JP2002172706A - Method and apparatus for manufacturing long fiber- reinforced resin molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method and an apparatus for manufacturing a long fiber-reinforced resin molding capable of executing a continuous work for a long period without necessity of disassembling a mold even by operating for a long time, easily controlling a ratio of fiber to the resin, and uniformly impregnating a long fiber bundle with a resin stock solution. SOLUTION: The method for manufacturing the long fiber-reinforced resin molding comprises the steps of guiding a plurality of long fibers F to a cylindrical space X between a columnar inner mold 2 having a resin stock solution discharge port 2d for discharging the resin stock solution 4 from an outer surface toward a radial outside and an outer mold 3 externally inserted into the mold 2, discharging the solution 4 from the port 2d toward the long fibers 1 in the space X, adhering the solution to the long fibers, bundling the fibers adhered with the solution to obtain the long fiber bundle impregnated with the solution, and curing the solution in the bundle.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for producing a long fiber reinforced resin molded product.

[0002]

2. Description of the Related Art JP-A-10-119141 discloses that
A manufacturing apparatus and a manufacturing method of a long fiber reinforced resin molded product are disclosed. The manufacturing apparatus described in the prior art will be described with reference to FIG.

[0003] A resin solution impregnated region A and a resin solution impregnated fiber converging region B connected to the lower portion of the resin solution impregnated region A are provided. The two regions A and B are composed of an inner mold 91 having a cylindrical portion, a conical portion below the cylindrical portion, and an inner mold 9.
1 is formed by a gap between the outer mold 92 and the periphery of the outer mold 92.

In the area A, a ring-shaped fiber inlet 93 at the upper end of the gap between the molds, a cylindrical gap 94 for sending fibers therebelow to a lower part, A ring gap 95 for impregnating the undiluted solution, an injection pipe 96 for sending the undiluted resin solution to the gap 95, and a ring-shaped undiluted resin exit 97 for sending the undiluted fiber impregnated fiber from the gap 95 to the lower region B are provided. . On the other hand, the inner mold 9
A gap 98 is provided so that the thickness gradually increases toward the tip 99 of the one conical portion.

[0005] Using this apparatus, a plurality of fibers F are fed into a fiber inlet 93 in a ring shape. When the fiber F is guided into the annular gap 95 through the cylindrical gap 94, the fiber F is impregnated with the stock resin L stored in the annular gap 95. Next, the undiluted resin impregnated fibers F / L are pulled out and converged from the ring-shaped undiluted resin reservoir outlet 97, and the fiber bundle impregnated with the undiluted resin solution is extracted. By curing the resin stock solution of the fiber bundle impregnated with the resin stock solution, a long fiber reinforced resin molded product is obtained.

Therefore, by using the apparatus described in the prior art, the fibers F are brought into contact with the latest resin stock solution L supplied from the injection pipe 96 and, together with the fibers F, the gap 9.
The air that has entered inside 5 passes through the upper portion of fiber inlet 93 to the outside. Therefore, it is difficult for coarse bubbles to be taken into the resin stock solution-impregnated fibers F / L.

[0007]

However, the apparatus described in the above prior art has the following problems. (1) Although a thermosetting resin composition is usually used as the resin stock solution L, if a manufacturing apparatus is used for a long period of time,
In some cases, the resin adhering to the gap 95 is cured and deposited, and the gap 95 is closed. Therefore, the operation must be stopped in a relatively short period of time, and the inside of the gap 95 must be cleaned. However, cleaning is difficult only by stopping the operation, and the inner mold 91, the outer mold 92, and the injection pipe must be disassembled each time, and the cleaning work is very complicated.

Further, as described above, the operation must be stopped in a short period of time, and the dismantling operation has to be performed for cleaning, so that continuous operation cannot be performed for a long period of time. (2) In the manufacturing method described in the above-mentioned prior art, since the resin stock solution L accumulated in the annular gap 95 is impregnated into the fiber F, the ratio between the fiber and the resin in the long fiber reinforced resin molded product is controlled. It was difficult.

(3) Further, in the manufacturing apparatus described in the above prior art, the manufacturing of the long fiber reinforced resin molded article is performed such that the area B is located below the area A, that is, the fibers are moved in the vertical direction. Is scheduled to take place. That is, when the inner mold and the outer mold shown in FIG. 6 are rotated by 90 ° and the manufacturing apparatus is used sideways, the resin stock solution tends to move downward by its own weight. It is difficult to accumulate uniformly over the circumference. For this reason, the resin stock solution cannot be uniformly dispersed over the entire circumference of the annular gap 95, and the dispersibility of the resin in the long fiber reinforced resin molded product varies, so that a uniform long fiber reinforced resin molded product cannot be obtained. Was.

[0010] An object of the present invention is to eliminate the above-mentioned disadvantages of the prior art and to enable continuous operation for a long period of time.
It is an object of the present invention to provide a method for producing a long-fiber-reinforced resin molded product that can easily control the ratio of fiber to resin and can uniformly impregnate a long fiber bundle with a stock resin solution.

