JP2000219754A - Production of prepreg and production apparatus - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a process for producing prepregs capable of effecting their production at a low equipment cost without requiring much labor of cleaning and maintenance and, in addition, capable of preventing formation of voids. SOLUTION: A solvent-free thermosetting matrix resin formed in the form of a membrane on a transfer roll 2 is transferred in the molten state from the transfer roll 2 onto one side of a sheet-shaped reinforcing substrate 1 to effect coating and, at the same time, to impregnate this sheet-shaped reinforcing material 1 with the thermosetting matrix resin. Then, a roll 3 disposed at the side of the coated thermosetting matrix resin of the sheet-shaped reinforcing substrate 1 is pressed onto one side of the sheet-shaped reinforcing substrate to rotate the roll 3 in the opposite direction of the coated surface of the sheet- shaped reinforcing substrate 1 of the thermosetting matrix resin. Subsequently, this sheet-shaped reinforcing substrate 1 coated and impregnated with the thermosetting resin is heated in a non-contacting type heating unit 4 to semi-cure the thermosetting matrix resin.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION The present invention relates to a prepreg which is continuously coated with a thermosetting matrix resin containing no solvent while continuously feeding a long sheet-like reinforcing substrate made of fibers to impregnate a prepreg. The present invention relates to a method and an apparatus for manufacturing a prepreg to be manufactured.

[0002]

2. Description of the Related Art As a technique for continuously producing a prepreg by continuously applying and impregnating a thermosetting matrix resin containing no solvent while continuously feeding a long sheet-like reinforcing base made of fiber, There is one provided in JP-A-8-281645.

That is, this is a first coating step in which a thermosetting matrix resin containing no solvent is applied in a molten state to one surface of a sheet-like reinforcing substrate using a die coater; Heating the sheet-shaped reinforcing base material coated with a non-contact type heating unit with a non-contact type heating unit to impregnate the thermosetting matrix resin into the sheet-shaped reinforcing base material, and sheet-like reinforcing impregnated with the thermosetting matrix resin A second coating step of applying a thermosetting matrix resin to the base material using a die coater from a side opposite to the resin coated surface in the first coating step, and applying the thermosetting matrix resin to the base material; A step of heating the impregnated sheet-shaped reinforcing base material by a non-contact type heating unit and semi-curing the thermosetting matrix resin to form a sheet-shaped prepreg; It become one.

[0004]

As described above, Japanese Unexamined Patent Application Publication No.
According to the technology provided in Japanese Patent No. 281645, a thermosetting matrix resin is applied to a sheet-like reinforcing substrate using a die coater. However, the die coater has a problem that the thermosetting matrix resin is likely to adhere to the inside of the die coater and coating accuracy may be deteriorated, and it takes time to perform cleaning and maintenance for removing the resin adhered to the inside of the die coater. The die coater itself is a very expensive device, and it is necessary to arrange a die coater on one side of the sheet-shaped reinforcing substrate and one side of the other, and apply a thermosetting matrix resin on each side. However, there is also a problem that equipment costs increase. Furthermore, since the thermosetting matrix resin is applied from both sides of the sheet-shaped reinforcing base material, there is a problem that air in the sheet-shaped reinforcing base material is confined and voids are easily generated. .

[0005] The present invention has been made in view of the above points, and can be manufactured at low equipment costs without requiring labor for cleaning and maintenance, and can prevent the generation of voids. It is an object of the present invention to provide a prepreg manufacturing method and a prepreg manufacturing apparatus.

[0006]

According to a first aspect of the present invention, there is provided a method for producing a prepreg, which comprises applying a thermosetting matrix resin while continuously feeding a long sheet-like reinforcing substrate 1 made of fibers. When a prepreg is continuously produced by impregnation, a solvent-free thermosetting matrix resin formed in the form of a film on the surface of the transfer roll 2 is melted from the transfer roll 2 to one side of the sheet-like reinforcing substrate 1 in a molten state. This thermosetting matrix resin is impregnated into the sheet-like reinforcing substrate 1 and then coated on the side of the sheet-like reinforcing substrate 1 on which the thermosetting matrix resin is applied. The surrounding roll 3 is pressed against one surface of the sheet-shaped reinforcing substrate 1 to rotate the thermosetting matrix resin on the opposite side of the coated surface of the sheet-shaped reinforcing substrate 1, and thereafter, the thermosetting matrix resin is applied. Engineering / impregnated Is characterized in that by heating over preparative shaped reinforcing substrate 1 by the heating unit 4 of the non-contact type is semi-cured thermosetting matrix resin.

According to a second aspect of the present invention, a heater 5 for heating the thermosetting matrix resin applied and impregnated on the sheet-like reinforcing substrate 1 is provided on the opposite side of the sheet-like reinforcing substrate 1 from the coating surface. It is characterized by being arranged in a non-contact manner.

The invention according to claim 3 is characterized in that the circling rolls 3 are arranged at a plurality of positions along the feeding direction of the sheet-like reinforcing substrate 1.

Further, according to the invention of claim 4, the releasability of the thermosetting matrix resin is obtained by contacting the surface of the sheet-like reinforcing substrate 1 opposite to the rotating roll 3 with the surface opposite to the coating surface. The backup sheet 6 is disposed.

The invention according to claim 5 is characterized in that the side opposite to the coated surface of the sheet-shaped reinforcing substrate 1 is subjected to air negative pressure.

Further, the invention according to claim 6 is characterized in that the turning roll 3 is rotated in a direction opposite to the feeding direction of the sheet-like reinforcing substrate 1.

Further, the invention according to claim 7 is characterized in that the turning roll 3 is rotated in the same direction as the feeding direction of the sheet-like reinforcing substrate 1.

The invention according to claim 8 is characterized in that a wiping roll 7 for moving the sheet-like reinforcing substrate 1 so as to wind the sheet-like reinforcing substrate 1 around the outer peripheral surface of the transfer roll 2 is provided. is there.

According to a ninth aspect of the present invention, the metering roll 12 is disposed to face the transfer roll 2 and the molten thermosetting matrix resin supplied to the surface of the transfer roll 2 is spread by the metering roll 12. In the state of being transferred, the transfer state from the transfer roll 2 to one side of the sheet-like reinforcing base material 1 is applied, and the coating state of the thermosetting matrix resin applied to the sheet-like reinforcing base material 1 is detected, The inclination angle of the rotation axis of the metering roll 12 with respect to the rotation axis of the transfer roll 2 is calculated according to the detected coating state,
Metering roll 1 so that it has the calculated inclination angle
2 is characterized in that the angle is adjusted.

Further, according to the present invention, the coated state of the thermosetting matrix resin applied to the sheet-shaped reinforcing base material 1 is detected, and the sheet-shaped reinforcing base material is determined according to the detected coated state. Roll 3 that rotates in the direction that intersects the feed direction 1
Is calculated, and the turning roll 3 is moved and adjusted by the calculated movement amount.

According to the eleventh aspect of the present invention, the rotation speed and the torque value of the roll are measured, and the measured rotation speed and the torque value are compared with the preset rotation speed and the torque value to determine whether the rotation is normal or abnormal. And detecting an abnormality.

Further, the invention according to claim 12 is characterized in that when an abnormality of the roll is detected, the rotation of the roll is stopped or reversely rotated.

According to a thirteenth aspect of the present invention, the thermosetting matrix resin is a two-component mixed resin of a bisphenol type epoxy resin and a cresol novolak type epoxy resin.

A prepreg manufacturing apparatus according to a fourteenth aspect of the present invention operates at the time of switching between the unwinding unit 8 for continuously feeding out the long sheet-like reinforcing substrate 1 made of fiber and the sheet-like reinforcing substrate 1. Accumulator unit 9
And a resin delivery unit 10 that mixes a main agent and a curing agent and sends out a thermosetting matrix resin containing no solvent,
A resin gun 11 for supplying the thermosetting matrix resin sent from the resin delivery unit 10 in a molten state, and a thermosetting matrix resin in the molten state supplied from the resin gun 11 to the outer peripheral surface on one side of the sheet-shaped reinforcing base material 1. A transfer roll 2 for transferring and coating, a metering roll 12 for uniformly spreading a molten thermosetting matrix resin supplied from a resin gun 11 on an outer peripheral surface of the transfer roll 2, and a sheet-like reinforcing base material 1 are transferred. A backup roll 13 pressed against the outer peripheral surface of the roll 2, and a rotation of the thermosetting matrix resin applied to one surface of the sheet-shaped reinforcing substrate 1 around the surface opposite to the coated surface of the sheet-shaped reinforcing substrate 1. Roll 3 and
A non-contact type heating unit 4 for heating and semi-curing the thermosetting matrix resin impregnated in the sheet-like reinforcing substrate 1 is provided.

The invention according to claim 15 is a rotating roll 3
Between the heating unit 4 and the heating unit 4, a pair of smoothing rolls 25 that are arranged in a stepped manner in contact with both surfaces of the sheet-shaped reinforcing base material 1 and rotated in a direction opposite to a feeding direction of the sheet-shaped reinforcing base material 1 are provided. It is characterized by comprising.

According to a sixteenth aspect of the present invention, there is provided a detecting means for detecting a coating state of the thermosetting matrix resin transferred from the transfer roll 2 and coated on the sheet-like reinforcing substrate 1. It is a feature.

