JP2006212803A - Method and apparatus for manufacturing resin film for use in manufacture of reinforcing fiber prepreg - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a resin film for use in the manufacture of a reinforcing fiber prepreg reduced in coating irregularity or weight irregularity, and a manufacturing apparatus therefor. <P>SOLUTION: When the resin discharged from a resin supply means while metered is applied to the mold release film running on a backup roll, the mold release film runs on a vacuum sucking and grasping means or, when the resin metered on a coating roll is applied to the mold release film running on the backup roll by transfer, the mold release film runs on the vacuum sucking and grasping means and there is a relation of C/F≥1.0 between the speed C of the coating roll and the speed F of the mold release film. Further, the manufacturing apparatus of the resin film for use in the manufacture of the reinforcing fiber prepreg is provided with a means comprising a coater equipped with the backup roll and sucking and grasping the running mold release film, which is coated with the resin by the coater, under vacuum. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method for producing a release film (referred to herein as a resin film for producing reinforced fiber prepreg) coated with a resin for producing a reinforced fiber prepreg, which is an intermediate substrate for producing a fiber reinforced composite material. In particular, the present invention relates to a manufacturing method and a manufacturing apparatus that suppresses fluctuations in coating speed and consequently reduces resin coating unevenness.

  For reinforcing fiber prepregs, which are intermediate substrates for manufacturing fiber reinforced composite materials, for example, fiber reinforced composite materials suitable for sports applications such as lightweight golf shafts and fishing rods, in order to suppress variations in quality and dimensions of molded products. In addition, it is desired to reduce the variation in the resin basis weight as much as possible. In particular, when a long reinforcing fiber prepreg is used, it is desired to minimize the variation in the resin basis weight in the longitudinal direction of the reinforcing fiber prepreg.

  As a typical method for manufacturing a reinforcing fiber prepreg, a release film coated with and supported by a resin is stacked on a sheet made of reinforcing fibers, and the resin applied to the release film is transferred to the reinforcing fiber sheet side. A method of impregnating a reinforcing fiber sheet is known. For the purpose of making the fiber reinforced composite material obtained from the prepreg lighter and stronger, the reinforced fiber content of the prepreg is increased. For this purpose, a resin film for producing a reinforced prepreg with a low resin basis weight is obtained. Various proposals have been made. Resin film for reinforced fiber prepreg production is generally a top feed reverse roll coater or comma reverse applied by measuring the amount of resin to be applied on a coating roll and transferring it to a substrate running on a backup roll. Roll coater including coater, lip reverse coater, etc., and lip coater, die coater, gravure coater, knife coater, etc. A method in which various coaters are used is known. In general, many of the reinforcing fiber prepreg resins have a high viscosity, so when applied, they are heated to a molten state, but even when heated, the viscosity is still very high. Since there are many cases, it was difficult to apply this thinly and uniformly. For example, when applying a resin to a release film with a roll coater, a proposal has been made to apply the resin film to a uniform basis weight by heating the release film (for example, Patent Document 1). However, even if the release film is heated, the resin is still very viscous, so the resistance force from the resin acts at the moment the resin is applied to the release film, contrary to the direction of travel of the release film. As a result, the running speed of the release film becomes unstable, and as a result, there is a problem that the variation in the basis weight of the resin cannot be sufficiently reduced.

Moreover, the proposal which applies the fabric weight of a resin film uniformly by changing the speed of a roll with a roll coater is made (for example, patent document 2 or 3). However, as described above, when a resin having a high viscosity is applied to the release film, the resin serves as a resistance for running the release film, which may cause uneven running speed and increase the variation in basis weight. This variation in weight per unit area has not been reduced to a level that can be sufficiently satisfied.
Japanese Patent Laid-Open No. 60-2313 Japanese Patent Laid-Open No. 3-123670 JP-A-11-254435

  Accordingly, an object of the present invention is to provide a method for producing a resin film for producing a reinforced fiber prepreg having a stable resin basis weight with a stable running speed of a release film and an apparatus therefor.

In order to solve the above problems, a method for producing a resin film for producing reinforced fiber prepreg according to the present invention comprises the following constitution. That is, in a method for producing a resin film for producing a reinforced fiber prepreg in which resin that is metered and discharged from a resin supply means is applied to a release film that runs on a backup roll, the release film runs on a vacuum suction gripping means. It is the method characterized by this. As the coater mentioned here, a coating roll such as a lip coater, a die coater, a gravure coater, and a knife coater is not used. For example, it has a resin supply means for measuring resin with a knife or die and discharging it to a substrate. Various general coaters can be selected as appropriate.
Moreover, in order to solve the said subject, as another aspect of the manufacturing method of the resin film for reinforced fiber prepreg manufacture concerning this invention, it consists of the following structure. That is, in a method for producing a resin film for producing a reinforced fiber prepreg in which a resin weighed on a coating roll is applied to a release film that runs on a backup roll by transfer, the release film runs on a vacuum suction gripping means. And it is the manufacturing method of the resin film for reinforced fiber prepreg manufacture characterized by the coating roll speed | rate C and the release film speed | rate F having the following relationship.