Another object of the present invention is to eliminate the necessity of dismantling the mold even after long-term operation, thus enabling continuous operation for a long term and easily controlling the ratio of fiber to resin. It is an object of the present invention to provide a manufacturing apparatus capable of uniformly impregnating a long fiber bundle with a stock resin solution and stably obtaining a long fiber reinforced resin molded product even if the long fiber bundle is installed in any of vertical and horizontal directions.

[0012]

Means for Solving the Problems A method for producing a long fiber reinforced resin molded article according to the first invention of the present application is a method of impregnating a fiber bundle with a resin stock solution, molding the resultant, and producing a fiber reinforced resin molded article. There is a column-shaped inner mold that is configured so that the resin stock solution is injected into the inside and is provided with a resin stock solution discharge hole for discharging the resin stock solution from the outer surface toward the outside in the radial direction,
Guiding a plurality of long fibers to a cylindrical space between an outer mold having an outer peripheral surface having a similar cross-sectional shape and a cross-sectional shape of the inner die; and A step of discharging the resin stock solution from the stock solution discharge hole toward the long fiber and attaching the resin stock solution to the long fiber; and a step of bundling the long fiber to which the resin stock solution is attached and obtaining a long fiber bundle impregnated with the resin stock solution. ,
Curing the undiluted resin solution in the long fiber bundle impregnated with the undiluted resin solution.

[0013] In a specific aspect of the first invention, the stock resin solution is a foamable resin stock solution, and the long fiber bundle impregnated with the foamable resin stock solution is removed from a space between the inner mold and the outer mold. It is led to an open space and foamed before curing to obtain a long fiber reinforced resin foam.

In another specific aspect of the first invention, the column-shaped inner mold has a columnar shape, and the cylindrical space has a cylindrical shape. In another specific aspect of the first invention, the inner mold has a prismatic shape, and the cylindrical space has a rectangular cylindrical shape.

[0015] In still another specific aspect of the first invention,
The curing step is performed in a movable mold that moves in the same direction as the long fiber bundle and has a molding space having a cross-sectional shape corresponding to a target shape, and accordingly, according to the molding space in the movable mold. A long-fiber-reinforced resin molded article having a cross-sectional shape having a reduced cross section is obtained.

The second invention of the present application is a method for producing a fiber-reinforced resin molded article by impregnating a long fiber bundle with a stock resin solution and molding the same. The stock resin solution is injected into a column-shaped inner mold and inside. It is configured so that the outer shape and the cross section of the cross section of the inner mold have an inner peripheral surface and an outer peripheral surface of similar shapes, and the inner peripheral surface and the outer peripheral surface are radially inward and outward, respectively. A cylindrical first outer mold having first and second resin stock solution discharge holes for discharging a resin stock solution, and an inner peripheral surface having a cross-sectional shape and a cross-sectional shape similar to those of the first outer mold; A first cylindrical space between the inner mold and the first outer mold of the mold having a second outer mold having a second outer mold, and a second cylindrical space between the first and second outer molds. Guiding a plurality of long fibers to the respective spaces, discharging the resin stock solution toward the long fibers from the first and second resin stock solution discharge holes, A step of adhering the undiluted resin solution to the long fibers in the cylindrical space, a step of bundling the long fibers to which the undiluted resin solution is attached to obtain a long fiber bundle impregnated with the undiluted resin solution, and a step of impregnating the undiluted resin solution. Curing the undiluted resin solution of the fiber bundle.

In the first and second inventions, preferably, a thermosetting resin stock solution is used as the resin stock solution. In the case of a thermosetting resin stock solution, in the above-described prior art, the deposition of a cured product of the resin becomes a larger problem, but according to the present invention, since the deposition of the resin is unlikely to occur, when a thermosetting resin stock solution is used, Especially effective.

A third invention of the present application is an apparatus for producing a fiber-reinforced resin molded article by the method for producing a long-fiber-reinforced resin molded article according to the first invention, wherein a resin for discharging a resin stock solution to an outer surface is provided. A substantially columnar inner mold in which a stock solution discharge hole is formed, and a resin injection path connected to the resin stock solution discharge hole is formed therein, and an inner periphery having a cross-sectional shape similar to that of the cross-section of the inner mold. A cylindrical outer mold having a surface, wherein the diameter of the cylindrical space is reduced toward the downstream side downstream from the resin stock solution discharge port, whereby a plurality of the resin stock solutions are attached. It is configured so that long fibers are bundled, and further comprises a resin injection member for injecting a resin stock solution into the resin injection path of the inner mold, and a molding member for curing and shaping the long fiber bundle to which the resin stock solution has adhered. It is characterized by.

An apparatus for producing a fiber-reinforced resin molded article according to a fourth invention is an apparatus for obtaining a fiber-reinforced resin molded article by the method for producing a fiber-reinforced resin molded article according to the second invention. The inner mold and the inner mold have an inner peripheral surface and an outer peripheral surface whose outer cross-section and cross-section are similar to each other, and a resin injection path is formed therein. 1, a first outer die in which a second resin stock solution discharge hole is formed, and extrapolated to the first outer die, the outer cross-sectional shape of which is similar to that of the first outer die. A second outer mold having an inner peripheral surface, so as to bundle a plurality of long fibers to which the stock resin solution is attached, on the downstream side of the stock resin port, of the first and second cylindrical spaces. A space reduction area is formed in which the diameter is reduced toward the downstream side. Curing the stock solution, and further comprising a molding member for molding.