According to a seventeenth aspect of the present invention, there is provided an arithmetic unit for calculating the inclination angle of the rotation axis of the metering roll 12 with respect to the rotation axis of the transfer roll 2 in accordance with the coating state detected by the detection unit. Means, and a driving means for adjusting the angle of the metering roll 12 so that the calculated inclination angle is obtained.

According to the eighteenth aspect of the present invention, the turning roll 3 is moved in a direction intersecting the feeding direction of the sheet-like reinforcing substrate 1 in accordance with the above-mentioned detecting means and the coating state detected by the detecting means. It is characterized by comprising calculating means for calculating the moving amount, and driving means for moving and adjusting the rotating roll 3 with the calculated moving amount.

The invention according to claim 19 is characterized in that the rotating roll 3
Measuring means for measuring the number of rotations and torque of the backup roll 13 and the clearance between the backup roll 13 and the transfer roll 2 and controlling the number of rotations and torque of the rotation roll 3 And a control means for controlling the rotation speed and torque value of the backup roll 13 and the clearance between the backup roll 13 and the transfer roll 2.

[0025]

Embodiments of the present invention will be described below.

FIG. 1 shows an embodiment of the first aspect of the present invention. The sheet-shaped reinforcing substrate 1 is formed into a long object made of fiber such as glass cloth, and is continuously fed in the direction of the arrow. This sheet-shaped reinforcing substrate 1
Is transferred so as to be turned around the outer periphery of the backup roll 13, and the transfer roll 2 is disposed so as to face the backup roll 13 via the sheet-shaped reinforcing base material 1. The transfer roll 2 is driven to rotate in a direction opposite to the feeding direction of the sheet-like reinforcing substrate 1 (the direction of movement of the opposing surfaces of the sheet-like reinforcing substrate 1 and the transfer roll 2 is opposite). On the outer circumference of the roll 2, a metering roll 12 that is driven to rotate in the rotation direction and the reverse direction of the transfer roll 2 (the direction of movement of the opposing surfaces of the transfer roll 2 and the metering roll 12 is opposite) is disposed. The turning roll 3 is disposed at a position on the side of the sheet-like reinforcing substrate 1 in the traveling direction from the position where the transfer roll 2 is disposed. The turning roll 3 is driven to rotate in a direction opposite to the feeding direction of the sheet-like reinforcing substrate 1 (the moving direction of the opposing surfaces of the sheet-like reinforcing substrate 1 and the turning roll 3 is in the opposite direction). Further, at a position on the traveling direction side of the sheet-like reinforcing base material 1 with respect to the position where the turning roll 3 is disposed, the heating unit 4
Is arranged. The heating unit 4 is formed, for example, so as to be able to circulate heated air therein and heat it in a non-contact manner.

As the thermosetting matrix resin, a non-solvent type epoxy resin or the like is used. A tank 20a for storing a composition (main component) containing a thermosetting resin as a main component and a hardening agent as a main component are used. A resin feed unit 10 for feeding and mixing a predetermined amount of each composition from a tank 20b for storing the composition to be measured by metering pumps 21a and 21b formed by a gear pump or the like is provided. The non-solvent type thermosetting matrix resin prepared by mixing the respective compositions as described above is supplied to the transfer roll 2 in a molten state. When the thermosetting matrix resin in the molten state is supplied to the outer peripheral surface of the transfer roll 2, the thermosetting matrix resin is uniformly spread on the outer peripheral surface of the transfer roll 2 by the metering roll 12, and
Is formed in a uniform film shape on the outer peripheral surface of.

One side of the sheet-like reinforcing substrate 1 is pressed by the backup roll 13 against the outer peripheral surface of the transfer roll 2 on which the thermosetting matrix resin in the molten state is formed into a uniform film. The thermosetting matrix resin is transferred from the transfer roll 2 to one surface of the sheet-like reinforcing substrate 1 and is uniformly applied. Since the thermosetting matrix resin applied to one surface of the sheet-like reinforcing substrate 1 is in a molten state, the thermosetting matrix resin naturally penetrates into and impregnates the sheet-like reinforcing substrate 1. Go. The application of the thermosetting matrix resin to the sheet-like reinforcing substrate 1 can be performed by the transfer with the transfer roll 2 in this manner, and it is not necessary to use a die coater as in the related art. This eliminates problems such as the case where a thermosetting matrix resin adheres to the inside.

Here, in the invention of claim 13, as the thermosetting matrix resin, a liquid bisphenol type epoxy resin such as a bisphenol A type epoxy resin and a cresol novolak type epoxy resin among the solventless type epoxy resins. A liquid mixed resin is used. The two-component mixed resin of bisphenol-type epoxy resin and cresol novolak-type epoxy resin has low melt viscosity (viscosity at 100 ° C. of conventional epoxy resin is about 1/20), and the thermosetting matrix resin is transferred as described above. 2 is transferred to the sheet-like reinforcing substrate 1 and applied, and the coating is facilitated, and the bisphenol-type epoxy resin and the cresol novolak-type epoxy resin are inexpensive as resin materials, It can be manufactured at a low material cost. In the two-part mixed resin, the mixing ratio of the bisphenol-type epoxy resin and the cresol novolak-type epoxy resin is set so that the cresol novolak-type epoxy resin is in the range of 5.0 to 15.0% by mass based on the total amount of both. Is preferred.

Next, the sheet-like reinforcing substrate 1 coated and impregnated with the thermosetting matrix resin in the molten state is continuously fed to the position of the rotating roll 3. The turning roll 3 is arranged so as to be pressed against the surface of the sheet-shaped reinforcing substrate 1 on which the thermosetting matrix resin has been applied. When passing through the outer periphery of the sheet-like reinforcing substrate 1, the molten thermosetting matrix resin applied and impregnated on the sheet-like reinforcing substrate 1 is pressed by the surrounding roll 3, and the coated surface of the sheet-like reinforcing substrate 1 is coated. It will be pushed out and turned around on the opposite side. In this way, by simply applying the thermosetting matrix resin to one surface of the sheet-shaped reinforcing substrate 1 with the transfer roll 2, the thermosetting matrix resin is uniformly applied to both surfaces of the sheet-shaped reinforcing substrate 1. It can be rotated and uniformly impregnated with a thermosetting matrix resin, and a die coater is arranged on one side and the other side of the sheet-shaped reinforcing base material 1 as in the related art, and a This eliminates the need to apply a thermosetting matrix resin. Further, the operation of applying the thermosetting matrix resin to the sheet-like reinforcing base material 1 by the transfer roll 2 and the operation of turning the thermosetting matrix resin to the opposite side of the application surface by the turning roll 3 are all performed. Since it is performed on the same one side of the sheet-like reinforcing substrate 1, the air in the sheet-like reinforcing substrate 1 does not easily escape from the other side and is not contained, thereby preventing generation of voids. is there.

The sheet-like reinforcing substrate 1 coated and impregnated with the thermosetting matrix resin in this manner is
The thermosetting matrix resin is heated while passing through the heating unit 4 in a non-contact manner, and the thermosetting matrix resin is semi-cured to the B-stage state to obtain the sheet-shaped prepreg 22. is there. This sheet-shaped prepreg 22 is sent by a transport roll 23 and wound or
Alternatively, it is cut to a certain length and sent to the next step.

FIG. 2 shows an embodiment of the second aspect of the present invention, in which the thermosetting matrix resin of the sheet-like reinforcing base material 1 is placed between the transfer roll 2 and the surrounding roll 3. A heater 5 is arranged on the side opposite to the coated surface. As the heater 5, a non-contact type heater that heats by radiant heat such as far infrared rays or blows hot air to heat is used. Other configurations are the same as those in FIG. In this device, the thermosetting matrix resin applied to the sheet-like reinforcing base material 1 by the transfer roll 2 is heated by the heater 5, and the temperature is lowered to increase the viscosity of the molten thermosetting matrix resin. The thermosetting matrix resin in the sheet-like reinforcing base material 1 promotes the penetration of the thermosetting matrix resin in a molten state into the sheet-like reinforcing base material 1 so that the thermosetting matrix resin can be kept in the sheet-like reinforcing base material 1. Can be satisfactorily impregnated. The heater 5 is adjusted so that the penetration condition of the thermosetting matrix resin in the molten state into the sheet-like reinforcing substrate 1 is optimized.
It is preferable to adjust the heating temperature by heating.

FIG. 3 shows an example of the embodiment of the third aspect of the present invention. At a position between the transfer roll 2 and the heating unit 4, a plurality of positions in the traveling direction of the sheet-like reinforcing substrate 1 are respectively provided. A turning roll 3 is arranged and provided.
Other configurations are the same as those in FIG. In this device, a thermosetting matrix resin coated and impregnated on one side of a sheet-shaped reinforcing base material 1 is respectively rotated by respective rotating rolls 3,
It can be wrapped around the surface of the sheet-shaped reinforcing substrate 1 on the side opposite to the coating surface, so that the amount of wrap around can be more finely controlled. That is, although there is a limit in the amount of rotation in one rotation roll 3, by arranging a plurality of rotation rolls 3 in this way, the amount of rotation can be supplemented, and the number of rotation rolls can be increased. By adjusting each peripheral speed among the three, the amount of rotation can be more finely controlled.

