JP2001277239A - Manufacturing method for prepreg, prepreg, and manufacturing device for prepreg - Google Patents

Abstract

PROBLEM TO BE SOLVED: To smoothly peel a mold release paper when the mold release paper bonded to one surface of a prepreg is peeled after a carrier resin is transferred and infiltrated into a reinforcing fiber bundle, and at the same time, prevent a coating agent applied on the surface of the mold release paper from being transferred to the prepreg, or prevent the resin of the prepreg from transferring to the mold release paper. SOLUTION: On the downstream side of a hot zone wherein the carrier resin is transferred and infiltrated in the reinforcing fiber bundle, a cooling air-jetting nozzle 42, which jets air at a room temperature or higher, and a chilled plate 43 are arranged in parallel. Then, the cooling and a positive radiation of the prepreg 50 which comes out from the hot zone are accelerated by these cooling means.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a prepreg manufacturing method, a prepreg manufactured by the manufacturing method, and a prepreg manufacturing apparatus for performing the above-described prepreg manufacturing method.

[0002]

2. Description of the Related Art For example, Japanese Patent Publication No. 4-60009 discloses that a resin-supporting sheet is superposed on both sides of a sheet-like reinforcing fiber bundle, and the superposed body is heated by impregnating rolls provided in multiple stages in the transport direction. A method for producing a prepreg in which a resin is transferred and impregnated into a reinforcing fiber by applying pressure is disclosed. The prepreg manufactured by such a method is composed of, for example, an epoxy resin in which a supported resin, that is, a matrix resin is in a semi-cured state, and is molded using such a prepreg, thereby forming a fiber-reinforced resin of various shapes. Things are obtained.

[0003] In the production process of a prepreg, which is an intermediate raw material for molding such a fiber-reinforced resin molded article, as disclosed in Japanese Patent Publication No. 4-60009, the prepreg is heated and pressed by an impregnating roll. After the resin is transferred and impregnated into the reinforcing fibers, one of, for example, the release paper on the upper side is to be peeled off, and the prepreg is to be wound into a roll with the release paper attached to only one side. I have. That is, the prepreg is supplied with release paper attached to one surface thereof.

[0004]

In such a conventional prepreg manufacturing method, one release paper, which is particularly peeled off, is formed immediately after leaving the hot zone in which the resin is transferred and impregnated into the reinforcing fiber bundle. However, at this time, there is a problem that the temperature of the prepreg is quite high and the release paper cannot always be peeled off properly.

[0005] A coating agent is originally applied to the release surface of the release paper, but when the release paper is released from the prepreg after leaving the hot zone, the coating agent on the surface of the release paper adheres to the prepreg side. Will be transcribed. Such coatings are not inherently required by prepreg. If such a coating agent remains on the prepreg, it causes a decrease in physical properties such as strength of a molded product formed by the prepreg.

Further, when the release paper is peeled from the prepreg immediately after leaving the hot zone and the temperature of the prepreg is still high, the resin of the prepreg is transferred to the release paper in a mottled state. That is, the resin that should originally remain on the prepreg side adheres to the release paper in a mottled shape, thereby deteriorating the surface properties of the prepreg,
Alternatively, it may cause the surface smoothness to deteriorate.

[0007] The present invention has been made in view of the above problems, and in particular, when the release paper is peeled after the supporting resin is transferred and impregnated into the reinforcing fiber bundle, the surface of the release paper is coated. The prepreg is designed to prevent the coating agent from being transferred to the prepreg or to prevent the resin from transferring to the release paper, thereby facilitating the release of the release paper and eliminating troubles in prepreg production. An object of the present invention is to provide a manufacturing method, a prepreg manufactured by such a method, and a prepreg manufacturing apparatus.

[0008]

The main invention relating to a method for producing a prepreg is to join a reinforced fiber bundle with a resin layer carried on release paper from both sides thereof, or from one side. In a method of manufacturing a prepreg, which is configured to join the release resin supported on the release paper and bond only the release paper from the opposite side and transfer and impregnate the support resin into the reinforcing fiber bundle by heating.
It is characterized by forcibly cooling after heating, peeling off the release paper bonded to one side of the cooled prepreg, and winding it into a roll with the release paper bonded to only one side And a method for producing a prepreg.