In a specific aspect of the third and fourth inventions, there is further provided a deformed member for changing a cross-sectional shape of the long fiber to which the resin stock solution is attached.

[0021]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be clarified by describing specific embodiments of the present invention with reference to the drawings.

(Resin stock solution) The resin stock solution used in the present invention broadly includes a liquid resin or a resin composition. As the resin, any of a thermosetting resin and a thermoplastic resin can be used. Preferably, a thermosetting resin is used, and according to the present invention, curing and deposition of the thermosetting resin can be reliably suppressed.

The thermosetting resin is not particularly restricted but includes, for example, urethane resins, phenol resins, unsaturated polyester resins, urea resins, epoxy resins,
Examples include diallyl phthalate-based resins, and among them, urethane-based resins are preferably used because of their excellent durability and mechanical strength.

The thermoplastic resin is not particularly restricted but includes, for example, styrene resins. Preferably, a foamable resin stock solution is used as the resin stock solution, whereby a long fiber reinforced resin foam can be obtained. Examples of such a foamable resin stock solution include a foamable resin composition containing the thermosetting resin or the thermoplastic resin and a pyrolytic foaming agent.

If the viscosity of the above resin stock solution is too high, it becomes difficult to impregnate the long fibers, and therefore, it is difficult to impregnate the resin in a molten state at 10,000 c.
ps or less, more preferably 3000 cps
The following are more preferred. In addition, in the above resin stock solution, if necessary, a catalyst, a coloring agent, a crosslinking agent, a filler,
Additives such as an ultraviolet absorber, an antioxidant, and a flame retardant may be blended.

(Long Fiber) The long fiber for constituting the long fiber bundle in the present invention is not particularly limited, but is preferably a string formed by lightly attaching a strand with a binder, such as roving or yarn. Used for
Above all, roving is preferably used because it is easy to impregnate the resin solution, is easy to mold, and has excellent mechanical properties of the molded body.

The filaments constituting the strands may be monofilaments or fibrillated (fiber-like fibers) fibers. The material of the long fiber is not particularly limited, and glass fiber,
Carbon fibers, organic fibers (synthetic fibers or natural fibers) and the like are used. Among them, glass fibers and carbon fibers are preferably used because the mechanical strength can be effectively increased. The synthetic fibers include, for example, vinylon, polyamide, polyester, polyolefin, rayon and the like.

(First Embodiment) FIGS. 1A and 1B
1 is a front sectional view for explaining a manufacturing apparatus 1 for a long fiber reinforced resin molded product according to a first embodiment of the present invention, and FIG.
It is sectional drawing which shows typically the part which follows the BB line in (a).

In the manufacturing apparatus 1 of this embodiment, a plurality of long fibers F are transported in the direction of arrow A shown in the figure, that is, from above to below. In the manufacturing apparatus of the present embodiment,
When bundling the long fibers F and impregnating the undiluted resin solution, the apparatus may be arranged such that the long fibers F are moved not in the vertical direction but in the horizontal direction. This will be described in detail later.

The manufacturing apparatus 1 of the present embodiment has a substantially cylindrical inner mold 2 and a cylindrical outer mold 3. Inner peripheral surface 3 of outer mold 3
“a” has a cross section similar to the outer shape of the cross section of the inner mold 2. That is, the outer shape of the cross section of the inner mold 2 and the shape of the inner peripheral surface in the cross section of the outer mold 3 are both circular. A cylindrical space X is formed between the outer peripheral surface 2a of the inner die 2 and the inner peripheral surface 3a of the outer die 3. A plurality of long fibers F are guided into the cylindrical space X, and the resin stock solution is attached to the long fibers in the space X as described later.

On the other hand, a resin stock solution injection path 2c is formed to extend downward from the upper end surface 2b of the inner mold 2. The resin stock solution injection path 2c is connected to a resin stock solution supply unit (not shown) connected to the upper end surface 2b. The resin solution is
It is configured to be supplied into the inner mold 2 by the resin solution injection path 2c.

On the other hand, on the outer peripheral surface 2a of the inner mold 2, a plurality of resin stock solution discharge ports 2d are formed at an intermediate height position. The plurality of resin stock solution discharge ports 2d are dispersedly arranged in the circumferential direction at an intermediate height position of the inner mold 2. Preferably, the plurality of resin stock solution discharge ports 2d are provided on the outer peripheral surface 2a of the inner mold 2.
At a certain height in the circumferential direction.

The lower part of the resin stock solution injection path 2c is branched to form a branched resin stock solution injection path part 2c.
₁ is connected to each resin stock solution discharge port 2d. Further, the branched resin stock solution injection path portion 2c ₁ is constructed from the center of the cross section of the inner mold 2 so as to extend radially outward. Therefore, the resin stock solution is configured to be discharged from the resin stock solution discharge port 2d toward the outside in the radial direction of the cross section of the inner mold 2.