FIG. 4 shows an embodiment of the fourth aspect of the present invention, in which a surface of a sheet-like reinforcing substrate 1 coated with a thermosetting matrix resin is provided at a position facing a turning roll 3. The backup sheet 6 is arranged in contact with the surface on the opposite side to the above. The backup sheet 6 is formed endlessly with release paper or the like having releasability from the thermosetting matrix resin.
A backup sheet 6 is suspended between the base sheets 6, and the backup sheet 6 moves in the same direction at the same speed and in the same direction as the feeding of the sheet-shaped reinforcing substrate 1 while being in contact with the sheet-shaped reinforcing substrate 1. I have. Other configurations are the same as those in FIG. In this device, when a molten thermosetting matrix resin coated and impregnated on one side of the sheet-shaped reinforcing base material 1 is pressed by the surrounding roll 3 and extruded on the other side, the surface tension of the backup sheet 6 is reduced. The thermosetting matrix resin can be spread along the surface of the other one surface of the sheet-shaped reinforcing substrate 1 by utilizing And the amount of rotation can be increased.

FIG. 5 shows an example of the embodiment of the fifth aspect of the present invention. The surface of the sheet-like reinforcing substrate 1 coated with a thermosetting matrix resin at a position facing the turning roll 3. The suction device 24 is arranged on the opposite side to the above. The suction device 24 has a suction surface 24a close to and opposed to a surface of the sheet-like reinforcing substrate 1 on the side opposite to the coating surface. Other configurations are the same as those in FIG. In this case, when the suction device 24 is operated to suction from the suction surface 24a, the portion of the sheet-like reinforcing substrate 1 on the opposite side to the coating surface becomes negative pressure,
A pressure difference is generated between the coated surface of the sheet-shaped reinforcing substrate 1 and the surface opposite to the coated surface, and the coated thermosetting matrix resin is applied to one surface of the sheet-shaped reinforcing substrate 1. The sheet-like reinforcing base material 1 can easily penetrate into the opposite side of the work surface, so that the turning speed of the thermosetting matrix resin by the turning roll 3 can be increased and the turning amount can be increased. . In addition, by adjusting the suction by the suction device 24 to adjust the degree of negative pressure in the portion on the opposite side of the coated surface of the sheet-like reinforcing substrate 1 from the coating surface, the amount of rotation of the thermosetting matrix resin can be controlled. Things.

FIG. 6 shows an embodiment of the sixth aspect of the present invention, in which the rotating roll 3 is driven to rotate in the direction opposite to the feeding direction of the sheet-like reinforcing substrate 1. Other configurations are the same as those in FIG. In this way, by rotating the turning roll 3 in the reverse direction to the feeding direction of the sheet-like reinforcing substrate 1, the sheet-like reinforcing substrate 1
And the opposing surface of the turning roll 3 has the moving direction opposite to the
The molten thermosetting matrix resin applied to one surface of the sheet-like reinforcing substrate 1 is subjected to the action of being rubbed against the sheet-like reinforcing substrate 1 by the rotating roll 3. This rubbing action becomes stronger as the rotation speed (peripheral speed) of the circling roll 3 increases, and the amount of circling of the thermosetting matrix resin to the other side of the sheet-shaped reinforcing substrate 1 by the circling roll 3 is reduced. More. Therefore, by adjusting the rotation speed (peripheral speed) of the turning roll 3, the turning amount of the thermosetting matrix resin can be easily controlled.

FIG. 7 shows an example of the embodiment of the invention according to claim 7, wherein the turning roll 3 is rotated in the same direction as the feeding direction of the sheet-like reinforcing substrate 1. Other configurations are the same as those in FIG. In this way, by rotating the turning roll 3 in the same direction as the feeding direction of the sheet-like reinforcing substrate 1, the facing surfaces of the sheet-like reinforcing substrate 1 and the turning roll 3 move in the same direction, The thermosetting matrix resin in a molten state applied to one surface of the sheet-shaped reinforcing base material 1 is pushed into the sheet-shaped reinforcing base material 1 by the pressurizing action of the circling roll 3 so as to be wrapped around the other surface. Become. Accordingly, if the winding angle of the sheet-shaped reinforcing substrate 1 around the turning roll 3 is small and the contact distance is short as shown in FIG. 7A, the thermosetting matrix resin is applied to the other side of the sheet-shaped reinforcing substrate 1. When the amount of rotation is small and the winding angle of the sheet-shaped reinforcing substrate 1 around the turning roll 3 is large and the contact distance is long as shown in FIG. 7B, the other of the sheet-shaped reinforcing substrate 1 of the thermosetting matrix resin is used. By adjusting the winding angle of the sheet-like reinforcing substrate 1 around the turning roll 3 by increasing the amount of turning on one side,
The amount of the thermosetting matrix resin that can be turned around can be easily controlled.

FIG. 8 shows an embodiment of the invention according to claim 8, wherein the sheet-like reinforcing base material 1 is located at a position opposite to the feeding direction of the sheet-like reinforcing base material 1 with respect to the backup roll 13. A wiping roll 7 is disposed on the side opposite to the coating surface of the wiping sheet. The wiping roll 7 is movable between a side position of the transfer roll 2 and a lower position of the transfer roll 2. In FIG. 8, reference numeral 25 denotes a smoothing roll for smoothing the surface of the sheet-like reinforcing substrate 1. Other configurations are the same as those in FIG. In this case, at the time of normal production, the wiping roll 7 is arranged at a side position of the transfer roll 2 as shown in FIG. 8A, and is not in contact with the sheet-like reinforcing base material 1. When a temporary stop occurs due to a trouble, the thermosetting matrix resin supplied to the surface of the transfer roll 2 may be hardened and fixed on the surface of the transfer roll 2. It is necessary to wipe off the thermosetting matrix resin on the surface of the transfer roll 2, and it is necessary to wipe off the thermosetting matrix resin on the surface of the transfer roll 2 even when the type is changed. Therefore, when it becomes necessary to wipe off the thermosetting matrix resin on the surface of the transfer roll 2, the wiping roll 7 is moved to the lower position of the transfer roll 2 as shown in FIG. The sheet-like reinforcing base material 1 is wound around the outer peripheral surface of the transfer roll 2 with the sheet-like reinforcing base material 1 thus wound, and the thermosetting matrix resin on the surface of the transfer roll 2 is wiped off. To prevent the thermosetting matrix resin from sticking to the surface.

FIG. 9 shows an embodiment of the apparatus used in the invention of claim 14. In FIG. 9, reference numeral 8 denotes an unwinding unit, which is formed by providing a pair of unwinding rolls 28a and 28b around which the long sheet-shaped reinforcing substrate 1 is wound, and a sheet unreeled from one unwinding roll 28a. The reinforcing substrate 1 is fed to an accumulator unit 9. The accumulator unit 9 has a plurality of movable rolls 29, 29,.
And a sheet-like reinforcing substrate 1
Are suspended from the movable rolls 29, 29 ... so as to meander. When switching the sheet-like reinforcing substrate 1 from the one unwinding roll 28a to the other unwinding roll 28b, the accumulator unit 9 is operated to enable continuous operation of the apparatus. The backup roll 13, the transfer roll 2, the turning roll 3, the smoothing roll 25, and the heating unit 4 are arranged along the feeding direction of the sheet-shaped reinforcing base 1. Further, the resin feed unit 10 is a resin gun 1
1 so that the molten thermosetting matrix resin can be supplied from the resin gun 11 to the transfer roll 2 while being mixed. And as already mentioned,
By heating the sheet-like reinforcing substrate 1 impregnated and coated with the thermosetting matrix resin with the heating unit 4, the thermosetting matrix resin is semi-cured to the B-stage state to obtain the sheet-shaped prepreg 22. You can do it. The sheet-shaped prepreg 22 is fed by a transport roll 23, and the surface of the sheet-shaped prepreg 22 is compressed and compressed by a compaction roll 30.
The sheet-shaped prepreg 22 is wound around one winding roll 32. In addition, in addition to winding the sheet-shaped prepreg 22, a cutter unit and a stacking device are provided, the sheet-shaped prepreg 22 is cut into a predetermined fixed size by the cutter unit, and the cut fixed-size prepreg is loaded. You may make it pile up on an apparatus.

FIG. 10 shows an example of the embodiment of the invention according to claim 16, and FIG. 10 (a) shows a thermosetting resin which is transferred from the transfer roll 2 to the sheet-like reinforcing substrate 1 and coated. 3 shows an example of a detection unit that detects a coating state of a matrix resin. That is, the coating state detecting means shown in FIG. 10A includes an irradiator 35 that irradiates radiation such as X-rays,
A light receiver 36 is disposed on the optical axis to face the irradiator 35 and receives radiation emitted from the irradiator 35. Then, an irradiator 35 and a light receiver 36 are arranged on one side and the other side of the sheet-like reinforcing base material 1 coated with the thermosetting matrix resin, and the radiation irradiated from the irradiator 35 is sheet-like reinforced. The coating state of the thermosetting matrix resin can be detected by irradiating the substrate 1 and receiving the radiation transmitted through the sheet-shaped reinforcing substrate 1 with the light receiver 36 and measuring the amount of transmission. . That is,
Measure the radiation transmission distribution because the amount of radiation transmission increases in the area where the coating amount of the thermosetting matrix resin is small, and the amount of radiation transmission decreases in the area where the coating amount of the thermosetting matrix resin is large. By doing so, the coating state of the thermosetting matrix resin can be detected. FIG. 10B shows an example of a coating state of the thermosetting matrix resin detected as described above.
The coating amount is large at the center in the width direction of the sheet-shaped reinforcing base material 1,
The coating state in which the coating amount is small at both ends is shown. Also,
The transfer roller 2 is irradiated with the radiation irradiated from the irradiator 35, and the radiation transmitted through the thermosetting matrix resin and reflected on the surface of the transfer roll is received by the light receiver 36,
By measuring the amount of transmission and reflection, it is also possible to detect the coating state of the thermosetting matrix resin supplied to the surface of the transfer roll 2.

