JPH0970826A - Method and apparatus for preparing fiber reinforced resin intermediate molded article - Google Patents

Abstract

PROBLEM TO BE SOLVED: To stabilize the quality of a resin molded article by preventing the deviation of reinforcing fibers to one side and to miniaturize an apparatus in the preparation of an uncured fiber reinforced resin intermediate molded article in which a reinforcing mat impregnated with a synthetic resin is placed in the uncured synthetic resin between a pair of support films. SOLUTION: A synthetic resin 2 and a reinforcing fiber mat 3 are supplied to each of a pair of support films 1, 1 which is moved and supplied, each of composite layers 5 composed of the resin 2 and the mat 3 is pressed to the support film 1, an impregnation body 6 in which the mat 3 is impregnated with the resin 2 is formed, the impregnation bodies 6, 6 on the moving support films 1, 1 are integrated by being surface-contacted with each other, and a multilayered reinforcing fiber mat 3 is placed in the resin 2.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a method for manufacturing an uncured fiber-reinforced resin intermediate molded body for manufacturing a fiber-reinforced resin molded body, and a manufacturing apparatus therefor. In, a method for producing a fiber-reinforced resin intermediate molded article in which a reinforced fiber mat impregnated with the uncured synthetic resin is interposed, and between the pair of supplied support films, an uncured synthetic resin, The present invention relates to an apparatus for producing a fiber-reinforced resin intermediate molded body which supplies a reinforcing fiber mat and impregnates the reinforcing fiber mat with the synthetic resin to form an impregnated body.

[0002]

2. Description of the Related Art Conventionally, in manufacturing a fiber-reinforced synthetic resin molded body, as shown in FIG. 4, one of a pair of supporting films 1 made of polypropylene or the like is supplied onto a single conveyor 8 and the supporting film is formed. A synthetic resin 2 such as a phenol resin is supplied onto the synthetic resin 2, and a reinforcing fiber mat 3 such as a glass fiber mat and the synthetic resin 2 are sequentially and repeatedly supplied and laminated on the synthetic resin 2 and reinforced by pressing from above. The fiber mat 3 is impregnated with the synthetic resin 2, and the other supporting film 1 is supplied on top of the laminated resin to form a fiber reinforced resin intermediate molded body 7
Is being formed.

[0003]

In the conventional method and apparatus for manufacturing a fiber-reinforced resin intermediate molded body, the layers are sequentially laminated, so that the synthetic resin 2 is impregnated in the reinforcing fiber mat 3 as shown in FIG. As shown, the synthetic resin 2 penetrates the reinforcing fiber mat 3, the reinforcing fiber mat 3 sinks, and even if the reinforcing fiber mat 3 is pressed from above for impregnation, the spring back of the reinforcing fiber mat 3 causes When the reinforcing fiber mat 3 overlaps, the pressure is not sufficiently transmitted from the upper reinforcing fiber mat 3 to the lower synthetic resin 2, and as a result, the thickness of each layer does not reach a predetermined value, and the reinforcing fiber mat 3 is There is a problem in that the reinforced resin intermediate molded body 7 is biased to one side in the thickness direction, causing unevenness in the strength of the molded body after curing.
This is a problem that the larger the number of the reinforcing fiber mats 3 laminated, the larger the number. That is, the reinforcing fiber mat 3 is unevenly distributed within the fiber-reinforced resin intermediate molded body 7. In particular, when manufacturing a foamed resin molded body using this fiber-reinforced resin intermediate molded body 7, the unevenness of the reinforcing fiber mat 3 is caused. This is a point that must be avoided because it is expanded by the foaming of the synthetic resin 2, the influence on the product strength becomes large, and the quality becomes unstable. Further, since the whole laminating process is successively performed on the conveyor 8, there is a problem that the total length of the apparatus is inevitably long. Therefore, the object of the present invention is to solve the above problems, prevent the bias to one of the reinforcing fibers during the formation of the fiber-reinforced resin intermediate molded body, while stabilizing the quality of the resin molded body, An object of the present invention is to provide a manufacturing method and a manufacturing apparatus for a fiber-reinforced resin intermediate molded body that enables downsizing of the apparatus.