In the portion where the undiluted resin solution is discharged, the porosity of the cylindrical space X is preferably in the range of 0 to 40%. Here, the porosity refers to a ratio obtained by dividing the volume of the space by subtracting the volume of the long fiber and the volume of the resin stock solution by the total volume of the space. On the upstream side of the resin stock solution discharge port, in order to prevent the resin stock solution from flowing back, it is desirable that the space ratio of the cylindrical space in the portion where the resin stock solution discharge port is provided be smaller than that of the resin stock solution. It is desirable to configure so as to occupy nearly 100% of the space. Therefore, in the embodiment shown in FIG. 1, the volume of the cylindrical space X is lower in the portion where the resin stock solution discharge port 2 d is provided and below the portion where the resin stock solution discharge port 2 d is provided. Has been bigger.

If the above-mentioned space ratio in the portion where the resin stock solution discharge port 2d is provided exceeds 40%, the impregnating property of the resin may be deteriorated, and a stagnant resin may be generated to improve the continuous operability. May decrease.

It is preferable that the resin is discharged from the undiluted resin outlet 2d at a high speed. However, if the speed is too high, the long fibers may be cut. Therefore, 0.3
~ 200 m / sec is preferred.

Further, in order to enhance the resin impregnating property, in addition to a method of increasing the discharge speed of the resin stock solution from the resin stock solution discharge port 2d,
A method of increasing the number of the resin stock solution discharge ports 2d and reducing the thickness of the space X in the portion where the resin stock solution discharge ports 2d are provided. To increase the resin stock solution discharge speed itself, the discharge speed is desirably in the range of 5 to 200 m / sec. A large number of resin stock solution discharge ports 2d are provided and are opposed to the resin stock solution discharge ports 2d in the space X. In the case of the method of reducing the thickness at the portion, the discharge speed of the resin stock solution itself may be 0.3 to 200 m / sec.

The lower end of the substantially cylindrical inner mold 2 has a conical portion 2e, and the inner peripheral surface of the lower end of the outer mold 3 is shaped so as to become the conical portion. Is reduced as the diameter of the space X goes downward. It is configured so that the long fibers to which the undiluted resin solution has passed are bundled while passing through this reduced area.

In producing a long fiber reinforced resin molded article,
First, a plurality of long fibers F are inserted into the cylindrical space X, and are taken down by a take-off device (not shown). Therefore, the long fiber F moves in the cylindrical space X from above to below. In this step, the resin stock solution 4 is discharged from the resin stock solution discharge port 2d, and the resin stock solution 4 is attached to the long fibers F. The long fiber to which the resin stock solution 4 is attached is moved downward,
The bundles are bundled in a reduced area below the cylindrical space X, whereby a long fiber bundle impregnated with the resin solution is obtained.

In the manufacturing apparatus 1, as described above, the resin stock solution 4 is discharged from the resin stock solution discharge port 2d toward the outside in the radial direction of the cross section of the inner mold 2. Therefore, since the fiber bundle fed from the upstream is impregnated while cleaning the wall surface, even when the continuous operation is performed for a long period of time, accumulation of the resin stock solution and adhesion of the resin stock solution hardly occur. Therefore, the process for obtaining the fiber bundle impregnated with the stock resin solution can be continuously performed over a long period of time.

The long fiber bundle impregnated with the undiluted resin solution as described above is guided into the movable mold 5 shown in FIG. 2 and is cured in the movable mold 5, thereby forming the long fiber reinforced resin molded product. Is obtained. In FIG. 2, reference numeral 6 schematically shows a block composed of the inner mold 2 and the outer mold 3 shown in FIG.
Indicates a conduit connected to a resin stock solution injection path provided in the inner mold, and an end of the pipe 4 a is connected to the resin stock solution supply unit 4.
b. The long fiber bundle Fa impregnated with the resin stock solution discharged from the cylindrical space X is
It is guided to the molding space 5a inside, and is cooled and hardened.

It should be noted that a foamed resin stock solution may be used as the stock resin solution and foamed prior to curing to obtain a foam Fc. Thus, a long fiber reinforced resin molded product is obtained.

As the movable mold 5, an arrow Y direction shown in FIG.
That is, it is possible to use an appropriate movable mold that can be moved in the direction in which the long fiber bundle Fa impregnated with the resin stock solution is taken out. The molding space 5a is configured to have a cross section corresponding to the shape of the target fiber-reinforced resin molded body. That is, when it is intended to obtain a long fiber reinforced resin molded article having a circular cross section, the cross section of the molding space 5a is circular, and when it is intended to obtain a long fiber reinforced resin molded article having a rectangular cross section. The cross section of the molding space 5a is rectangular.

In FIG. 2, the movable mold 5 is used. However, as shown in a modification shown in FIG. May be arranged. In other words, the long fiber bundle 5 impregnated with the resin stock solution is cured in the fixedly arranged mold 7 while the long fiber bundle is being taken by the take-off device 8, and the long-fiber reinforced resin molding obtained by the take-off device 8 is obtained. You may be comprised so that a body may be withdrawn.

Further, as shown in FIG. 4, a reducer 9 is provided after the block 6A comprising the inner mold 2A and the outer mold 3A.
And a sliding section 1 at the subsequent stage of the reducer 9 for making the resin distribution in the long fiber bundle impregnated with the undiluted resin more uniform.
0 may be provided.