FIG. 11 shows an embodiment of the ninth and seventeenth aspects of the present invention. A metering roll 12 is disposed so as to be in close proximity to the transfer roll 2, and the metering roll 12 is connected to the transfer roll. 2 is rotated in the reverse direction (the moving direction of the opposing surfaces of the transfer roll 2 and the metering roll 12 is in the opposite direction) to meter the molten thermosetting matrix resin supplied to the surface of the transfer roll 2. The roll 12 pushes and spreads in the axial direction along the surface of the transfer roll 2, and in this state, the thermosetting matrix resin is transferred from the transfer roll 2 to one surface of the sheet-like reinforcing substrate 1 and coated. . And transfer roll 2
Rotating shaft 2a and rotating shaft 12a of metering roll 12
Are set substantially parallel to each other. In this embodiment, as shown in FIGS. 11B and 11C, the rotation axis 1a of the metering roll 12 is
2a is tilted so that the tilt angle θ, which is the angle between the rotating shafts 2a and 12a, can be adjusted.

By adjusting the inclination angle θ of the rotating shaft 12a of the metering roll 12 with respect to the rotating shaft 2a of the transfer roll 2, both ends in the axial direction between the transfer roll 2 and the metering roll 12 are adjusted. The clearance in can be adjusted. That is, when the inclination angle θ is small, the difference in the clearance between the central portion and both ends in the axial direction of the transfer roll 2 and the metering roll 12 is small, but when the inclination angle θ is large, the transfer roll 2 and the metering roll 12 The clearance at both ends in the axial direction increases, and the difference between the clearance at the center and the clearance at both ends increases. Therefore, by adjusting the inclination angle θ of the metering roll 12, the molten thermosetting matrix resin supplied to the surface of the transfer roll 2 can be spread by the metering roll 12 in the axial direction of the transfer roll 2. , Transfer roll 2
The thickness of the thermosetting matrix resin at both ends can be adjusted.

FIG. 12 shows an example of a driving means for adjusting the angle of the metering roll 12. Bearings 38 for supporting the roll shafts 37 at both ends of the metering roll 12 are individually mounted on a rack 39. is there. Each of the pair of racks 39 is engaged with a pinion 41 which is rotationally driven by a motor 40 which is independently operated. Each of the racks 39 is rotated by operating each of the motors 40 to rotate each of the pinions 41. Can be moved in its longitudinal direction. In this device, each motor 40 is operated to drive a pinion 41.
Are driven to rotate, and each rack 39 is moved in FIG.
When the metering rolls 12 are moved in opposite directions as indicated by the arrows in FIG. 12A, the metering rolls 12 are rotated in the direction indicated by the arrows in FIG. 12A. When it is moved in the direction opposite to the arrow, metering roll 1
Numeral 2 is rotated in the direction opposite to the arrow in FIG. By rotating the metering roll 12 in this manner, the angle of the metering roll 12 with respect to the transfer roll 2 can be adjusted.

Here, since the supply of the molten thermosetting matrix resin to the transfer roll 2 is performed in the central portion of the transfer roll 2 in the axial direction, the adhesion distribution of the thermosetting matrix resin on the transfer roll 2 is Is larger at the center portion in the axial direction, and tends to be smaller at both ends. The coating state of the thermosetting matrix resin transferred from the transfer roll 2 to the sheet-like reinforcing substrate 1 is shown in FIG. Easy to be like. on the other hand,
By adjusting the inclination angle θ of the metering roll 12 as described above, the molten thermosetting matrix resin supplied to the surface of the transfer roll 2 is pushed and spread in the axial direction of the transfer roll 2 by the metering roll 12. In this case, the thickness of the thermosetting matrix resin at both end portions of the transfer roll 2 can be adjusted, and when the inclination angle θ of the metering roll 12 is increased, the central portion of the surface of the transfer roll 2 in the axial direction is increased. It can be adjusted so that the adhesion amount of the thermosetting matrix resin is small and the adhesion amount of the thermosetting matrix resin at both ends is increased. Therefore, the application state of the thermosetting matrix resin which is transferred from the transfer roll 2 to the sheet-like reinforcing base material 1 is large at the center in the width direction as shown in FIG. When the inclination angle θ of the metering roll 12 is adjusted to be large when the amount is small, the amount of the thermosetting matrix resin adhered to the central portion in the axial direction of the surface of the transfer roll 2 is small, and the heat at both ends is reduced. The amount of the curable matrix resin can be adjusted so as to increase, and the transfer roll 2
The transfer and application of the thermosetting matrix resin from the substrate to the sheet-like reinforcing substrate 1 can be made uniform.

Therefore, data on how the application state of the thermosetting matrix resin in the width direction of the sheet-like reinforcing substrate 1 changes when the inclination angle θ of the metering roll 12 is changed is obtained in advance by experiments or the like. In advance, data indicating the relationship between the inclination angle θ of the metering roll 12 and the application state of the thermosetting matrix resin created based on this data is registered in an arithmetic unit such as a personal computer. Then, at the position between the transfer roll 2 and the rotation roll 3, the coating state detecting means including the light emitting device 35 and the light receiving device 36 shown in FIG. The application state of the thermosetting matrix resin is detected, and the detection result is input to the calculation means as shown in FIG. When the data of the coating state detected by the coating state detecting means is inputted to the calculating means, the data is compared with the above-mentioned registered data and calculated, and the metering roll 1 is calculated.
2 is determined. Metering roll 12
Is determined, the data is input to a control means formed by a CPU or the like as shown in FIG.
This control means controls the driving of the motor 40 which constitutes the driving means for adjusting the angle of the metering roll 12, and the motor 4 is controlled based on the data inputted to the control means.
0, the metering roll 12 is rotated to rotate the metering roll 12 at a predetermined inclination angle θ.
Is inclined.

As described above, the metering roll 1 with respect to the transfer roll 2 is determined according to the detection result of the coating state of the thermosetting matrix resin coated on the sheet-like reinforcing substrate 1.
2 can be adjusted, and the thermosetting matrix resin is applied to the sheet-like reinforcing base material 1 in a state where the thickness of the thermosetting matrix resin at the axial end and the center of the transfer roll 2 is adjusted. The resin can be uniformly transferred and coated.

FIG. 14 shows an embodiment of the invention according to claim 10 and claim 18, wherein the rotating roll 3
Can be moved and driven in a direction substantially orthogonal to and crossing the feeding direction of the sheet-shaped reinforcing substrate 1. When the rotating roll 3 is moved to the side of the sheet-like reinforcing substrate 1, FIG.
4, the pressing force of the surrounding roll 3 on the sheet-like reinforcing substrate 1 is increased, and the winding angle of the sheet-like reinforcing substrate 1 on the surrounding roll 3 is increased. When the rotating roll 3 is moved to the side opposite to the sheet-shaped reinforcing substrate 1, the sheet-shaped reinforcing substrate 1 can be turned around the rear side more, and as shown in FIG. The pressing force of the surrounding roll 3 on the reinforcing sheet 1 is reduced, and the winding angle of the sheet-like reinforcing substrate 1 on the surrounding roll 3 is reduced, so that the back surface of the sheet-shaped reinforcing substrate 1 made of a thermosetting matrix resin. It is possible to reduce the amount of rotation to the side (the surface opposite to the coating surface), and the rotation of the thermosetting matrix resin to the back surface of the sheet-like reinforcing substrate 1 by moving the rotation roll 3. Adjust the amount It is those that can.

FIG. 15 shows an example of a driving means for moving the turning roll 3, and bearings 44 for respectively supporting the roll shafts 43 at both ends of the turning roll 3 are attached to racks 45, respectively. This pair of racks 45
Is engaged with a pinion 47 which is rotationally driven by a motor 46. The racks 45 can be moved in the longitudinal direction by operating the motors 46 to rotate the pinions 47, respectively. It is. In this case, when both motors 46 are rotated in the same direction to rotate the pinions 47 in the same direction, and the respective racks 45 are respectively moved in the same direction as shown by arrows in FIG. The turning roll 3 is moved toward the sheet-like reinforcing base material 1, and when each rack 45 is moved in the direction opposite to the arrow in FIG.
The turning roll 3 is moved in a direction opposite to the arrow in FIG. In this way, the turning roll 3 can be driven to move in a direction substantially perpendicular to the feeding direction of the sheet-like reinforcing substrate 1.