C / F ≧ 1.0 (1)
Here, the coating roll is one in which a resin weighed in advance is placed on the surface, and the resin is transferred and applied onto the substrate while rotating in the direction opposite to or in the forward direction of the substrate. As such a roll coater, for example, a roll coater including a top feed reverse roll coater, a comma roll coater, a lip reverse coater and the like can be appropriately selected. Among them, a reverse roll coater provided with a metering roll, a coating roll, and a backup roll can be suitably used for applying a highly viscous resin.

Here, when the C / F is less than 1.0, the resin on the coating roll is applied while stretching the resin when applied to the release film. Since the resistance force of the resin works greatly, the running speed of the release film becomes unstable. For this reason, by setting it as the range of (1), driving | running | working of a release film can be stabilized. However, as the C / F is increased, the basis weight of the resin applied on the release film becomes larger than the amount of resin measured by the coating roll. C / F ≦ 2.0, more preferably 1.0 ≦ C / F ≦ 1.5.
Furthermore, the release film can be run at a stable speed by running the release film on the vacuum suction gripping means. In addition, here, the relationship between the release film speed F and the backup roll speed B is preferably in the following relationship in order to reduce the resin basis weight unevenness.

0.9 ≦ F / B ≦ 1.1 (2)
The reduced-pressure suction gripping means in the present invention is a device that sucks and grips one surface of a release film by vacuum suction, and can hold and release the release film by driving the sucked portion. This may be composed of a driving roll having a plurality of suction ports or a driving belt, and specific examples thereof include a suction roll and a suction belt device. In order to reduce the unevenness in the running speed of the release film, the reduced-pressure suction gripping means holds and transports the release film before or after the backup roll, and the backup roll itself is the reduced-pressure suction gripping means. It doesn't matter.
The release film may be continuously wound into a roll by a winder after the resin is applied, and a continuous long resin film can be produced by this method. Also in this case, the vacuum suction gripping means may be installed before or after the backup roll, but it is installed between the backup roll and the winder, and the release film is run on the roll. It is preferable because the release film can be traveled stably.
The relationship between the release film speed F and the reduced-pressure suction gripping means speed S (the driving speed of the belt, roll, etc., which is the reduced-pressure suction gripping means) is such that F / S is 1 or 1 in order to transport the release film at a stable speed. It is preferable to be smaller, but if the F / S is less than 1, the release film may slip on the vacuum suction gripping means and make the release film speed unstable, so it is preferably in the following range. Is preferred.

0.9 ≦ F / S ≦ 1.0 (3)
Here, the vacuum suction gripping means may be determined in conjunction with the driving of the backup roll, and the respective speeds may be determined in conjunction with each other. For example, the vacuum suction grip means speed S may be determined based on the speed B of the backup roll, and S / B may be controlled to 1 or more. For example, a suitable condition can be selected within a range satisfying the above-described expressions (2) and (3).

  In the present invention, the resin used is preferably a thermosetting resin having a minimum viscosity of 0.1 to 300 poise. If the viscosity is lower than this range, the resin after application tends to move on the release film, and it becomes difficult to apply with a desired application thickness, that is, with a desired resin basis weight. In addition, it is difficult to adjust the coating thickness to a thin film, and the resistance force of the resin when the resin is applied onto the release paper greatly acts, so that the running speed of the release film tends to become unstable. Here, the resin viscosity can be measured using a dynamic viscoelastic method. For example, an RDA-II type apparatus manufactured by Rheometrics can be used. The minimum viscosity in the present application refers to the minimum value of the viscosity immediately before this transition, when the resin viscosity is gradually lowered when the temperature is increased, and finally a curing reaction occurs and the viscosity starts to increase. Moreover, the temperature which shows this minimum viscosity is called minimum viscosity temperature.

  As the resin, any resin usually used for the production of reinforcing fiber prepregs can be used, and examples thereof include epoxy resins, unsaturated polyester resins, vinyl ester resins, phenol resins, and cyanate ester resins. In particular, an epoxy resin or a resin composition containing an epoxy resin as a main component can be used.