[0004]

The characteristic means of the method for producing a fiber-reinforced resin intermediate molded article of the present invention for the above purpose is as follows:
(a) supplying a synthetic resin and a reinforcing fiber mat on each of a pair of supporting films that are moved and supplied, and pressing each composite layer composed of the synthetic resin and the reinforcing fiber mat toward the supporting film, An impregnated body impregnated with the synthetic resin is formed on the reinforcing fiber mat, and (b) the both impregnating bodies on both the moving support films are brought into face-to-face contact with each other to be integrated to form a plurality of layers of the reinforcing fiber mat. It lies in that it is interposed in the synthetic resin (corresponding to claim 1). Further, the characteristic configuration of the manufacturing apparatus of the fiber-reinforced resin intermediate molded body of the present invention, (c)
On the first conveyor, a first supporting film supply device for supplying one of the pair of supporting films is provided,
A second support film supply device for supplying the other of the pair of support films on the second conveyor, and a resin supply device for supplying the synthetic resin to the support films on the first and second conveyors, respectively. And a reinforcing fiber mat supplying device for supplying the reinforcing fiber mat, which are separately provided,
An impregnating device for impregnating the supplied reinforcing fiber mat with the synthetic resin to form a first impregnated body on a conveyor, and impregnating the reinforcing resin mat supplied with the synthetic resin on the second conveyor. And separately disposing an impregnating device for forming a second impregnated body, and (d) guiding the both supporting films from the first and second conveyors, and the first on both supporting films, An impregnated body merging device is provided for bringing the second impregnated bodies into face-to-face contact with each other to combine them.
Corresponding to). In addition to the above (c) and (d), the following (e) is more preferable. (e) The impregnated body coalescing device is provided in front of the first conveyor in the conveying direction, and the second conveyor is arranged in a space above the impregnated body coalescing device (corresponding to claim 3).

[Operation and Effect of Characteristic Means of the Present Invention] Therefore, according to the characteristic means of the method for producing a fiber-reinforced resin intermediate molded article of the present invention according to claim 1, (a) by the above means (a) Since each impregnated body divided in the thickness direction is formed on each support film, even if the reinforced fiber mat is biased in the impregnated body, it is possible to suppress the bias of the reinforced fiber mat with respect to both support films. Further, (b) By the means (b), since the two impregnated bodies are united by making the bias directions of the reinforcing fiber mat opposite to each other, the above-mentioned (a) on both the support films, Even if the fiber mat is biased, there is no difference in the bias of the reinforcing fiber mat to both sides of the fiber-reinforced resin intermediate molded body in the thickness direction.
Furthermore, (c) As a result of combining the above means (a) and (b), the arrangement of each means can be three-dimensionalized, and thus it is possible to avoid the planar spread of the device. As a result, by the characteristic means of the present invention, as a result of the above (a) and (b), it is possible to avoid a bias in one side of the reinforcing fiber in the formed fiber-reinforced resin intermediate molded body, resulting in a strength difference depending on the bending direction. It becomes possible to form a fiber-reinforced resin intermediate molded body that prevents the above, and it becomes possible to manufacture a fiber-reinforced resin molded body of stable quality.
As a result of (c), it has become possible to downsize the manufacturing apparatus for the fiber-reinforced resin intermediate molded body. [Operation and Effect of Characteristic Configuration of the Present Invention] Further, according to the characteristic configuration of the apparatus for producing a fiber-reinforced resin intermediate molded article of the present invention according to claim 2, (d) by the configuration (c), Since the first and second impregnated bodies are separately formed, the function described in (a) above can be realized, and (e) the above configuration (d) provides
(B) The described effect can be realized. If the configuration of the above configuration (e) is added, (f) the upper space of the impregnated coalescing apparatus can be effectively utilized, and the planar expansion of the manufacturing apparatus for the fiber-reinforced resin intermediate molded body of the present invention Can be avoided. As a result, by the characteristic configuration of the present invention, as a result of the above (d) and (e), it is possible to avoid biasing one of the reinforcing fibers in the formed fiber-reinforced resin intermediate molded body, resulting in a strength difference depending on the bending direction. It is possible to form a fiber-reinforced resin intermediate molded product that prevents this, and it becomes possible to manufacture stable quality fiber-reinforced resin molded products.As a result of the above (f), a fiber-reinforced resin intermediate molded product manufacturing device I was able to downsize.