Here, when the thermosetting matrix resin applied to the sheet-like reinforcing substrate 1 is applied to the back surface of the sheet-like reinforcing substrate 1 and the amount of the thermosetting matrix resin applied to the back surface is small, the above-mentioned figure is used. As shown in FIG. 14A, the turning roll 3 is moved to the side of the sheet-like reinforcing substrate 1 so as to adjust the turning amount to be large. As shown in FIG. 14B, the turning roll 3 is moved to the side opposite to the sheet-like reinforcing substrate 1 so as to adjust the turning amount to be small, so that the sheet-like reinforcing substrate 1
Can be controlled to control the amount of rotation to the rear surface, thereby making the amount of rotation uniform.

Therefore, data on how the turning state of the thermosetting matrix resin on the back surface of the sheet-like reinforcing base material 1 changes when the moving amount (and moving direction) of the turning roll 3 is changed were examined by experiments. Data indicating the relationship between the amount of movement of the turning roll 3 and the turning state created based on this data is registered in an arithmetic unit such as a personal computer. Then, a coating state detecting means is arranged at a position between the turning roll 3 and the heating unit 4, and the coating state of the thermosetting matrix resin of the sheet-like reinforcing substrate 1 at this position is detected, Reinforcement substrate 1
The state of the rotation of the thermosetting matrix resin on the back surface of is detected. In this case, the coating state detecting means is formed as a scattering thickness gauge as shown in FIG. 10 (c), and the radiation emitted from the light emitting portion 50a of the detector 50 is applied to the sheet-like reinforcing substrate 1 And the amount of radiation scattered from the sheet-shaped reinforcing substrate 1 is received and measured by the light receiving section 50b of the detector 50. Since the thickness of the thermosetting matrix resin R on the surface of the sheet-like reinforcing substrate 1 is calculated from the amount of radiation received by the light receiving unit 50b, the coating state of both surfaces of the sheet-like reinforcing substrate 1 is referred to as this coating state. By detecting the thickness of the thermosetting matrix resin R on the surface by detecting with the detecting means, it is possible to detect the rotation state of the thermosetting matrix resin. This detection result is shown in FIG.
Is input to the arithmetic means as shown in FIG. When the data of the turning state detected by the coating state detecting means is input to the calculating means, the data is compared with the registered data and the moving amount (and the moving direction) of the turning roll 3 is determined. You. When the moving amount of the turning roll 3 is determined, the data is input to a control means formed by a CPU or the like as shown in FIG. This control means controls the driving of the motor 46 which constitutes the driving means for moving the turning roll 3, and drives the motor 46 based on the data input to the control means, thereby controlling the turning roll. 3 is moved by a predetermined moving amount.

Thus, the thermosetting matrix resin on the back surface of the sheet-like reinforcing substrate 1 obtained by detecting the coating state of the thermosetting matrix resin applied to the sheet-like reinforcing substrate 1 is obtained. By adjusting the moving amount of the turning roll 3 with respect to the sheet-like reinforcing substrate 1 in accordance with the detection result of the turning state of the sheet-like reinforcing substrate 1, the turning amount is adjusted, and the sheet-like reinforcing substrate 1 is adjusted.
The uniformity of the amount of the thermosetting matrix resin applied to the back of the substrate can be made uniform.

FIG. 17 shows an example of the embodiment of the nineteenth aspect of the present invention, and shows the configuration of drive control of the turning roll 3 and the backup roll 13. Reference numeral 52 denotes a motor for rotating the rotation of the rotating roller 3, and the number of rotations and the rotating torque of the rotating roller motor 52 are detected by a sensor 53 such as a rotary encoder or a torque sensor. Reference numeral 54 denotes a motor for rotating the backup roll 13, and the number of rotations and the rotation torque of the backup roll motor 54 are detected by a sensor 55 such as a rotary encoder or a torque sensor. Reference numeral 56 denotes a motor for moving the backup roll 13 in the direction of approaching / separating from the transfer roll 2 to operate a means for adjusting the clearance between the transfer roll 2 and the backup roll 13, and 57 denotes a motor for transferring the backup roll 2 and the backup roll 13. This is a gap sensor for measuring the clearance between the gaps 13. The rotating roller motor 52 and the backup roller motor 54 are driven to rotate by controlling the number of rotations by motor drivers 58 and 59, respectively.
Numeral 6 is controlled by a motor driver 60 to be rotationally driven. The data of the number of revolutions, the rotation torque and the clearance measured by the measuring means including the sensors 53 and 55 and the gap sensor 57 are inputted to the calculating means 61 formed by a personal computer or the like. Calculation means 61 according to the data
Motor drivers 58, 59, 60 based on commands from
Is activated.

FIG. 18 shows a means for measuring the clearance between the transfer roll 2 and the backup roll 13. The transfer roll 2 and the backup roll 13 are supported on the same rail 62, and the backup roll 13 has a guide shaft 64 having its roll shaft 63 provided on the rail 62.
And is movable along the guide slot 64. The backup roll 13 is moved and driven by a mechanism having a configuration similar to that of FIG.
By operating the clearance motor 56,
The backup roll 13 can be moved along the guide slot 64 in a direction approaching or separating from the transfer roll 2. The gap sensor 57 is attached to the roll shaft 63, and the gap sensor 57 is opposed to a sensor dog 65 provided on the rail 62 at a position lateral to the transfer roll 2. Backup roll 13
By detecting the gap between the sensor dog 65 and the gap sensor 57 when moving the transfer roller 2 in the direction of moving toward and away from the transfer roll 2, the clearance between the transfer roll 2 and the backup roll 13 can be measured. Things. That is, the gap between the gap sensor 57 and the sensor dog 65 is detected by a method using ultrasonic waves or the like, but since the gap sensor 57 moves integrally with the backup roll 13, the clearance between the backup roll 13 and the transfer roll 2 is zero. The clearance between the transfer roll 2 and the backup roll 13 is measured by detecting the gap between the sensor dog 65 and the gap sensor 57 by adjusting the gap between the gap sensor 57 and the sensor dog 65 to zero at times. You can do it.

The turning roll 3 shown in FIG.
And the drive control mechanism of the backup roll 13, the rotation speed and the torque of the turning roll 3 and the backup roll 13 are constantly measured by the sensors 53 and 55, and the measured data is input to the calculating means 61. ing.
The clearance between the transfer roll 2 and the backup roll 13 is always measured by the gap sensor 57, and the measured data is input to the calculating means 61. When the measurement data of the rotation speed, the torque, and the clearance are input to the calculating means 61 in this way, the data is compared with the data of the optimum rotation speed, the optimum torque and the optimum clearance preset in the calculating means 61, and the optimum rotation speed is obtained. The command value calculated so as to obtain the torque, the clearance, and the like is calculated by the calculating means 6.
1 to the motor drivers 58, 59, 60.
That is, a command value is output to the motor drivers 58 and 59 so as to rotate the rotating roll motor 52 and the backup roll motor 54 at a predetermined number of rotations, and the motor driver 60 moves the backup roll 13 by a predetermined amount. A command value is output to rotate the clearance motor 56 at the rotation speed. In this way, even if the rotation speed and the torque of the turning roll 3 and the backup roll 13 and the clearance between the transfer roll 2 and the backup roll 13 change in accordance with the aging of the process, these are measured by the measuring means. In accordance with the measurement result, the control means can automatically adjust the number of rotations of the turning roll 3 and the backup roll 13 and the clearance between the transfer roll 2 and the backup roll 13, and always keep the coating conditions to be optimal, Defective loss at the time of construction can be suppressed.

FIG. 19 is a flow chart showing an example of the embodiment of the present invention. In this embodiment, as in the case of FIG. 17 described above, the measuring device including the sensor 55 and the gap sensor 57
And the clearance between the transfer roll 2 and the backup roll 13 is measured. In addition, the setting data of the optimum rotation speed of the backup roll 13, the setting data of the optimum torque, and the setting data of the optimum clearance between the transfer roll 2 and the backup roll 13 are input to the arithmetic means 61 in advance.

Then, the rotation speed and torque of the backup roll 13 and the clearance between the transfer roll 2 and the backup roll 13 are measured for a certain period of time. Is made. That is, the measured value M of the measured rotation speed
And the set value Mr of the number of rotations are compared, and twice the difference is
The rotation of the backup roll 13 is determined to be normal when the rotation width of the backup roll 13 is not larger than the preset rotation width Mw, and abnormal when the rotation of the backup roll 13 is larger than the preset rotation width Mw. And the rotation speed abnormality flag is output ON. Further, the measured value T of the measured torque is compared with the set value Tr of the torque, and when twice the difference is not larger than the preset torque variation Tw, the rotation of the backup roll 13 is normal. When it is determined that the torque variation width Tw is larger than the preset torque variation width Tw, it is determined that the rotation of the backup roll 13 is abnormal, and the torque abnormality flag is output ON. Furthermore, the measured value G of the measured clearance and the set value G of the clearance
r is calculated and the difference is determined to be normal when twice the difference is not larger than the preset clearance variation width Gw, and when the difference is larger than the preset clearance variation width Gw, the clearance is determined to be normal. Is determined to be abnormal, and the clearance abnormality flag is output ON. After determining whether the rotation speed, torque, and clearance are normal or abnormal, if the number of the abnormality flags is 0 or 1, it is determined that the backup roll 13 has no abnormality. If the number of error flags is 2 or more, the backup roll 1
It is determined that an abnormality such as the sheet-shaped reinforcing base material 1 has been caught in 3 has occurred, and the abnormality is detected.

