original arrangement. The sum of the maximum radii of the two pin rollers was 10 mm greater than the distance between the rotation axes of the two pin rollers.

[0056] The two pin rollers were both rotated so that the peripheral speed at the pin tips was 377 m / min and so that the pins on both sides facing the other pin roller moved from top to bottom. The filament number distribution of the chopped carbon fiber bundles in the produced carbon fiber mat is shown in FIG. In the produced carbon fiber mat, the content of carbon fiber bundles having a filament number exceeding 0.5K was 99.9% by weight or more.

[0057] 2.3.Experiment 3 A carbon fiber mat was prepared in the same manner as in Experiment 2, except that the two pin rollers were rotated so that the pins on each side facing the other pin roller moved from bottom to top, and the filament number distribution was measured. The filament number distribution of the chopped carbon fiber bundles in the produced carbon fiber mat is shown in FIG. It was found that the fragmentation process in Experiment 3 tended to fragment the chopped carbon fiber bundles into smaller pieces compared to that in Experiment 2.

[0058] Experiment 4 A carbon fiber mat was prepared in the same manner as in Experiment 2, except that the two pin rollers were rotated in the same direction, and the filament number distribution was measured. The filament number distribution of the chopped carbon fiber bundles in the produced carbon fiber mat is shown in FIG. It was found that the fragmentation process in Experiment 4 tended to fragment the chopped carbon fiber bundles into smaller pieces compared to that in Experiment 2.

[0059] 2.5. Experiment 5 A carbon fiber mat was prepared in the same manner as in Experiment 2, except that the distance between the rotation axes of the two pin rollers was set to the same as the sum of the maximum radii of these two pin rollers, and the filament number distribution was measured. The filament number distribution of the chopped carbon fiber bundles in the produced carbon fiber mat is shown in FIG.

[0060] 2.6. Experiment 6 A flat continuous carbon fiber bundle with 15,000 filaments (15K), an initial width of 8 mm, and a thickness of 0.1 mm was prepared, partially split, and then wound onto a paper bobbin with a diameter of 82 mm and a length of 280 mm at a traverse length of 254 mm to produce a square-end fiber package. The bundle was not widened using a spreader.

[0061] A splitter with four rotating blades was used to partially split the continuous carbon fiber bundle. By forming four rows of slits, each 1000 mm long and with a 5 mm gap between the slits, the continuous carbon fiber bundle was split into five 1.6 mm wide sub-bundles that were partially connected to each other. The position of the gap between the slits in the fiber direction was the same for all rows of slits. For winding, the helix angle at the start of winding was 9.9°, the helix angle at the end of winding was 5°, the wind ratio was 11.30, and the winding amount was 5.0 kg.

[0062] By adjusting the groove width of the grooved roll through which the continuous carbon fiber bundle passes after the splitting process, the total width of the continuous carbon fiber bundle wound around the bobbin was set to 6 mm, which is 75% of the sum of the widths of the sub-bundles. When the bobbin was pulled out from the fiber package and the continuous carbon fiber bundle was pulled out from the inside, no particular problems were found. In contrast, in a fiber package prepared in the same manner except that the total width of the continuous carbon fiber bundle wound onto the bobbin was 8 mm, the same as the sum of the widths of the sub-bundles, entanglement occurred relatively frequently when the bobbin was pulled out and the continuous carbon fiber was drawn out from the inside.

[0063] While the present invention has been described above with reference to specific embodiments, these embodiments are presented as examples and do not limit the scope of the present invention. Each embodiment described in this specification can be modified in various ways without departing from the spirit of the invention, and can be combined with features described in other embodiments to the extent possible. [Explanation of symbols]

[0064] 10 continuous carbon fiber bundles 11 sub-bundles 20 chopped carbon fiber bundles 100 Fiber package manufacturing equipment 110 Spread Section 120 Split Section 130 Winding Section 200 SMC manufacturing equipment 210 First Resin Coating Section 220 Second Resin Coating Section 230 Chop Section 240 Sedimentary Section 250 Impregnation Section 260 Fragmentation Processing Device

Claims

1. A method of manufacturing a continuous carbon fiber bundle having N K filaments, which has been partially split into n sub-bundles in advance, from a package; chopping the continuous carbon fiber bundle drawn out from the package with a rotary cutter to form chopped carbon fiber bundles; subjecting the chopped carbon fiber bundles to a fragmentation treatment using the following fragmentation treatment device (A); Including, A method for treating a carbon fiber bundle, wherein the continuous carbon fiber bundle is wound in the package so that there is an overlap between adjacent sub-bundles: (A) A fragmentation processing device comprising a first pin roller and a second pin roller having rotation axes parallel to each other, the first pin roller being driven to rotate so that the pins move from top to bottom on the side facing the second pin roller, and the second pin roller being driven to rotate so that the pins move from top to bottom on the side facing the first pin roller.