[0006]

BEST MODE FOR CARRYING OUT THE INVENTION An embodiment of a manufacturing apparatus of the present invention will be described below with reference to the drawings. As shown in FIG.
A first support film supply device 9A for supplying the polypropylene film 1 as one of the pair of support films is provided on the first conveyor 8A, and the polypropylene film 1 supplied in the conveying direction is provided on the conveyor 8A. A resin supply device 10 for supplying a phenol resin 2 as a synthetic resin on the above, and a reinforcing fiber supply for supplying a glass fiber mat 3 as a reinforcing fiber mat on the supplied phenol resin 2 to form a composite layer 5. A device 11 is provided. Furthermore, an impregnation device 4 for impregnating the glass fiber mat 3 with the phenol resin 2 by pressing the formed composite layer 5 from above is arranged behind the reinforcing fiber supply device 11 in the conveying direction. . The conveyor 8A
The first impregnated body 6a is formed by dividing the impregnated body 6 to be formed into two in the thickness direction. Also on the second conveyor 8B,
Similarly, the second support film supply device 9B for supplying the polypropylene film 1 as the other support film.
Is provided, and the phenol resin 2 as a synthetic resin is supplied on the polypropylene film 1 supplied in the conveying direction also on the conveyor 8B, which is separate from the one on the first conveyor 8A. Resin supply device 10
And a reinforcing fiber supplying device 11 separate from the one on the first conveyor 8A, which forms a composite layer 5 by supplying a glass fiber mat 3 as a reinforcing fiber mat onto the supplied phenol resin 2. It is provided. Furthermore, the first conveyor 8A for impregnating the glass fiber mat 3 with the phenol resin 2 by pressing the formed composite layer 5 from the rear side of the reinforcing fiber supply device 11 in the conveying direction.
An impregnation device 4 separate from the above is arranged. On the conveyor 8B, the other second impregnated body 6b is formed by dividing the impregnated body 6 to be formed into two in the thickness direction. The first and second impregnated bodies 6a and 6b respectively formed on both support films 1 fed from the both conveyors 8A and 8B are brought into face-to-face contact with each other to be united, and a fiber-reinforced resin intermediate molded body (hereinafter An impregnated body uniting device 12 for forming 7) is provided at a position where it can be linearly pulled out from the first conveyor 8A. The first conveyor 8A and the second conveyor 8B are provided so as to be driven at the same speed in opposite directions.
B is arranged higher than the first conveyor 8A. In the impregnated body coalescing device 12, while guiding the support film 1 from the first conveyor 8A horizontally and linearly,
A guide roll that guides the supporting film 1 from the second conveyor 8B by descending and inverting it is provided, and the first and second impregnated bodies 6a and 6b on both supporting films 1 are brought into face-to-face contact with each other from above and below so as to be combined. I have a pair of rolls. When the first and second impregnated bodies 6a and 6b are combined, the two impregnated bodies 6a and 6b are gradually brought close to each other to be brought into face-to-face contact so that air is not trapped between the contact surfaces of the both impregnated bodies 6a and 6b. There is. By arranging both the conveyors 8A and 8B and the impregnated body coalescing device 12 in this way, the space above the impregnated body coalescing device 12 is used, and the length of the second conveyor 8B is affected. Instead, the entire length of the equipment can be determined by the length of the first conveyor 8A and the impregnated body combining device 12 as a whole.