FIG. 4 schematically shows a portion composed of the inner mold 2A and the outer mold 3A. Here, the conduit 4a is inserted into the resin stock solution injection path 2c provided in the inner mold 2. And a resin solution supply unit 4b at the outer end of the conduit 4a.
Are connected.

The inner mold 2A and the outer mold 3A have a shape excluding the downstream portion of the block 6 in FIG. 1, that is, the above-mentioned reduced portion for bundling the long fibers F. Instead, a binding member is used. Reducer 9 is connected. The plurality of long fibers to which the resin solution is attached are guided from the cylindrical space X to the path 9 a in the reducer 9. In the path 9a, a conical inner mold portion 9b and a conical inner mold portion 9b are formed so that the diameter of the cylindrical space X gradually decreases.
And an outer mold portion 9c having a shape following the outer peripheral side surface of the outer mold portion 9c. Accordingly, the plurality of fibers to which the resin stock solution is attached are bundled as they pass through the reducer 9, and the long fibers to which the resin stock solution is attached are bundled at the subsequent stage of the conical inner mold portion 9b. It is a long fiber bundle. As described above, the reduced portion that bundles the long fibers F may be configured as a separate member from the block 6A.

Further, a sliding portion 10 as a deformed portion provided at a stage subsequent to the reducer 9 is provided with a plurality of rollers 1.
0a, and the sheet 11 is stretched between the plurality of rollers 10a. The sheet 11 is arranged along the peripheral surface of the roller 10a, and as shown in FIG.
It is configured to have a twist in the transport direction of a. Therefore, the long fiber bundle Fa to which the resin solution is attached is rubbed between the sheets 11, and the long fiber bundle Fa is deformed.

By being squeezed by the sliding portion 10, the undiluted resin solution is uniformly impregnated into the long fiber bundle and deformed into a desired shape. Thereafter, by curing, a fiber-reinforced resin molded article having a deformed shape is obtained.

(Second Embodiment) FIGS. 5A and 5B
FIG. 4 is a longitudinal sectional view showing a manufacturing apparatus for a long fiber reinforced resin molded product according to a second embodiment of the present invention and a sectional view schematically showing a portion along line CC in FIG.

In this embodiment, a cylindrical inner mold 21, a first outer mold 22, and a second outer mold 23 are provided.
The first outer mold 22 has a cylindrical shape. Therefore, the cross-sectional shape of the inner peripheral surface 22 a of the outer mold 22 is similar to the outer shape of the cross-section of the inner mold 21. Similarly, the first outer mold 2
The cross-sectional shape of the outer peripheral surface 22b of the second outer mold 22 and the cross-sectional shape of the inner peripheral surface 23a of the second outer mold 23 are both circular and similar.

Therefore, the outer peripheral surface 21a of the inner die 21 and the outer die 2
A first cylindrical space X1 is defined between the outer peripheral surface 22b of the first outer mold 22 and the second outer mold 23.
A second cylindrical space X2 is formed between the inner peripheral surface 23a and the inner peripheral surface 23a.

In this embodiment, a plurality of long fibers F are respectively guided into the first and second cylindrical spaces. On the other hand, on the inner peripheral surface of the first outer mold 22, a plurality of first resin stock solution discharge ports 22c are formed at intermediate height positions. The plurality of first resin stock solutions discharge ports 22c are configured to discharge the resin stock solution radially inside the cross section, that is, into the cylindrical space X1. On the other hand, also on the outer peripheral surface of the first outer mold 22, a plurality of second resin undiluted liquid discharge ports 22d are formed in the circumferential direction at the intermediate height position. The resin stock solution discharge port 22d is configured to discharge the resin stock solution radially outward of the cross section, that is, into the second cylindrical space X2.

First and second undiluted resin discharge ports 22c, 22
d is preferably formed at the same height position in FIG. In addition, the first and second resin stock solution discharge ports 22c,
In order to discharge the resin concentrate from 22d, a resin concentrate injection path for supplying the resin concentrate is configured in the first outer mold 22. That is, the resin stock solution injection path 22e is provided. The undiluted resin injection path 22e communicates with the undiluted resin injection path 21b in the inner mold 21. The resin stock solution injection path 21a is connected to a resin stock solution supply unit (not shown).

Note that the resin stock solution injection path may not be provided in the inner mold 21, and the resin stock solution supply unit is directly connected to the first outer mold 22, and the resin stock solution injection path 22 e in the first outer mold 22 is provided. May be directly supplied to the resin.

In this embodiment, a plurality of long fibers F are supplied to the first and second cylindrical spaces X1 and X2, respectively, and radially inward from the first and second resin stock solution discharge ports 22c and 22d. Alternatively, the resin solution is discharged radially outward.
Therefore, the stock resin solution is attached to the plurality of long fibers F, and the long fibers F to which the stock resin solution is attached are discharged from the spaces X1 and X2.

Thereafter, similarly to the first embodiment,
The long fibers to which the undiluted resin solution is attached are bundled, and a long fiber bundle impregnated with the undiluted resin solution is obtained. The unity is performed by connecting a reducer or by connecting the inner mold 21 and the outer mold 2.
This can be achieved by providing a reduced portion in the sections 2 and 23.