FIG. 20 is a flowchart showing another example of the eleventh embodiment of the present invention. In this embodiment, the number of rotations and torque of the turning roll 3 are measured by the measuring means including the sensor 53 in the same manner as in FIG. 17 described above. In addition, the setting data of the optimum rotation speed and the setting data of the optimum torque of the turning roll 3 are input to the calculating means 61 in advance.

Then, the rotation speed and the torque of the rotating roll 3 are measured for a certain period of time, and the measured data are used as the calculation means 61.
, A comparison operation is performed with the above setting data. That is, the measured value M of the measured rotation speed is compared with the set value Mr of the rotation speed, and when the difference is not larger than twice the variation width Mw of the preset rotation speed,
When it is determined that the rotation of the rotation roll 3 is normal, and the rotation width is larger than a predetermined variation width Mw of the rotation speed,
It is determined that the rotation of the turning roll 3 is abnormal, and the rotational speed abnormality flag is output ON. Further, the measured value T of the measured torque is compared with the set value Tr of the torque, and the difference between the measured value T and the set value Tr of the torque is calculated.
When the double is not larger than the preset torque variation width Tw, the rotation of the turning roll 3 is determined to be normal. When the double is larger than the preset torque variation Tw, the rotation of the turning roll 3 is determined. Is determined to be abnormal, and the torque abnormality flag is output ON. After determining whether the rotation speed and the torque are normal or abnormal, if the number of the abnormality flags is 0 or 1, it is determined that there is no abnormality in the turning roll 3. If the number of abnormality flags is two, it is determined that an abnormality such as the sheet-like reinforcing base material 1 or foreign matter has been involved in the turning roll 3, and an abnormality is detected.

As described above, the backup roll 1
It is possible to automatically detect line abnormalities, such as abnormalities in biting 3 and entrainment in the rotating roll 3, and to monitor them remotely, so that prompt measures can be taken against line abnormalities. Is possible. In addition, normality or abnormality is determined based on a plurality of pieces of information, and abnormality detection is performed by performing a plurality of abnormality determinations, so that erroneous detection is reduced.

FIG. 21 shows an example of the embodiment of the twelfth aspect of the present invention. As in the embodiment of FIG. 19, the sheet-shaped reinforcing substrate 1 and foreign matter are caught in the backup roll 13. Is detected, the operation of the backup roll motor 54 is first controlled to control the backup roll 1.
3, the backup roll 13 is moved in a direction away from the transfer roll 2 by operation control of the clearance motor 56, and the clearance between the transfer roll 2 and the backup roll 13 is changed to a sheet-like material such as a glass cloth. After making the thickness sufficiently larger than the thickness of the reinforcing base material 1 and a predetermined time has passed, the backup roll 1
The number of rotations is returned to the original set value, and the backup roll 13 is moved in a direction approaching the transfer roll 2 to return the clearance to the original set value, thereby returning to the normal operation. When the rotation of the backup roll 13 is stopped and the clearance between the transfer roll 2 and the backup roll 13 is widened for a certain period of time, the sheet-shaped reinforcing base material 1 is also fed during this time. Then, the sheet-like reinforcing substrate 1 biting into the backup roll 13 is automatically disengaged from the backup roll 13 and the biting is released. Therefore, it is possible to quickly and automatically return to the steady state without stopping the line, thereby minimizing defective loss.

FIG. 22 shows another example of the embodiment of the twelfth aspect of the present invention. As in the embodiment of FIG. When it is detected that the rotation has been performed, first, the turning roll 3 is slowly rotated in the reverse direction by the operation control of the turning roll motor 52, and after a predetermined time has elapsed,
The rotation direction and the number of rotations of the turning roll 3 are returned to the original set values, and the operation returns to the normal operation. When a certain period of time elapses while the turning roll 3 is rotated in the reverse direction, the sheet-like reinforcing base material 1 is fed during this time, so that the sheet-shaped reinforcement wound around the turning roll 3 is rotated. The base material 1 is automatically released from the surrounding roll 3, and the entrainment is released. Therefore, without stopping the line,
The automatic return to the steady state can be promptly performed, and the failure loss can be minimized.

FIG. 23 shows an embodiment of the invention according to claim 15, in which a pair of smoothing rolls 25 are arranged between the turning roll 3 and the heating unit 4. The pair of smoothing rolls 25 are arranged in contact with both surfaces of the sheet-shaped reinforcing base material 1, and one smoothing roll 25 is close to the turning roll 3 and the other smoothing roll 25 is connected to the turning roll 3.
It is arranged unevenly so as to be farther than it is. Each smoothing roll 25 is driven to rotate in a direction opposite to the feeding direction of the sheet-like reinforcing substrate 1 (the direction of movement of the opposing surfaces of the sheet-like reinforcing substrate 1 and the smoothing roll 25 is in the opposite direction). After the thermosetting matrix resin is coated on one side of the sheet-like reinforcing base material 1 and circulated to the opposite side to the coating side by the circling roll 3, the thermosetting matrix on the surface of the sheet-like reinforcing base material 1 is formed. Although the resin is uneven, the pair of smoothing rolls 25 are brought into contact with both surfaces of the sheet-like reinforcing substrate 1 and rotated in a direction opposite to the feeding direction of the sheet-like reinforcing substrate 1 in this manner. The surface of the thermosetting matrix resin is leveled by the smoothing roll 25 so that the sheet-like reinforcing substrate 1 can be uniformly impregnated with the thermosetting matrix resin.

[0063]

As described above, in the method for producing a prepreg according to the first aspect of the present invention, a thermosetting matrix resin is coated and impregnated while continuously feeding a long sheet-like reinforcing substrate made of fibers. In the continuous production of prepregs by transferring, a thermosetting matrix resin containing no solvent formed in a film form on the surface of the transfer roll is transferred from the transfer roll to one side of the sheet-like reinforcing base material in a molten state. After coating, the thermosetting matrix resin is impregnated into the sheet-shaped reinforcing base material, and then a rotating roll disposed on the side of the sheet-shaped reinforcing base material coated with the thermosetting matrix resin is used for sheet-shaped reinforcement. A sheet-like reinforcing substrate coated with and impregnated with the thermosetting matrix resin by pressing the thermosetting matrix resin on one side of the substrate and rotating the thermosetting matrix resin on the opposite side of the coated surface of the sheet-shaped reinforcing substrate. The non Since the thermosetting matrix resin is semi-cured by heating with a tactile heating unit, the thermosetting matrix resin can be applied to the sheet-like reinforcing substrate by transfer using a transfer roll. As described above, it is possible to eliminate the need for labor for cleaning and maintenance as in the case of using a die coater, and it is possible to manufacture at a low equipment cost by using a transfer roll which is cheaper than a die coater. The thermosetting matrix resin applied to and impregnated on the sheet-shaped reinforcing substrate can also be turned around the surface opposite to the coating surface by a rotating roll. By applying a thermosetting matrix resin at the same time and pressing a surrounding roll, the curable matrix resin can be impregnated on both sides and inside of the sheet-like reinforcing substrate, and the sheet-like reinforcing substrate There is no need to arrange a die coater on one side and the other side, and to apply a thermosetting matrix resin on each side, so that equipment costs can be further reduced and a sheet-shaped reinforcing substrate The air inside is not easily escaped from one side of the other and is not contained, so that the generation of voids can be prevented.

The invention according to claim 2 further comprises a heater for heating the thermosetting matrix resin applied to and impregnated on the sheet-like reinforcing substrate, in a non-contact manner on the side opposite to the coating surface of the sheet-like reinforcing substrate. Since it is arranged, it is possible to keep the temperature of the thermosetting matrix resin in a molten state by heating with a heater so as to keep the viscosity of the thermosetting matrix resin in a low state. It promotes penetration and allows the thermosetting matrix resin to be favorably impregnated in the sheet-like reinforcing substrate.

According to the third aspect of the present invention, the circling rolls are arranged at a plurality of positions along the feeding direction of the sheet-shaped reinforcing substrate, so that one side of the sheet-shaped reinforcing substrate is coated and impregnated. The thermosetting matrix resin can be wrapped around the surface opposite to the coated surface of the sheet-shaped reinforcing base material by a plurality of wrapping rolls, and the wrapping amount can be more finely controlled. It becomes possible.

Further, according to a fourth aspect of the present invention, there is provided a backup having releasability from a thermosetting matrix resin by contacting a surface opposite to a coating surface of a sheet-like reinforcing substrate opposite to a rotating roll. Since the sheet is arranged, the thermosetting matrix resin can be spread along the surface of the other side of the sheet-like reinforcing base material using the surface tension of the backup sheet, and the thermosetting matrix resin can be used. Can be evenly wrapped around the other surface of the sheet-shaped reinforcing substrate, and the amount of wrap around can be increased.