Here, the forced cooling is carried out at a temperature above room temperature.
It may be an injection of qi. Also, forced cooling is prepreg
20-45 ° angle to the direction opposite to the running direction
It may be an injection of cooling air. Also forced cooling hands
Step is 500-700mmH₂ Cold wind blast with wind pressure in the range of O
It may be a shooting. In addition, forcible cooling makes the cooling plate take away heat
It may be contact of the prepreg with the prepreg. Also forced cold
Air injection at a temperature higher than room temperature and pre-cooling
Preg contact may be used in combination.

[0010] The invention relating to the prepreg relates to the prepreg produced by the invention of any of the above methods. Here, the resin content is 40 to 7 in weight ratio.
Preferably, it is within the range of 0%.

A main invention relating to a prepreg manufacturing apparatus is to join a support resin carried on release paper to both sides of the aligned reinforcing fiber bundle, or to carry a support resin carried on release paper from one side. Joining means for joining the resin and joining only the release paper from the opposite side; transfer impregnating means for transferring and impregnating the loaded resin into the reinforcing fiber bundle by heating; and transferring and impregnating the loaded resin into the reinforcing fiber bundle. And a cooling means for cooling the prepreg obtained by the above method.

In this case, the cooling means may be constituted by cooling air injection means. Further, the cooling means may be a cooling plate which contacts the prepreg to perform cooling. Further, a shielding plate may be provided between the transfer impregnating means and the cooling means.

[0013]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below with reference to an embodiment shown in the drawings. FIG. 1 shows an outline of a manufacturing method and a manufacturing apparatus according to an embodiment of the present invention. Here, a carbon fiber 10 is used as a reinforcing fiber, and a thermoplastic resin such as 1 shows a method and apparatus for producing a prepreg 50 impregnated with an epoxy resin.

Here, a creel 11 for supplying carbon fibers constituting the reinforcing fibers is provided. Creel 1
A large number of bobbins 12 are attached to 1, and the carbon fibers 10 are respectively drawn from these bobbins 12. A large number of carbon fibers 10 drawn from the bobbin 12 are guided by guide rolls 13 and are aligned by a comb 14 into a flat bundle having a predetermined width as shown in FIG. 2A, for example.

The carbon fibers 1 thus flattened and aligned.
0, the carrier resins 17, 21 from above and below
Are respectively polymerized. Here, the supported resin 17 is shown in FIG.
As shown in FIG. 1, it is carried on release paper 18, and is supplied by a roll 19 as shown in FIG. A release paper 22 is bonded to the lower surface of the lower supporting resin 21,
It is supplied by a roll 23.

The fiber bundle of the carbon fibers 10 shown in FIG. 2A, the upper carrier resin 17 shown in FIG. 2B, and the lower carrier resin 21 shown in FIG. 2C are arranged downstream of the comb 14 shown in FIG. Are joined by the joined joining rolls 26. That is, as shown in FIG. 2D, the fiber bundle of the carbon fibers 10 is sandwiched between the supporting resins 17 and 21 from above and below. At this time, release papers 18 and 22 are joined to the upper surface of the carrier resin 17 and the lower surface of the carrier resin 21, respectively.

Here, the upper and lower carrier resins 17 and 21 are transferred and impregnated between the fiber bundles of the carbon fiber 10, respectively.
Heating and pressurization are performed on the downstream side of the joining roll 26. That is, the upper and lower heater heating plates 27 and 28 provided immediately downstream of the joining roll 26 are used in FIG.
And the upper and lower supporting resins 17, 21 as shown in FIG.
Is heated.

Here, the carrier resin 17 carried on the release paper 18 and the carrier resin 21 carried on the release paper 22 are joined to the fiber bundle of the carbon fibers 10 from above and below, respectively. However, it is not always necessary to join the carrier resin from both sides, and the carrier resin may be joined only from one side. That is, the resin supported on the release paper may be joined to the fiber bundle of the carbon fibers 10 from above or below, and only the release paper may be joined to the opposite side.