As the molding member for curing and molding the long fiber bundle impregnated with the resin solution, the movable mold 5 and the fixed mold 7 shown in FIGS. 2 and 3 can be appropriately used. There is no particular limitation. Further, as for the member for transporting the plurality of long fibers F, the take-off device shown in FIG. 3 can be appropriately used.

Also in this embodiment, since the resin stock solution is configured to be discharged from the resin stock solution discharge ports 22c and 22d to the inside or outside in the radial direction of the cross section of the outer mold 22, the operation is performed for a long time. Even if resin stock solution is in space X
It is hard to accumulate in a specific portion at 1, X2. Therefore, continuous operation can be performed for a long period of time.

In the first and second embodiments, since the cylindrical space is cylindrical, a substantially cylindrical inner die is used, and the inner peripheral surface of the outer die and the first inner die are formed. The inner peripheral surface of the second outer mold is also cylindrical, but in the present invention, the cylindrical space may have a rectangular cylindrical shape. In that case, the inner mold has a prismatic shape.

Next, a specific embodiment will be described. (Example 1) Manufacturing apparatus 1 shown in FIGS. 1 (a) and 1 (b)
Was used. In addition, the outer diameter of the upper part from the resin stock solution discharge port of the inner mold 2 is 35 mm, the length is 200 mm, and the outer diameter of the lower part is 32 m.
m, length is 250 mm, inner diameter of the lower part of outer diameter 3 is 40
mm. Also, the diameter of the resin stock solution discharge port was 0.7 mm. A glass fiber (14000 count) having a diameter of 17 μm was twisted and weakly wound to obtain one roving, and the roving was prepared as a long fiber F. Further, for 100 parts by weight of a polyol (manufactured by Sumitomo Vinyl Urethane Co.), 0.6 parts by weight of water as a foaming agent and 0.1 part by weight of a catalyst (S-CM31A, manufactured by Sankyoki Gosei Co., Ltd.) are preliminarily mixed. And
Further, 130 parts by weight of diphenylmethane diisocyanate (44U20, manufactured by Sumitomo Vinyl Urethane Co., Ltd.) was collision-mixed to prepare a stock resin solution as a stock solution of polyurethane having a viscosity of 2000 cps at 20 ° C.

The 48 long fibers are led into a cylindrical space X,
The above-mentioned resin stock solution was injected into the resin stock solution injection path 2c, and the resin stock solution was discharged from the resin stock solution discharge port 2d to adhere to the long fibers. In this case, the weight ratio of the stock resin solution to the long fibers is 1: 1.
, And the long fiber F was taken out of the space X at a speed of 3 m / min. Thereafter, the long fibers impregnated with the undiluted resin solution are bundled, and bundled with the binding member shown in FIG.
Foam hardening molding was performed using the movable mold 5 to obtain a fiber-reinforced foam molded article.

(Example 2) The same long fiber and foaming resin stock solution as in Example 1 were prepared. In the manufacturing apparatus shown in FIG. 1, a resin stock solution and long fibers were supplied at a weight ratio of 1: 1 to the cylindrical space X in the same manner as in Example 1, and were taken out at a speed of 0.5 m / min. In the manufacturing apparatus shown in FIG. 1, the cylindrical space X has an inner diameter of 90 mm in a portion above the resin stock solution discharge port, and has a space X below the portion in which the resin stock solution discharge port is provided. 80mm inside diameter, 100 outside diameter
mm. Further, in the lower outside diameter portion, the one having an exit diameter of 56 mm was used so that the mold exit reduction ratio was 87.1%.

As described above, the undiluted resin solution was attached to the long fibers in the cylindrical space X, and then bundled at the outer diameter portion to obtain a long fiber bundle impregnated with the undiluted resin solution. In the fiber-reinforced resin molded products obtained in the above Examples 1 and 2, because the resin stock solution is uniformly impregnated, after foaming and hardening, a fiber-reinforced foamed resin molded product having excellent appearance and excellent bending strength is obtained. I got it. In addition, it is excellent in continuous operability.
It was confirmed that it was possible to operate continuously for 3 days or more in any of the above.

[0065]

According to the first aspect of the present invention, in the method for producing a long fiber reinforced resin molded product, in the cylindrical space, the undiluted resin solution is discharged from the undiluted resin discharge port toward the long fiber, and the undiluted resin solution is converted into the long fiber. Adhered to. Therefore, it is difficult for the stock resin solution to accumulate in a specific portion of the cylindrical space. Therefore, it is excellent in continuous operability, and it is possible to manufacture a long fiber reinforced resin molded body for a long period of time. That is, in the conventional method for manufacturing a long-fiber-reinforced resin molded body, the resin stock solution is accumulated in the annular gap and accumulated, so that the operation has to be stopped, and complicated operations such as dismantling and cleaning have to be frequently performed. In the manufacturing method according to the first aspect of the present invention, such complicated work does not have to be performed, and continuous operation can be performed for a long period of time.

In addition, the supply ratio of the above-mentioned resin stock solution and long fiber can be easily controlled, and a desired fiber-reinforced resin molded article can be stably obtained. Using a foamable resin stock solution as the resin stock solution, the long fiber bundle impregnated with the foamable resin stock solution is led to a space opened from the space between the inner mold and the outer mold, and when foamed prior to curing. According to the present invention, a long fiber reinforced resin foam can be obtained.