In the invention according to claim 5, the negative pressure is applied to the opposite side of the coated surface of the sheet-shaped reinforcing substrate from the coating surface, so that the coated surface of the sheet-shaped reinforcing substrate and the surface opposite to the coated surface. Pressure difference between the sheet-like reinforcing base material and the thermosetting matrix resin applied to one side of the sheet-like reinforcing base material easily penetrates the sheet-like reinforcing base material to the opposite side to the coating surface, and the heat generated by the surrounding rolls This makes it possible to increase the rotation speed of the curable matrix resin and increase the rotation amount.

According to a sixth aspect of the present invention, the rotating roll is rotated in a direction opposite to the feeding direction of the sheet-like reinforcing base material, so that the thermosetting matrix applied to one surface of the sheet-like reinforcing base material is applied. The resin is subjected to the action of being rubbed against the sheet-like reinforcing base material by the surrounding roll, and by adjusting the rotation speed of the surrounding roll, the amount of the thermosetting matrix resin around can be easily controlled. Things.

According to the seventh aspect of the present invention, the turning roll is rotated in the same direction as the feeding direction of the sheet-like reinforcing substrate, so that the winding angle of the sheet-like reinforcing substrate with respect to the turning roll is adjusted. Thus, the amount of the thermosetting matrix resin can be easily controlled.

Further, in the invention of claim 8, since the wiping roll for moving the sheet-like reinforcing substrate is provided so as to wind the sheet-like reinforcing substrate around the outer peripheral surface of the transfer roll, the outer peripheral surface of the transfer roll is provided by the wiping roll. The thermosetting matrix resin on the surface of the transfer roll can be wiped off by the sheet-like reinforcing base material wound around the surface, and the thermosetting matrix resin is applied to the surface of the transfer roll when the transfer roll temporarily stops. This can prevent the matrix resin from sticking.

According to a ninth aspect of the present invention, a metering roll is arranged to face a transfer roll, and the molten thermosetting matrix resin supplied to the surface of the transfer roll is spread by the metering roll. When transferring from the transfer roll to one side of the sheet-shaped reinforcing substrate and applying it,
Detects the coating state of the thermosetting matrix resin applied to the sheet-shaped reinforcing substrate and calculates the inclination angle of the metering roll rotation axis with respect to the transfer roll rotation axis according to the detected coating state. Then, since the angle of the metering roll is adjusted to be the calculated inclination angle, by adjusting the inclination angle of the rotation axis of the metering roll with respect to the transfer roll, the end of the transfer roll in the axial direction can be adjusted. The thickness of the thermosetting matrix resin at the center and the center can be adjusted, and the inclination angle of the metering roll is adjusted according to the coating state of the thermosetting matrix resin applied to the sheet-like reinforcing base material. Thus, the thermosetting matrix resin can be uniformly applied to the sheet-like reinforcing base material.

The invention according to claim 10 is to detect the coating state of the thermosetting matrix resin applied to the sheet-like reinforcing base material and to determine the coating state of the sheet-like reinforcing base material according to the detected coating state. The movement amount of the turning roll in the direction crossing the feed direction is calculated, and the moving amount of the turning roll is adjusted based on the calculated movement amount. The thermosetting matrix resin applied to the sheet-like reinforcing base material can adjust the pressing force of the surrounding roll on the reinforcing base material and the length of winding of the sheet-like reinforcing base material around the surrounding roll. By adjusting the amount of movement of the turning roll according to the coating state, it is possible to control the turning of the thermosetting matrix resin on the side opposite to the coating surface of the sheet-like reinforcing substrate.

According to the eleventh aspect of the present invention, the rotation speed and torque value of the roll are measured, and the measured rotation speed and torque value are compared with predetermined rotation speed and torque values to determine whether the roll is normal or abnormal. In addition, since the abnormality is detected at the same time, the abnormality of the line can be automatically detected and monitored remotely, and the abnormality can be promptly dealt with.

According to the twelfth aspect of the present invention, when an abnormality of the roll is detected, the rotation of the roll is stopped or reversely rotated. Even if the rotation of the roll is stopped or reversed, it is possible to automatically return to a steady state without stopping the line and eliminating abnormalities such as biting, thereby minimizing failure loss. It can be kept to a minimum.

According to a thirteenth aspect of the present invention, a two-component mixed resin of a bisphenol type epoxy resin and a cresol novolak type epoxy resin is used as the thermosetting matrix resin. The mixed resin has a low melt viscosity and can be easily applied when the thermosetting matrix resin is transferred from the transfer roll to the sheet-like reinforcing base material and applied.

A prepreg manufacturing apparatus according to claim 14 of the present invention comprises an unwinding unit for continuously feeding out a long sheet-like reinforcing substrate made of fiber, and an accumulator which is operated when the sheet-like reinforcing substrate is switched. A unit, a resin delivery unit that mixes a main component and a curing agent and sends out a thermosetting matrix resin containing no solvent, a resin gun that supplies the thermosetting matrix resin sent from the resin delivery unit in a molten state, and an outer peripheral surface A transfer roll for transferring and applying a molten thermosetting matrix resin supplied from a resin gun to one side of a sheet-like reinforcing substrate, and a molten thermosetting resin supplied from a resin gun to the outer peripheral surface of the transfer roll A metering roll that spreads the matrix resin evenly, and a backup that presses the sheet-shaped reinforcing substrate against the outer peripheral surface of the transfer roll A roll, a circling roll for applying a thermosetting matrix resin coated on one side of the sheet-shaped reinforcing base material to a surface opposite to the coated surface of the sheet-shaped reinforcing base material, and impregnated into the sheet-shaped reinforcing base material. A non-contact type heating unit for heating the thermosetting matrix resin to semi-curing by heating is provided, so that the prepreg as described above can be manufactured.

According to a fifteenth aspect of the present invention, between the rotating roll and the heating unit, the sheet-like reinforcing substrate is arranged in a stepwise manner in contact with both surfaces of the sheet-like reinforcing substrate, and is arranged in a direction opposite to the feeding direction of the sheet-like reinforcing substrate. Since a pair of rotating smoothing rolls is provided, the surface of the thermosetting matrix resin applied to the sheet-like reinforcing base material can be leveled by the smoothing roll, and the thermosetting matrix resin of the sheet-like reinforcing base material can be used. Can even out the surface condition.

Further, the invention of claim 16 is provided with a detecting means for detecting the coating state of the thermosetting matrix resin transferred from the transfer roll and coated on the sheet-like reinforcing base material. The coating state of the thermosetting matrix resin to the material can be monitored in real time, and it is possible to quickly cope with a change in the coating state.

According to a seventeenth aspect of the present invention, the inclination angle of the rotation axis of the metering roll with respect to the rotation axis of the transfer roll is calculated in accordance with the detection means of the sixteenth aspect and the coating state detected by the detection means. And a driving means for adjusting the angle of the metering roll so that the calculated inclination angle is obtained. By adjusting the inclination angle of the rotation axis of the metering roll with respect to the transfer roll by the driving means, the transfer is performed. It is capable of adjusting the thickness of the thermosetting matrix resin at the axial end and the center of the roll, and detects the coating state of the thermosetting matrix resin applied to the sheet-like reinforcing substrate. By adjusting the inclination angle of the metering roll according to the result, the thermosetting matrix resin can be uniformly applied to the sheet-like reinforcing substrate.

According to the eighteenth aspect of the present invention, there is provided a detecting means according to the sixteenth aspect, wherein the circling roll is rotated in a direction intersecting the feeding direction of the sheet-like reinforcing base material in accordance with the coating state detected by the detecting means. A sheet-like reinforcing base material is provided by calculating means for calculating a moving amount to be moved and driving means for moving and adjusting the rotating roll with the calculated moving amount. It is possible to adjust the pressing force of the surrounding roll and the length of winding of the sheet-like reinforcing substrate around the periphery of the surrounding roll, and to apply the thermosetting matrix resin applied to the sheet-like reinforcing substrate. By adjusting the amount of movement of the turning roll according to the result of detection of the state, it is possible to control the turning of the thermosetting matrix resin on the side opposite to the coated surface of the sheet-like reinforcing substrate.

The invention according to claim 19 is a measuring means for measuring the number of revolutions and torque value of the turning roll and measuring the number of revolutions and torque value of the backup roll and the clearance between the backup roll and the transfer roll. Control means for controlling the rotation speed and torque value of the rotating roll and the rotation speed and torque value of the backup roll and the clearance between the backup roll and the transfer roll are provided. While the line can be operated, the coating conditions can always be kept optimal and the loss of defects can be suppressed.

[Brief description of the drawings]

FIG. 1 is a schematic diagram showing an example of an embodiment of the present invention.

FIG. 2 is a schematic diagram showing an example of an embodiment of the invention according to claim 2;

FIG. 3 is a schematic diagram showing an example of an embodiment of the invention according to claim 3;

FIG. 4 is a schematic diagram showing an example of an embodiment of the invention according to claim 4;

FIG. 5 is a schematic diagram showing an example of the embodiment of the invention according to claim 5;

FIG. 6 is a schematic diagram showing an example of the embodiment of the invention according to claim 6;

FIG. 7 is a schematic diagram showing an example of the embodiment of the invention according to claim 7;

8 shows an example of the embodiment of the invention according to claim 8, wherein (a) and (b) are schematic diagrams, respectively. FIG.