On the downstream side of the heater heating plates 27 and 28, pressurization is performed by upper and lower press rolls 31 and 32, and thereafter, heating is performed from below by a hot plate 37. Pressing is further performed by the upper and lower press rolls 33 and 34, and when the press rolls 33 and 34 exit, they are heated by the hot plate 38. Heating and pressurizing are performed by upper and lower press rolls 35 and 36 disposed further downstream thereof.

By the transfer and impregnation step of applying heat and pressure to the joined body of the fiber bundle of the carbon fibers 10 and the support resins 17 and 21, the upper and lower support resins 17 and 21 gradually transfer and impregnate between the carbon fibers 10. As a result, as shown in FIG. 2E, the carrier resins 17 and 21 are impregnated almost uniformly between the carbon fibers 10, and the dispersion of the carrier resins 17 and 21 between the carbon fibers 10 is substantially uniform. become. At this time, the thermoplastic resin such as the epoxy resin constituting the supporting resins 17 and 21 is in a semi-cured state, that is, in a B-stage state.

After the transfer resins 17 and 21 are dispersed almost uniformly in the carbon fiber 10 by the transfer impregnation process, the cooling air is blown by a pair of cooling air injection nozzles 42 on the downstream side of the shielding plates 40 and 41. Inject, thereby cooling the prepreg. After that, the prepreg 50 is brought into contact with the chilled plate 43 on the downstream side of the cooling air jet nozzle 42 to further perform cooling. The chilled plate 43 is provided with a blower guide 44 for blowing air from above.

When the prepreg 50 is cooled by the cooling by the cooling air by the injection nozzle 42 and the cooling by the contact by the chilled plate 43, the release paper 18 on the upper side is peeled off at the guide roll 48, and Roll 49. Accordingly, as a result, as shown in FIG. 2F, the release paper 18 on the upper surface of the prepreg is removed, and the release paper 22 is bonded only to the lower surface. The prepreg 50 having the release paper 22 bonded to only one surface as described above is wound by the roll 51 shown in FIG.

The reinforcing fibers used here may be a group of reinforcing fibers generally used as reinforcing fibers in a fiber-reinforced resin composite material. Specifically, it is composed of inorganic fiber, organic fiber, metal fiber, metal-coated fiber or a mixture thereof, and as the inorganic fiber, carbon fiber, graphite fiber,
Silicon carbide fiber, alumina fiber, tungsten carbide fiber, boron fiber, glass fiber, or the like may be used. In the case of an organic fiber, an organic fiber such as an aramid fiber, a high-density polyethylene fiber, a nylon fiber, and a polyester fiber can be used. As the metal fiber, a stainless steel fiber may be used. The metal-coated fiber may be a fiber in which a metal layer of nickel, copper, or the like is formed on the surface of the inorganic fiber and the organic fiber by electrolytic plating or electroless plating. Particularly, carbon fibers or graphite fibers are preferable, and in this case, the basis weight may be usually 50 to 300 g / m ² .

On the other hand, the matrix resin impregnated with the upper resin sheet 17 or the lower resin sheet 21 may be a thermosetting resin usually used as a matrix resin of a reinforced fiber composite material.
Particularly, an epoxy resin is preferably used. As the epoxy resin curing agent, any compound having an active group capable of reacting with an epoxy group can be used. Preferably, a compound having an amino group, an acid anhydride group, or an azide group is suitable. Specifically, various isomers of dicyandiamide and diaminodiphenylsulfone and aminobenzoic acid esters are suitable. As thermosetting resins other than epoxy resins,
Unsaturated polyester resins, vinyl ester resins and the like are used.

In the one-way prepreg produced by the above method, it is also preferable to use a mixture of the above-mentioned thermosetting resin and a thermoplastic resin. Suitable thermoplastics include polyacrylates, polyamides, aramids,
Polyester, polyphenylene sulfide, polyimide, polyetherimide, polysulfone, polyethersulfone, polyetheretherketone, and the like. By using these thermoplastic resins together, it becomes possible to supply a curable molded product having high toughness.

The feature of the method and apparatus for producing a prepreg according to the present embodiment lies in the cooling means provided particularly downstream of the hot zone for transfer and impregnation of the loaded resin. That is, a pair of cooling air jet nozzles 42 and a chilled plate 43 are arranged downstream of the shielding plates 41 and 42, and the prepreg 50 coming out of the hot zone is forcibly cooled by these cooling means. This is a remarkable feature.