The length of 8B can be shortened as a result of halving the number of supplied reinforcing fiber mats 3, and the floor space for installation of equipment can be reduced. Both conveyors 8A and 8B are
Driven at the same speed. This conveying speed is appropriately selected depending on the type, composition, etc. of the synthetic resin 2 forming the intermediate molded body 7 to be formed. The supporting film supply device 9A, 9
B is arranged on the conveyance start end side of the first and second conveyors 8A and 8B, respectively, and the reel for feeding and feeding the polyethylene film 1 and the polyethylene film 1 fed and fed from the reel are fed to the conveyors 8A and 8B, respectively. It is equipped with a guide roll that guides so that it can be closely contacted on the
The polyethylene film 1 is pulled out by being driven by the conveyors 8A and 8B, respectively.
The resin supply devices 10 are provided so as to supply the phenol resin 2 in a fixed amount near the center of the polyethylene film 1 in the width direction. The supply amount of the phenol resin 2 is determined by the size of the intermediate molded body 7 to be formed, the transport speed of the conveyors 8A and 8B, and the like. The reinforcing fiber supply device 11 is configured to stack the reel for feeding and feeding the glass fiber mat 3 and the glass fiber mat 3 fed on two layers of phenol resin to form the composite layer 5 so as to form the composite layer 5. 3 and a roll for guiding the conveyor 3, and each of the conveyors 8
Following the conveyance of A and 8B, the polyethylene film 1
Are being pulled out. The impregnating device 4 is
It is composed of a transverse roll 4a and a consolidation roll 4b.
The traverse roll 4a has its axial direction in the conveyor 8
In parallel with the moving directions of A and 8B, the conveyors 8A and 8A,
8B is provided so that it can be reciprocally driven from one end to the other end in the width direction (the drive device is not shown), and the distances from the upper surfaces of the conveyors 8A and 8B can be adjusted. By providing the traverse roll 4a,
The phenol resin 2 can be spread in the width direction of both the conveyors 8A and 8B just by supplying the phenol resin 2 to the vicinity of the central portion of the polyethylene film 1 in the width direction. Phenolic resin 2 can be evenly applied on top. Further, when the traverse roll 4a is positioned at a height such that it comes into contact with the glass fiber mat 3 on the polyethylene film 1 and is reciprocated to both ends in the width direction of the polyethylene film 1, the phenol resin 2 is The polyethylene film 1 can be repeatedly and evenly spread in the width direction, the composite layer 5 can be pressed from above with the spread pressure, and the glass fiber mat 3 can be impregnated with the phenol resin 2. Further, since it acts to stir the supplied phenol resin 2, it is also possible to degas the phenol resin 2. Immediately after the traverse roll 4a, the compacting roll 4b is arranged with its axial direction oriented in the width direction of each of the conveyors 8A and 8B so that the separation distance from the upper surface of each of the conveyors 8A and 8B can be adjusted. , Is rotatably driven (a drive mechanism is not shown). Incidentally, in the resin supply device 10 for directly supplying the phenol resin 2 onto the polyethylene film 1, a doctor knives 14 which are commonly used for adjusting the thickness of the phenol resin 2 after the pressure spreading are provided.