In the case where the columnar inner mold has a columnar shape and the cylindrical space is cylindrical, a cylindrical long-fiber reinforced resin molded product can be easily obtained finally. When the mold has a prismatic shape and the cylindrical space is a prismatic shape, a long fiber reinforced resin molded product having a rectangular cross section can be obtained.

In the case where the curing step is performed in a movable mold having a molding space having a cross-sectional shape corresponding to a target shape, moving in the same direction as the long fiber bundle, the molding space in the movable mold is used. It is possible to easily obtain a long fiber reinforced resin molded article having a cross sectional shape according to the cross sectional shape.

Also in the second invention, the resin stock solution is discharged from the first and second cylindrical spaces toward the long fibers, and the resin stock solution is attached to the long fibers. ,
It is difficult for the stock resin solution to accumulate in the first and second cylindrical spaces, so that continuous operation can be performed for a long period of time. Also,
It is possible to simplify complicated operations such as shutting down, dismantling, and cleaning required in the related art. Further, by adjusting the supply ratio between the long fiber and the resin stock solution, a desired long fiber reinforced resin molded article can be easily obtained.

Further, in the second invention, since the long fibers are respectively guided to the first and second cylindrical spaces, the resin stock solution can be more effectively and uniformly impregnated as compared with the first invention. In addition, a long fiber reinforced resin molded article containing more long fibers can be obtained.

In the manufacturing apparatus according to the third aspect of the present invention, the inner mold having the resin stock solution discharge port, the cylindrical outer mold having an inner peripheral surface whose cross section is similar to the outer shape of the cross section of the inner mold, the resin stock solution, Since it comprises an injection member and a molded member, according to the first invention,
A long fiber reinforced resin molded product can be obtained, and a long fiber reinforced resin molded product can be manufactured by continuous operation for a long period of time.

Similarly, in the manufacturing apparatus according to the fourth aspect of the present invention, the inner mold and the inner mold are formed so as to have the first and second cylindrical spaces.
A first outer die and a second outer die are configured, and the resin stock solution is discharged from the first and second resin stock solution discharge ports toward the long fibers, and the resin stock solution is attached to the long fibers. Therefore, according to the second invention, a long-fiber-reinforced resin molded article can be obtained, complicated operations such as stoppage, dismantling, and cleaning can be simplified, and continuous operation can be performed for a long period of time.

[Brief description of the drawings]

FIGS. 1 (a) and 1 (b) are longitudinal sectional views showing a tool of an apparatus for manufacturing a long fiber reinforced resin molded product according to a first embodiment of the present invention, and are along the line BB in FIG. 1 (a). The typical sectional view of a part.

FIG. 2 is a schematic vertical sectional view showing an example of an apparatus for curing and molding a long fiber bundle impregnated with a stock resin solution.

FIG. 3 is a schematic longitudinal sectional view showing another example of an apparatus for curing and molding a long fiber bundle impregnated with a stock resin solution.

FIG. 4 is a schematic longitudinal sectional view for explaining a modified example in which a reducer for binding long fiber bundles impregnated with a stock resin solution is connected to a cylindrical space.

FIG. 5 is a view showing an apparatus for manufacturing a long fiber reinforced resin molded product according to a second embodiment of the present invention, wherein (a) is a longitudinal sectional view,
(B) is a schematic sectional view of a portion along the line CC in (a).

FIG. 6 is a longitudinal sectional view showing an apparatus for manufacturing a long fiber reinforced resin molded product according to a third embodiment of the present invention.

[Explanation of symbols]

 2 ... Inner mold 2a ... Outer peripheral surface 2b ... Top end surface 2c ... Resin stock solution injection path 2d ... Resin stock solution discharge port 3 ... Outer mold 3a ... Inner circumferential surface 4 ... Resin stock solution 4a ... Conduit 4b ... Resin stock solution supply member 5 ... Movable metal Mold 5a Molding space 7 Fixed mold 8 Take-off device 9 Reducer 10 Sliding part 21 Inner mold 21a Outer peripheral surface 22 First outer mold 22a Inner peripheral surface 22b, 22c First, first Second resin stock solution discharge port 23: second outer mold 23a: inner peripheral surface F: long fiber X: cylindrical space X1, X2: first and second cylindrical spaces

Continuing on the front page (72) Inventor Takumi Murata 2-2, Kamitobakamichocho, Minami-ku, Kyoto Sekisui Kagaku Kogyo Co., Ltd. (72) Koji Motoi 2-2, Kamikotokamicho, Minami-ku, Kyoto-shi Sekisui Chemical Co., Ltd. F term (reference) 4F072 AA04 AA07 AB09 AB22 AB25 AD43 AG03 AG12 AH02 AH25 AK02 AK14 4F205 AA36 AA42 AB02 AD16 AG14 AG20 HA05 HA25 HA27 HA33 HA34 HA37 HA46 HB02 HC02 HF01 HF05 HF23 HL17

Claims (10)

