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

Abstract

Provided is a method for manufacturing a fiber-reinforced resin molding material having excellent productivity at low cost for manufacturing a fiber-reinforced resin molded article having excellent strength properties. Provided is a method for manufacturing a sheet-shaped fiber-reinforced resin molding material containing a plurality of cut fiber bundles and a resin impregnated between filaments of the cut fiber bundles, the method comprising an integrated material manufacturing step for obtaining an integrated material by collecting a sheet-shaped fiber bundle aggregate obtained by arranging and spreading a plurality of consecutive fiber bundles in a width direction.

1 . (canceled) 
     
     
         2 . A method for manufacturing a winding body comprising:
 spreading a continuous carbon fiber bundle drawn out from a bobbin in a width direction to obtain an opened continuous carbon fiber bundle;   separating the opened continuous carbon fiber bundle intermittently in a longitudinal direction to obtain an intermittently separated continuous carbon fiber bundle; and   winding the intermittently separated continuous carbon fiber bundle on another bobbin.   
     
     
         3 . The method according to  claim 2 , wherein the opened continuous carbon fiber bundle is separated intermittently in a longitudinal direction to satisfy the following condition (1):
   1≤ a/L    (1),
   wherein a represents a length of a separated part in the intermittently separated continuous carbon fiber bundle and L is 5 mm.   
     
     
         4 . The method according to  claim 2 , wherein the opened continuous carbon fiber bundle is separated intermittently in a longitudinal direction to satisfy the following condition (2):
     a/L≤ 10   (2),
   wherein a represents a length of a separated part in the intermittently separated continuous carbon fiber bundle and L is 100 mm.   
     
     
         5 . The method according to  claim 2 , wherein the opened continuous carbon fiber bundle is separated intermittently in a longitudinal direction to satisfy the following condition (3):
   0.9≤1/( a+b )<1   (3),
   wherein a represents a length of a separated part in the intermittently separated continuous carbon fiber bundle and b represents a length between separated parts in the intermittently separated continuous carbon fiber bundle.   
     
     
         6 . The method according to  claim 2 , wherein the continuous carbon fiber bundle is formed of 12,000 or more filaments. 
     
     
         7 . A winding body comprising a bobbin and an intermittently separated continuous carbon fiber bundle wound on the bobbin, wherein the intermittently separated continuous carbon fiber bundle is a continuous carbon fiber bundle which is separated intermittently in a longitudinal direction. 
     
     
         8 . The winding body according to  claim 7 , wherein the intermittently separated continuous carbon fiber bundle satisfies the following condition (1):
   1≤ a/L    (1),
   wherein a represents a length of a separated part in the intermittently separated continuous carbon fiber bundle and L is 5 mm.   
     
     
         9 . The winding body according to  claim 7 , wherein the intermittently separated continuous carbon fiber bundle satisfies the following condition (2):
     a/L≤ 10   (2),
   wherein a represents a length of a separated part in the intermittently separated continuous carbon fiber bundle and L is 100 mm.   
     
     
         10 . The winding body according to  claim 7 , wherein the intermittently separated continuous carbon fiber bundle satisfies the following condition (3):
   0.9≤1/( a+b )<1   (3),
   wherein a represents a length of a separated part in the intermittently separated continuous carbon fiber bundle and b represents a length between separated parts in the intermittently separated continuous carbon fiber bundle.   
     
     
         11 . The winding body according to  claim 7 , wherein the intermittently separated continuous carbon fiber bundle is formed of 12,000 or more filaments. 
     
     
         12 . A method for separating a carbon fiber bundle comprising of:
 spreading a continuous carbon fiber bundle drawn out from a bobbin in a width direction to obtain an opened continuous carbon fiber bundle; and   separating the opened continuous carbon fiber bundle intermittently in a longitudinal direction to obtain an intermittently separated continuous carbon fiber bundle.   
     
     
         13 . The method according to  claim 12 , wherein the opened continuous carbon fiber bundle is separated intermittently in a longitudinal direction to satisfy the following condition (1):
   1≤ a/L    (1),
   wherein a represents a length of a separated part in the intermittently separated continuous carbon fiber bundle and L is 5 mm.   
     
     
         14 . The method according to  claim 12 , wherein the opened continuous fiber bundle is separated intermittently in a longitudinal direction to satisfy the following condition (2):
     a/L≤ 10   (2),
   wherein a represents a length of a separated part in the intermittently separated continuous carbon fiber bundle and L is 100 mm.   
     
     
         15 . The method according to  claim 12 , wherein the opened continuous carbon fiber bundle is separated intermittently in a longitudinal direction to satisfy the following condition (3):
   0.9≤1/( a+b )<1   (3),
   wherein a represents a length of a separated part in the intermittently separated continuous carbon fiber bundle and b represents a length between separated parts in the intermittently separated continuous carbon fiber bundle.   
     
     
         16 . The method according to  claim 12 , wherein the continuous carbon fiber bundle is formed of 12,000 or more filaments. 
     
     
         17 . An intermittently separated continuous carbon fiber bundle which is separated intermittently in a longitudinal direction to satisfy the following condition (1):
   1≤ a/L    (1),
   wherein a represents a length of a separated part in the intermittently separated continuous carbon fiber bundle and L is 5 mm.   
     
     
         18 . The intermittently separated continuous carbon fiber bundle according to  claim 17  which satisfies the following condition (2):
     a/L≤ 10   (2),
 
 wherein a represents a length of a separated part in the intermittently separated continuous carbon fiber bundle and L is 100 mm. 
 
     
     
         19 . The intermittently separated carbon fiber bundle according to  claim 17  which satisfies the following condition (3):
   0.9≤1/( a+b )<1   (3),
 
 wherein a represents a length of a separated part in the intermittently separated continuous carbon fiber bundle and b represents a length between separated parts in the intermittently separated continuous carbon fiber bundle. 
 
     
     
         20 . The intermittently separated continuous carbon fiber bundle according to  claim 17 , wherein the intermittently separated continuous carbon fiber bundle is formed of 12,000 or more filaments. 
     
     
         21 . An intermittently separated continuous carbon fiber bundle which is separated intermittently in a longitudinal direction to satisfy the following condition (2):
     a/L≤ 10   (2),
   wherein a represents a length of a separated part in the intermittently separated continuous carbon fiber bundle and L is 100 mm.   
     
     
         22 . The intermittently separated continuous carbon fiber bundle according to  claim 21  which satisfies the following condition (3):
   0.9≤1/( a+b )<1   (3),
 
 wherein a represents a length of a separated part in the intermittently separated continuous carbon fiber bundle and b represents a length between separated parts in the intermittently separated continuous carbon fiber bundle. 
 
     
     
         23 . The intermittently separated continuous carbon fiber bundle according to  claim 21 , wherein the intermittently separated continuous carbon fiber bundle is formed of 12,000 or more filaments.