An example of producing a fiber-reinforced foamed phenol resin molding (hereinafter, simply referred to as a product) by using the apparatus for manufacturing a fiber-reinforced resin intermediate molding having the above structure will be described below. The product to be manufactured is a glass fiber non-woven fabric reinforced with a phenol resin to which aluminum hydroxide is added as a filler. The product has a width of 920 mm and a thickness of 10.
mm, two glass fiber layers, and the glass fiber layer is composed of two 210 g / m ² glass fiber nonwoven fabrics. On the first conveyor 8A, the polypropylene film 1 having a width of 1150 mm and a thickness of 30 μm is supplied from the first supporting film supply device 9A. A phenol resin 2 having aluminum hydroxide added as a filler is supplied onto the polypropylene film 1 from a resin supply device 10. The supplied phenol resin 2 is spread in the width direction of the polypropylene film 1 by a spreading roll 13 similar to the transverse roll 4a, and is adjusted to a predetermined thickness (for example, 3 mm) by a doctor knife 14. The glass fiber non-woven fabric 3 is supplied from the reinforcing fiber supply device 11 onto the supplied phenol resin 2, and the resin supply device 10 is further provided on the glass fiber non-woven fabric 3.
The phenol resin 2 is supplied from the above to form the composite layer 5 slightly thicker than 5 mm. In order to impregnate the glass fiber nonwoven fabric 3 of the composite layer 5 thus formed with the phenolic resin 2, first, the phenol resin 2 is spread on the glass fiber nonwoven fabric 3 by the traverse roll 4 a of the impregnating device 4. The phenol resin 2 is pressed by a pressing roll 4b that is driven to rotate, and at the same time, the first impregnated body 6a having a thickness of 5 mm and the impregnated body 6 to be formed is divided into two in the thickness direction. Form.
Similarly, on the second conveyor 8B, a width of 1150 m
The polypropylene film 1 having a thickness of m and a thickness of 30 μm is supplied from the second supporting film supply device 9B. On the polypropylene film 1, the phenolic resin 2 added with aluminum hydroxide as a filler is added to the first
The resin supply device 10 separate from the one on the conveyor 8A
Supplied from The supplied phenol resin 2 is also spread in the width direction of the polypropylene film 1 by a spreading roll 13 similar to the transverse roll 4a, and is adjusted to a predetermined thickness (for example, 3 mm) by a doctor knife 14. Also on this supplied phenolic resin 2,
The glass fiber nonwoven fabric 3 is supplied from the reinforcing fiber supply device 11 which is separate from the one on the first conveyor 8A, and the resin supply device 10 is further provided on the glass fiber nonwoven fabric 3.
The phenol resin 2 is supplied from the above to form the composite layer 5 slightly thicker than 5 mm. The glass fiber non-woven fabric 3 of the composite layer 5 thus formed is applied to the phenol resin 2
In order to impregnate the resin, first, the phenol resin 2 is spread from above the glass fiber nonwoven fabric 3 by the traverse roll 4a of the impregnation device 4 which is separate from the one on the first conveyor 8A, and further rotationally driven. The phenolic resin 2 is rolled down by a compacting roll 4b which is formed at the same time as a thickness of 5 m.
The second second impregnated body 6b, which is obtained by dividing the impregnated body 6 to be formed into two in the thickness direction, is continuously formed. Both the conveyors 8A and 8B are driven at a conveying speed of 4 m / min. The first and second impregnated bodies 6a and 6b formed as described above are provided in the impregnated body coalescing device 12, a guide roll for guiding the support film 1 from the first conveyor 8A, and the first and second guide rolls. 2 Supporting film 1 from conveyor 8B
Guide rollers for guiding the two conveyors 8
Face-to-face contact with both support films 1 guided by A and 8B, and united to form the intermediate molded body 7 between the support films.
Will be formed. As described above, the intermediate molded body 7
As a result of forming the impregnated body 6 in two, it contributes to the fact that the impregnation step can be shortened, and as shown in FIG. 2, the deviation of the glass fiber nonwoven fabric 3 in the first and second impregnated bodies 6a and 6b is Even if the deviation can be suppressed, the first and second impregnated bodies 6a and 6b are brought into face-to-face contact with each other as shown in FIG.
Since the glass fiber nonwoven fabric 3 in the impregnated body 6 is biased only in the direction of each of the polypropylene films 1 since it is formed by uniting, the intermediate molded body 7 has the same degree of unevenness. Since it is biased toward both polypropylene films 1, there is no problem of biasing the glass fiber nonwoven fabric 3 in one of the intermediate thicknesses 7 in the thickness direction of the product, and it becomes possible to manufacture a product of stable quality.