FIG. 9 is a schematic diagram showing an example of the embodiment of the invention according to claim 14;

FIG. 10 shows an example of the embodiment of the invention according to claim 16, wherein (a) is a schematic diagram showing an example of a detecting means for detecting a coating state of a thermosetting matrix resin, and (b) is a schematic view showing an example of the detecting means. FIG. 7C is a diagram illustrating an example of a detection result, and FIG. 7C is a schematic diagram illustrating another example of a detection unit that detects a coating state of a thermosetting matrix resin.

11 shows an example of an embodiment of the invention according to claims 9 and 17, wherein (a) is a schematic front view and (b)
And (c) is a schematic plan view.

FIGS. 12A and 12B show the angle adjusting drive means of the metering roll of the above, wherein FIG. 12A is a schematic plan view and FIG. 12B is a schematic front view.

FIG. 13 is a block diagram showing an operation of the above.

FIG. 14 is a schematic diagram showing an example of the embodiment of the invention according to claims 10 and 18;

FIGS. 15A and 15B show the above-mentioned turning roll moving drive means, wherein FIG. 15A is a schematic plan view and FIG. 15B is a schematic front view.

FIG. 16 is a block diagram showing the operation of the above.

FIG. 17 is a schematic diagram showing an example of the embodiment of the nineteenth invention.

FIG. 18 is a schematic view of a clearance measuring unit according to the third embodiment.

FIG. 19 is a flowchart showing an example of the embodiment of the invention according to claim 11;

FIG. 20 is a flowchart showing another example of the embodiment of the eleventh invention.

FIG. 21 is a flowchart showing an example of the embodiment of the invention according to claim 12;

FIG. 22 is a flowchart showing another example of the embodiment of the twelfth invention.

FIG. 23 is a schematic diagram showing an example of the embodiment of the invention according to claim 15;

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 sheet-like reinforcing substrate 2 transfer roll 3 rotating roll 4 heating unit 5 heater 6 backup sheet 7 wiping roll 8 unwinding unit 9 accumulator unit 10 resin feeding unit 11 resin gun 12 metering roll 13 backup roll

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Hiroshi Harada 1048 Kazuma Kadoma, Kadoma City, Osaka Prefecture Matsushita Electric Works, Ltd. (72) Inventor Matsu ▲ Saki ▼ Yoshinori Matsushita Electric Works Co., Ltd., 1048 Kadoma, Kadoma, Osaka Prefecture (72) Inventor Hiroyuki Mori 1048 Kadoma, Kazuma, Kadoma, Osaka Prefecture

Claims (19)

[Claims] 1. A method for continuously producing a prepreg by coating and impregnating a thermosetting matrix resin while continuously feeding a long sheet-like reinforcing substrate made of fibers, a film is formed on a surface of a transfer roll. The solvent-free thermosetting matrix resin formed in a shape is transferred from a transfer roll to one side of a sheet-shaped reinforcing base material in a molten state and coated, and the thermosetting matrix resin is impregnated into the sheet-shaped reinforcing base material. Then, a rotating roll disposed on the side of the sheet-shaped reinforcing base material coated with the thermosetting matrix resin is pressed against one surface of the sheet-shaped reinforcing base material, so that the thermosetting matrix resin is applied to the sheet-shaped reinforcing base material. After that, the sheet-like reinforcing base material coated and impregnated with the thermosetting matrix resin is heated by a non-contact type heating unit to reduce the thermosetting matrix resin to a half. A method for producing a prepreg, which is cured. 2. A heater for heating a thermosetting matrix resin applied to and impregnated on a sheet-like reinforcing base material is provided in a non-contact manner on a side opposite to a coating surface of the sheet-like reinforcing base material. The method for producing a prepreg according to claim 1. 3. The method for producing a prepreg according to claim 1, wherein circling rolls are arranged at a plurality of positions along a feeding direction of the sheet-shaped reinforcing base material. 4. A method of disposing a backup sheet having releasability from a thermosetting matrix resin by contacting a surface opposite to a coating surface of a sheet-like reinforcing substrate opposite to a turning roll. A method for producing a prepreg according to any one of claims 1 to 3. 5. The method for producing a prepreg according to claim 1, wherein an air negative pressure is applied to a side of the sheet-like reinforcing substrate opposite to a coating surface. 6. The method for producing a prepreg according to claim 1, wherein the rotating roll is rotated in a direction opposite to a feeding direction of the sheet-shaped reinforcing base material. 7. The method for producing a prepreg according to claim 1, wherein the rotating roll is rotated in the same direction as the feeding direction of the sheet-like reinforcing base material. 8. A wiping roll for moving the sheet-like reinforcing substrate so as to wind the sheet-like reinforcing substrate around the outer peripheral surface of the transfer roll.
The method for producing a prepreg according to any one of the above. 9. A sheet-like reinforcement from a transfer roll in a state where a metering roll is arranged opposite to the transfer roll and the thermosetting matrix resin in a molten state supplied to the surface of the transfer roll is spread by the metering roll. When transferring and applying to one side of the substrate, the application state of the thermosetting matrix resin applied to the sheet-like reinforcing substrate is detected, and the rotation of the transfer roll is performed according to the detected application state. The prepreg according to any one of claims 1 to 8, wherein an inclination angle of the rotation axis of the metering roll with respect to the axis is calculated, and the angle of the metering roll is adjusted so as to have the calculated inclination angle. Method. 10. A direction intersecting with a feeding direction of the sheet-like reinforcing base material according to the detected coating state while detecting a coating state of the thermosetting matrix resin applied to the sheet-like reinforcing base material. The method for producing a prepreg according to any one of claims 1 to 9, wherein a moving amount for moving the turning roll is calculated, and the moving of the turning roll is adjusted based on the calculated moving amount. 11. A method for measuring the number of revolutions and torque value of a roll,
11. The apparatus according to claim 1, wherein the measured rotation speed or torque value is compared with a preset rotation speed or torque value to determine whether the rotation speed is normal or abnormal, and to detect an abnormality. Method for producing prepreg. 12. The method for producing a prepreg according to claim 11, wherein when the abnormality of the roll is detected, the rotation of the roll is stopped or reversely rotated. 13. The resin according to claim 1, wherein the thermosetting matrix resin is a two-component mixed resin of a bisphenol type epoxy resin and a cresol novolak type epoxy resin.
13. The method for producing a prepreg according to any one of claims 12 to 12. 14. An unwinding unit for continuously feeding out a long sheet-like reinforcing substrate made of fibers, an accumulator unit that is operated when switching between sheet-like reinforcing substrates, and mixing a main agent and a curing agent to form a solvent. A resin delivery unit that sends out a thermosetting matrix resin that does not contain, a resin gun that supplies the thermosetting matrix resin sent from the resin sending unit in a molten state, and a thermosetting resin that is supplied from the resin gun to the outer peripheral surface in a molten state A transfer roll for transferring and applying the matrix resin to one side of the sheet-shaped reinforcing base material, a metering roll for uniformly spreading the molten thermosetting matrix resin supplied from the resin gun on the outer peripheral surface of the transfer roll, and a sheet. Roll that presses the sheet-shaped reinforcing substrate against the outer peripheral surface of the transfer roll, and is coated on one side of the sheet-shaped reinforcing substrate A non-contact, which rotates the thermosetting matrix resin around the surface opposite to the coated surface of the sheet-like reinforcing substrate, and heats and semi-cures the thermosetting matrix resin impregnated in the sheet-like reinforcing substrate An apparatus for manufacturing a prepreg, comprising: a heating unit of a prepreg type. 15. A pair of smoothing disposed between the rotating roll and the heating unit so as to be in contact with both surfaces of the sheet-shaped reinforcing base material and to be stepped and rotated in a direction opposite to the feeding direction of the sheet-shaped reinforcing base material. The prepreg manufacturing apparatus according to claim 14, further comprising a roll. 16. A detecting means for detecting a coating state of a thermosetting matrix resin transferred from a transfer roll and coated on a sheet-like reinforcing base material, wherein the detecting means detects a coating state of the thermosetting matrix resin. 3. The prepreg manufacturing apparatus according to claim 1. 17. A detecting means according to claim 16, and a calculating means for calculating an inclination angle of a rotation axis of a metering roll with respect to a rotation axis of a transfer roll according to a coating state detected by the detecting means. 17. The prepreg manufacturing apparatus according to claim 16, further comprising a driving unit that adjusts the angle of the metering roll so that the inclination angle is adjusted to a predetermined angle. 18. A moving amount for moving a rotating roll in a direction intersecting with a feeding direction of a sheet-like reinforcing substrate according to the detecting means according to claim 16 and a coating state detected by the detecting means. 18. The prepreg manufacturing apparatus according to claim 16, further comprising: an operation unit that performs the operation, and a driving unit that moves and adjusts the turning roll by the calculated amount of movement. 19. The rotational speed and torque value of the follow-up roll are measured, and the rotational speed and torque value of the backup roll are measured.
Measuring means for measuring the clearance between the backup roll and the transfer roll, and controlling the rotation speed and the torque value of the rotating roll and controlling the rotation speed and the torque value of the backup roll, and the clearance between the backup roll and the transfer roll. 19. The prepreg manufacturing apparatus according to claim 14, further comprising a control unit.