In particular, by setting the temperature of the cooling air injected by the injection nozzle 42 to a temperature higher than room temperature, rapid cooling of the prepreg 50 is suppressed and cooling is actively promoted. This is because if the temperature is rapidly decreased, the release paper 18 peeled off at the guide roll 48 will condense, absorb moisture, and curl. Such curling due to condensation and moisture absorption prevents reuse of the release paper 18. However, when air at a room temperature or higher is supplied by the cooling air jet nozzle 42, not only is it possible to improve the releasability of the release paper 18, prevent dew condensation and prevent the prepreg 50 from curling, but also to prevent the release paper 22 from being released. A prepreg having excellent handleability is provided.

As described above, in the present embodiment, prior to the winding of the prepreg 50 by the roll 51, the cool air having a temperature higher than the room temperature is positively supplied to promote the cooling, whereby the release paper 18 is formed. An object of the present invention is to provide a prepreg 50 excellent in handleability by improving the releasability between the prepreg 50 and the dew condensation during cooling and preventing the prepreg 50 from curling. In particular, such a prepreg is suitable for a prepreg having a higher resin content than reinforcing fibers. The reason is that if the content of the resin is high, the cooling of the prepreg is delayed and the separation of the upper release paper 18 becomes more difficult, so that this cooling mechanism functions suitably.

Furthermore, since the temperature of the cooling air injected by the cooling air injection nozzle 42 is set to a temperature higher than room temperature to prevent rapid cooling of the prepreg 50, not only the prepreg 50 but also the release paper 18 It is also possible to prevent dew condensation. Here, the injection nozzle 42
The value of the angle θ (see FIG. 3) with respect to the direction in which the cooling air injected from
When the angle is in the range of 0 to 45 °, the hot film does not flow, and thereby the promotion of cooling is further improved. The above angle θ
Is smaller than 20 °, the effect of cooling is reduced. On the other hand, when the value of θ exceeds 45 °, the thermal film easily flows.

FIG. 4 shows a prepreg 5 formed by such a combination of the cooling air jet nozzle 42 and the chilled plate 43.
This shows a situation where the cooling of the prepreg 50 is promoted and the temperature is reduced, and it is clearly shown that the temperature of the prepreg 50 is reduced more rapidly than in the case of the natural cooling indicated by the dotted line. Since the shielding plates 40 and 41 are provided on the upper and lower sides of the cooling air jet nozzle 42, the cool air of the cooling means 42 and 43 is not transmitted to the hot zone upstream of the press rolls 35 and 36. This does not hinder transfer impregnation of the loaded resin into the reinforcing fiber bundle.

[0031]

The main invention relating to the method for producing a prepreg is as follows: the aligned reinforcing fiber bundle is bonded to the release resin layer supported on the release paper from both sides thereof;
In the method of manufacturing a prepreg in which the carrier resin carried on the release paper was joined from one side and only the release paper was joined from the opposite side, and the carrier resin was transferred and impregnated into the reinforcing fiber bundle by heating. After the cooling is forcibly performed, the release paper bonded to one surface of the cooled prepreg is peeled off, and the release paper is wound on a roll in a state where the release paper is bonded to only one surface. .

Therefore, the forced cooling performed after the heating ensures that the release paper bonded to one surface is peeled off from the prepreg, and even if the coating agent adheres to the surface of the release paper. The coating agent is not transferred to the prepreg, or the resin on the prepreg side is prevented from being transferred to the release paper in a mottled state. Therefore, it is possible to prevent a decrease in the physical properties of a molded product using such a prepreg, or to prevent deterioration in the smoothness of the surface of the prepreg.

The main invention relating to the manufacturing apparatus is to join the loaded resin supported on release paper to both sides of the aligned reinforcing fiber bundle, or to carry the loaded resin supported on release paper from one side. Joining means for joining and releasing only the release paper from the opposite side, transfer impregnation means for transferring and impregnating the loaded resin into the reinforcing fiber bundle by heating, and transfer impregnation of the loaded resin into the reinforcing fiber bundle, which is obtained. And cooling means for cooling the prepreg.