Another embodiment of the present invention will be described below. <1> The synthetic resin can be selected according to the intended use such as polyester resin and epoxy resin. <2> Reinforcing fiber mat means a continuous fiber reinforcing material, and refers to a continuous fiber bundle, a fiber woven fabric, a non-woven fabric, or the like. <3> The mutual arrangement of the first conveyor and the second conveyor is not limited to the above-mentioned embodiment, and may be arranged at a position where the support films drawn from both conveyors are smoothly conveyed. <4> The number of conveyors provided is not limited to two, but may be four, for example.
A base may be provided. In this case, the impregnated bodies are united every two groups, one of the supporting films supporting the respective impregnated bodies is peeled off, and the surface of each of the united impregnated bodies after peeling off the supporting film. Are subjected to face-to-face contact and combined to form an intermediate molded body.

[0009]

As described above, according to the present invention,
It was possible to provide a manufacturing method and a manufacturing apparatus for a fiber-reinforced resin intermediate molded body that not only stabilizes the quality of the resin molded body but also enables downsizing of the apparatus.

It should be noted that although reference numerals are given in the claims for convenience of comparison with the drawings, the present invention is not limited to the structures of the accompanying drawings by the entry.

[Brief description of drawings]

FIG. 1 is an explanatory view of an embodiment of an apparatus for manufacturing a fiber-reinforced resin intermediate molded body of the present invention.

FIG. 2 is an explanatory view of suppressing unevenness of the reinforcing fiber mat in the divided impregnated body.

FIG. 3 is an explanatory diagram of the effect of the present invention.

FIG. 4 is an explanatory diagram of a conventional apparatus for manufacturing a fiber-reinforced resin intermediate molded body.

FIG. 5 is an explanatory view of occurrence of bias of the reinforcing fiber mat in the impregnated body in the conventional technique.

[Explanation of symbols]

 1 Support Film 2 Synthetic Resin 3 Reinforcing Fiber Mat 4 Impregnation Device 5 Composite Layer 6 Impregnation Body 6a First Impregnation Body 6b Second Impregnation Body 8A First Conveyor 8B Second Conveyor 9A First Support Film Supply Device 9B Second Support Film Supply Device 10 Resin supply device 11 Reinforcing fiber mat supply device 12 Impregnated coalescence device

Claims (3)

[Claims] 1. Fiber reinforced by interposing a reinforcing fiber mat (3) in which an uncured synthetic resin (2) is impregnated with the synthetic resin (2) between a pair of support films (1), (1). A method for producing a resin intermediate molded body, comprising supplying the synthetic resin (2) and the reinforcing fiber mat (3) on a pair of support films (1), (1) that are moved and supplied, and Each of the composite layers (5) composed of the resin (2) and the reinforcing fiber mat (3) is pressed against the supporting film (1) so that the synthetic resin (2) is applied to the reinforcing fiber mat (3). The impregnated body (6) impregnated is formed, and the both impregnated bodies (6) and (6) on the moving support films (1) and (1) are brought into face-to-face contact with each other and integrated to form a plurality of layers. The reinforcing fiber mat (3) is replaced with the synthetic resin (2).
A method for producing a fiber-reinforced resin intermediate molded body which is provided inside. 2. A pair of supporting films (1) supplied,
An uncured synthetic resin (2) and a reinforcing fiber mat (3) are supplied between (1) and the reinforcing resin mat (3) is impregnated with the synthetic resin (2) to obtain an impregnated body (6). )
A first support film supply device (9A) for supplying one of the pair of support films (1) onto the first conveyor (8A), which is a device for manufacturing a fiber-reinforced resin intermediate molded body. Provided and on the second conveyor (8B),
A second support film supply device (9B) for supplying the other of the pair of support films (1) is provided, and each of the support films (1) on the first and second conveyors (8A) and (8B) is provided. A resin supply device (10) for supplying the synthetic resin (2) and a reinforcing fiber mat supply device (11) for supplying the reinforcing fiber mat (3) are separately provided, and on the first conveyor (8A). The impregnating device (4) for impregnating the supplied reinforcing fiber mat (3) with the synthetic resin (2) to form the first impregnated body (6a) and the second conveyor (8B), The reinforced fiber mat (3) thus obtained is impregnated with the synthetic resin (2) to obtain a second impregnated body (6).
The impregnating device (4) for forming b) is separately provided, and the supporting films (1) and (1) are guided from the first and second conveyors (8A) and (8B), respectively. The first and second impregnated bodies (6a) on both supporting films (1) and (1),
An apparatus for producing a fiber-reinforced resin intermediate molded body, which is provided with an impregnated body coalescing device (12) for bringing face-to-face contact with each other (6b) and coalescing. 3. The impregnated coalescing device (12) is provided in front of the first conveyor (8A) in the conveying direction, and the second conveyor (8B) is arranged in a space above the impregnated coalescing device (12). The manufacturing apparatus of the fiber-reinforced resin intermediate molded body according to claim 2.