2. A method of manufacturing a continuous carbon fiber bundle having N K filaments, which has been partially split into n sub-bundles in advance, from a package; chopping the continuous carbon fiber bundle drawn out from the package with a rotary cutter to form chopped carbon fiber bundles; subjecting the chopped carbon fiber bundles to a fragmentation treatment using the following fragmentation treatment device (A); Including, A method for treating a carbon fiber bundle, wherein the continuous carbon fiber bundle wound on the package has a total width smaller than the sum of the widths of the sub-bundles: (A) A fragmentation processing device comprising a first pin roller and a second pin roller having rotation axes parallel to each other, the first pin roller being driven to rotate so that the pins move from top to bottom on the side facing the second pin roller, and the second pin roller being driven to rotate so that the pins move from top to bottom on the side facing the first pin roller.

3. 3. The processing method according to claim 1, wherein the sum of the maximum radius of the first pin roller and the maximum radius of the second pin roller is equal to or greater than the distance between the rotation axes of the first pin roller and the second pin roller.

4. The processing method according to claim 3 , wherein the sum of the maximum radius of the first pin roller and the maximum radius of the second pin roller is greater than the distance between the rotation axes of the first pin roller and the second pin roller.

5. 3. The processing method according to claim 1, wherein the sum of the maximum radius of the first pin roller and the maximum radius of the second pin roller is smaller than the distance between the rotation axes of the first pin roller and the second pin roller, and the difference is 10 mm or less.

6. The processing method according to any one of claims 1 to 5, wherein the radius of the cylinder of each of the first pin roller and the second pin roller is equal to or greater than half of the maximum radius.

7. The processing method according to any one of claims 1 to 6, wherein the peripheral speed at the pin tips of the first pin roller is equal to the peripheral speed at the pin tips of the second pin roller.

8. A method of manufacturing a continuous carbon fiber bundle having N K filaments, which has been partially split into n sub-bundles in advance, from a package; chopping the continuous carbon fiber bundle drawn out from the package with a rotary cutter to form chopped carbon fiber bundles; subjecting the chopped carbon fiber bundles to a fragmentation treatment using the following fragmentation treatment device (A); depositing the chopped carbon fiber bundles after fragmentation treatment on a carrier film traveling below the rotary cutter to form a carbon fiber mat; impregnating the carbon fiber mat with a thermosetting resin composition; Including, The method for producing an SMC, wherein the continuous carbon fiber bundles are wound in the package such that there is an overlap between adjacent sub-bundles. (A) A carbon fiber bundle fragmentation treatment device comprising a first pin roller and a second pin roller having rotation axes parallel to each other, wherein the first pin roller is rotationally driven so that the pins move from top to bottom on the side facing the second pin roller, and the second pin roller is rotationally driven so that the pins move from top to bottom on the side facing the first pin roller.

9. A method of manufacturing a continuous carbon fiber bundle having N K filaments, which has been previously partially split into n sub-bundles, from a package; chopping the continuous carbon fiber bundle drawn out from the package with a rotary cutter to form chopped carbon fiber bundles; subjecting the chopped carbon fiber bundles to a fragmentation treatment using the following fragmentation treatment device (A); depositing the chopped carbon fiber bundles after fragmentation treatment on a carrier film traveling below the rotary cutter to form a carbon fiber mat; impregnating the carbon fiber mat with a thermosetting resin composition; Including, The method for producing an SMC, wherein the continuous carbon fiber bundle wound on the package has a total width that is smaller than the sum of the widths of the sub-bundles. (A) A fragmentation processing device comprising a first pin roller and a second pin roller having rotation axes parallel to each other, the first pin roller being driven to rotate so that the pins move from top to bottom on the side facing the second pin roller, and the second pin roller being driven to rotate so that the pins move from top to bottom on the side facing the first pin roller.

10. The manufacturing method according to claim 8 or 9, wherein the sum of the maximum radius of the first pin roller and the maximum radius of the second pin roller is equal to or greater than the distance between the rotation axes of the first pin roller and the second pin roller.

11. The manufacturing method according to claim 10 , wherein the sum of the maximum radius of the first pin roller and the maximum radius of the second pin roller is greater than the distance between the rotation axes of the first pin roller and the second pin roller.

12. 10. The manufacturing method according to claim 8 or 9, wherein the sum of the maximum radius of the first pin roller and the maximum radius of the second pin roller is smaller than the distance between the rotation axes of the first pin roller and the second pin roller, and the difference therebetween is 10 mm or less.

13. The manufacturing method according to any one of claims 8 to 12, wherein the radius of the cylinder of each of the first pin roller and the second pin roller is equal to or greater than half of the maximum radius.

14. The manufacturing method according to any one of claims 8 to 13, wherein a peripheral speed at the pin tips of the first pin roller and a peripheral speed at the pin tips of the second pin roller are equal.

15. The manufacturing method according to any one of claims 8 to 14, wherein the carbon fiber mat has a content of carbon fiber bundles having a filament number of more than 0.5K of 99% by weight or more.

16. The manufacturing method according to any one of claims 8 to 15, wherein the carbon fiber mat is pressed together with the thermosetting resin composition to impregnate the carbon fiber mat with the thermosetting resin composition.

17. The manufacturing method according to any one of claims 8 to 16, wherein at least a portion of the thermosetting resin composition is applied to an upper surface of the carrier film before depositing the chopped carbon fiber bundles to form the carbon fiber mat.

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