Therefore, according to such a prepreg manufacturing apparatus, particularly, a prepreg having a high temperature which has exited the transition impregnating means can be cooled by the cooling means to accelerate the cooling thereof. When the release paper is peeled off, the coating agent adhering to the surface of the release paper is prevented from being transferred to the prepreg, or the resin on the prepreg side is prevented from being transferred to the release paper, thereby making it possible to manufacture the prepreg smoothly. Will be possible.

[Brief description of the drawings]

FIG. 1 is a side view of a main part of a prepreg manufacturing apparatus.

FIG. 2 is an enlarged cross-sectional view of a main part of a raw material or a prepreg showing production of the prepreg.

FIG. 3 is an enlarged side view illustrating a configuration of a cooling unit of the manufacturing apparatus.

FIG. 4 is a graph showing a temperature change of a prepreg.

[Explanation of symbols]

 Reference Signs List 10 carbon fiber 11 creel 12 bobbin 13 guide roll 14 comb 17 supported resin (upper) 18 release paper 19 roll 21 supported resin (lower) 22 release paper 23 roll 26 bonding roll 27 heater heating plate (upper) 28 heater heating plate (lower) 31) Press roll (upper) 32 Press roll (lower) 33 Press roll (upper) 34 Press roll (lower) 35 Press roll (upper) 36 Press roll (lower) 37, 38 Hot plate 40 Shielding plate (upper) 41 Shielding Plate (bottom) 42 Cooling air jet nozzle 43 Chilled plate 44 Blast guide 48 Guide roll 49 Roll 50 Pre-preg 51 Roll

 ────────────────────────────────────────────────── ─── Continued on the front page F term (reference) 4F072 AA01 AA07 AB04 AB05 AB06 AB09 AB10 AB11 AD08 AD23 AD38 AG03 AG18 AH12 AH44 AJ19

Claims (12)

[Claims] 1. A reinforced fiber bundle which has been aligned is joined to a carrier resin layer carried on release paper from both sides thereof, or a carrier resin carried on release paper is joined from one side to the opposite side. A method for producing a prepreg, in which only the release paper is joined and heated to cause the carrier resin to be transferred and impregnated into the reinforcing fiber bundle, comprising: A method for producing a prepreg, characterized in that the release paper bonded to the surface of the prepreg is peeled off, and the release paper is wound into a roll in a state where the release paper is bonded to only one surface. 2. The method for producing a prepreg according to claim 1, wherein the forced cooling is injection of air at a temperature equal to or higher than room temperature. 3. The method according to claim 1, wherein the forced cooling is an injection of cooling air at an angle of 20 to 45 ° with respect to a direction opposite to a running direction of the prepreg. Method for producing prepreg. 4. The forced cooling means is 500 to 700 mmH.
_The method for producing a prepreg according to claim 1, wherein the blast is a jet of cold air having a wind pressure in a range of ₂ O. 5. 5. The method for producing a prepreg according to claim 1, wherein the forced cooling is a contact of the prepreg with a cooling plate for removing heat. 6. A method according to claim 1, wherein said forced cooling is a combination of injection of air at a temperature equal to or higher than room temperature and contact of said prepreg with said cooling plate. 3. The method for producing a prepreg according to 1. 7. A prepreg produced by the method according to claim 1. 8. The prepreg according to claim 7, wherein the content of the resin is in the range of 40 to 70% by weight. 9. The aligned reinforcing fiber bundle is joined with a carrier resin carried on release paper from both sides thereof, or a carrier resin carried on release paper is joined from one side and from the other side. Joining means for joining only the release paper; transfer impregnating means for transferring and impregnating the loaded resin into the reinforcing fiber bundle by heating; and cooling for cooling the prepreg obtained by transferring and impregnating the loaded resin into the reinforcing fiber bundle. Means for producing a prepreg, comprising: 10. The prepreg manufacturing apparatus according to claim 9, wherein said cooling means comprises cooling air injection means. 11. The prepreg manufacturing apparatus according to claim 9, wherein the cooling means is a cooling plate that contacts and cools the prepreg. 12. The prepreg manufacturing apparatus according to claim 9, wherein a shielding plate is provided between the transfer impregnating means and the cooling means.