US 12,319,017 B2
Method for manufacturing SMC
Hiroyuki Nakao, Tokyo (JP); Yasushi Watanabe, Tokyo (JP); Tadao Samejima, Tokyo (JP); and Yukihiro Mizutori, Tokyo (JP)
Assigned to Mitsubishi Chemical Corporation, Tokyo (JP)
Filed by Mitsubishi Chemical Corporation, Tokyo (JP)
Filed on Sep. 16, 2022, as Appl. No. 17/946,395.
Application 17/946,395 is a continuation of application No. PCT/JP2021/010601, filed on Mar. 16, 2021.
Claims priority of application No. 2020-056724 (JP), filed on Mar. 26, 2020.
Prior Publication US 2023/0021189 A1, Jan. 19, 2023
Int. Cl. B29C 70/50 (2006.01); B29C 70/12 (2006.01); B29C 70/18 (2006.01); B29C 70/54 (2006.01); B29K 21/00 (2006.01); B29K 307/04 (2006.01); B29L 7/00 (2006.01); C08J 5/04 (2006.01); C08J 5/24 (2006.01); D02J 1/18 (2006.01)
CPC B29C 70/508 (2013.01) [B29C 70/12 (2013.01); B29C 70/18 (2013.01); B29C 70/545 (2013.01); C08J 5/042 (2013.01); C08J 5/243 (2021.05); D02J 1/18 (2013.01); B29K 2021/006 (2013.01); B29K 2307/04 (2013.01); B29L 2007/002 (2013.01)] 18 Claims
OG exemplary drawing
 
1. A manufacturing method of an SMC, comprising:
(i) forming chopped carbon fiber bundles by chopping a continuous carbon fiber bundle having a filament number of NK with a rotary cutter;
(ii) fragmentation-processing the chopped carbon fiber bundles by using a fragmentation-processing apparatus;
(iii) forming a carbon fiber mat by depositing the fragmentation-processed chopped carbon fiber bundles on a carrier film traveling below the rotary cutter; and
(iv) impregnating the carbon fiber mat with a thermosetting resin composition,
wherein N is 20 or more, and
the fragmentation-processing apparatus comprises a first pin roller and a second pin roller which are disposed side by side, each having a rotation axis parallel to a rotation axis direction of the rotary cutter, and
a sum of a maximum radius of the first pin roller and a maximum radius of the second pin roller is equal to or greater than a distance between the rotation axes of the first pin roller and the second pin roller.