[Claims] 1. A method for producing a fiber reinforced resin molded article by impregnating a long fiber bundle with a stock resin solution, forming a fiber reinforced resin molded body, wherein the stock resin solution is injected into the inside, and the diameter is measured from the outer surface. Between a column-shaped inner mold provided with a resin stock solution discharge hole for discharging a resin stock solution toward the outside in the direction, and an outer mold having an inner peripheral surface having a cross-sectional shape similar to that of the cross-section of the inner mold. A step of guiding a plurality of long fibers to a cylindrical space, and a step of discharging the resin stock solution toward the long fibers from the resin stock solution discharge hole in the cylindrical space, and causing the resin stock solution to adhere to the long fibers, Bundling the long fibers to which the undiluted resin solution is attached to obtain a long fiber bundle impregnated with the undiluted resin solution, and curing the undiluted resin solution in the long fiber bundle impregnated with the undiluted resin solution. A method for producing a long fiber reinforced resin molded article. 2. The resin stock solution is a foamable resin stock solution,
The long fiber bundle impregnated with the foamable resin stock solution is led to a space opened from the space between the inner mold and the outer mold, and foamed before curing to obtain a long fiber reinforced resin foam. The method for producing a long fiber reinforced resin molded product according to claim 1. 3. The column-shaped inner mold has a columnar shape,
The method for producing a long fiber reinforced resin molded product according to claim 1, wherein the cylindrical space is a cylindrical shape. 4. The method for producing a long fiber reinforced resin molded product according to claim 1, wherein the inner mold has a prismatic shape, and the cylindrical space has a rectangular cylindrical shape. 5. The hardening step is performed in a movable mold that moves in the same direction as the long fiber bundle and has a molding space having a cross-sectional shape corresponding to a target shape. The method for producing a long-fiber-reinforced resin molded product according to any one of claims 1 to 4, wherein a long-fiber-reinforced resin molded product having a cross-sectional shape corresponding to the molding space of (i) is obtained. 6. A method for producing a fiber-reinforced resin molded article by impregnating a long fiber bundle with a resin stock solution, and forming a column-shaped inner mold and a resin stock solution into the inside. The outer shape and the cross section of the inner die have a similar inner peripheral surface and outer peripheral surface, and the inner die and the outer peripheral surface are respectively discharged radially inwardly and outwardly. 1, a cylindrical first outer die having a second resin stock solution discharge hole formed therein, and a second outer die having an inner peripheral surface having a cross-sectional shape similar to that of the first outer die. A plurality of molds are respectively provided in a first cylindrical space between the inner mold and the first outer mold of the mold having the mold and a second cylindrical space between the first and second outer molds. Guiding the long fibers, and discharging the resin stock solution toward the long fibers from the first and second resin stock solution discharge holes, and in the first and second cylindrical spaces, A step of adhering the undiluted solution to the long fibers; a step of bundling the long fibers to which the undiluted resin solution is attached to obtain a long fiber bundle impregnated with the undiluted resin solution; And a step of curing the stock solution. 7. The method for producing a long-fiber-reinforced resin molded article according to claim 1, wherein the resin stock solution is a thermosetting resin stock solution. 8. A long fiber bundle is impregnated with a stock resin solution and molded.
An apparatus for manufacturing a fiber-reinforced resin molded product, wherein a resin stock solution discharge hole for discharging a resin stock solution is formed on an outer surface, and a resin injection path connected to the resin stock solution discharge hole is formed inside. A substantially columnar inner mold, comprising a cylindrical outer mold having an inner peripheral surface having a similar cross-sectional shape to the outer shape of the cross-section of the inner mold, wherein the diameter of the cylindrical space is larger than that of the resin stock solution discharge port. On the downstream side, it is reduced as it goes to the downstream side, so that a plurality of long fibers to which the resin stock solution is attached are bundled, and the resin that injects the resin stock solution into the inner mold resin injection path. An apparatus for manufacturing a long-fiber-reinforced resin molded product, further comprising: an injecting member; and a molding member for curing and molding the long-fiber bundle to which the resin stock solution has adhered. 9. A long fiber bundle is impregnated with a stock resin solution and molded.
An apparatus for manufacturing a fiber-reinforced resin molded article, comprising: a substantially columnar inner mold; and an inner peripheral surface and an outer peripheral surface having a cross-sectional shape similar to the outer shape of a cross section of the inner mold, and a resin inside. An injection path is configured, a first outer die having first and second resin liquid discharge holes formed on an inner peripheral surface and an outer peripheral surface, respectively, and extrapolated to the first outer die, A second outer mold having an outer peripheral surface having a similar cross-sectional shape to the outer cross-section of the first outer mold, and the resin stock solution being bundled so as to bundle a plurality of long fibers to which the resin stock solution is attached; Downstream from the discharge port, a space reduction region is formed in which the diameters of the first and second cylindrical spaces are reduced toward the downstream side, and the resin stock solution of the long fiber bundle to which the resin stock solution has adhered is formed. An apparatus for producing a long-fiber-reinforced resin molded product, further comprising a molded member that is cured and molded. 10. A deformed member that changes a cross-sectional shape of a long fiber bundle to which the resin stock solution is attached,
An apparatus for manufacturing a long fiber reinforced resin molded product according to claim 8.