Further, as the release film, a plastic film or the like can be used, but it is particularly preferable that the release film is made of release paper having good release properties.
The resin preferably has a viscosity of 10 to 10000 poise when applied to a release film. If the viscosity is lower than this range, it is difficult to apply uniformly or thinly as described above. In addition, the running speed of the release film tends to become unstable.
It is preferable to heat the release film when the resin is applied to the release film. By heating the release film, the viscosity of the resin when applied can be reduced. The release film may be heated directly by using the backup roll as a heating roll, or may be heated by a contact or non-contact method with a heating facility in the vicinity of the backup roll. The release film is preferably heated in the range of 40 to 200 ° C. However, when a thermosetting resin is used for coating, the resin is likely to be deteriorated when the heating temperature is high. is there. Alternatively, after the resin is applied to the release film, a method of cooling the release film and the resin by spraying cold air at room temperature or lower on the resin or bringing the release film into contact with a cooling plate at room temperature or lower may be used. .
The apparatus of the present invention has the following configuration. That is, in the resin film manufacturing apparatus for reinforcing fiber prepreg comprising at least a roll coater provided with a backup roll, a means for vacuum-sucking and gripping the traveling release film coated with or coated with the resin by the coater is provided. Device.
Here, the vacuum suction gripping means may be a driving roll or a driving belt having a plurality of suction ports, and a heating means is provided in the vicinity of the backup roll and / or the backup roll. May be.

    According to the present invention, it is possible to suppress variation in the speed of the release film due to the resistance force from the resin acting when the resin is applied to the release film, and to be able to travel stably, thereby enhancing the variation in the applied resin basis weight. A method for producing a resin film for fiber prepreg and a production apparatus thereof can be provided.

  Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.

FIG. 1 shows a method for producing a resin film for producing reinforced fiber prepreg according to an embodiment of the present invention. The release film 2 unwound from the release film roll 1 is sent to a backup roll 4 through a guide roll 3 made of a free roll, and a resin weighed to a certain amount by a resin weighing means 5 is applied. Then, it becomes the resin film 6 for manufacturing the reinforcing fiber prepreg and is wound up as a continuous roll body by the winder 7.
2 to 5 show portions corresponding to the resin measuring means 5 as examples of various coater systems. 2 and 3 exemplify means for measuring and discharging the resin by the resin supply means and applying it to the substrate. FIG. 2 shows an example of a die coater method, in which a certain amount of resin 12 discharged from the die 11 is applied on the release film 2 conveyed on the backup roll 4, and a resin film 6 for producing reinforced fiber prepreg and Become. FIG. 3 shows an example of a knife coater system. A predetermined amount of resin is applied to the release film 2 by providing the knife 13 with a fixed clearance to the resin reservoir 15 stored in the weir 14. The
4 and 5 illustrate means for transferring and applying the resin measured by the coating roll to the substrate. FIG. 4 shows an example of a reverse roll coater system, in which the resin 12 on the surface of the coating roll 16 is transferred and applied onto the release film 2 conveyed on the backup roll 4. In this method, the resin 12 is supplied on the surface of the coating roll 16 with a predetermined thickness while being measured by the clearance between the metering roll 17 and the coating roll 16 and the respective roll speed ratios. The resin can be preferably selected because it can be thinly coated with a high resin. FIG. 5 shows an example of a comma roll coater. A certain amount of resin is measured on the coating roll 16 by the clearance between the non-rotating comma roll 18 and the coating roll 16 corresponding to the metering roll 17 in FIG. Since it is transferred and coated on the release film 2 conveyed on the roll 4, it is a system that can be preferably selected for the same reason as the reverse roll coater.
In the above-described reverse roll coater or comma roll coater, the relationship between the coating roll speed C and the speed F of the release film gripped and conveyed on the backup roll is preferably C / F ≧ 1.0. If it is removed, the resin is stretched when transferred from the coating roll to the release film, and as a result, a force in the direction opposite to the running direction of the release film is applied, resulting in disordered running of the release film and application spots. is there.

In the present invention, the release film runs on the vacuum suction gripping means 8. 6 and 7 show an example of the vacuum suction gripping means. In this example, a belt 21 having a belt opening 21 a composed of a large number of holes is driven by a drive roll 22 and is guided around by a free roll 23, and is circulated in a housing 24. 21 is exposed. The inside of the casing 24 is depressurized by being sucked from the inside of the casing 24 through the suction port 25 by an appropriate suction means, and further, the release film 20 running on the upper surface of the circulating belt 21 by this decompression and suction. Is gripped and conveyed. In such a vacuum suction gripping means, as shown in FIGS. 8 and 9, instead of the belt 21, a roll 26 having a roll opening 26 a composed of a large number of holes can be used.
The vacuum suction gripping means speed S, that is, the running speed of the belt 21 and the circumferential speed of the roll 26 are preferably closer to the speed F of the release film 20 as described above, and 0.9 ≦ F / S ≦ It is sufficient if the relationship is 1.0, and the backup roll speed B may be detected, and the drive may be driven in an interlocked manner so as to be constant speed or higher based on this. Here, the material of the belt 21 and the roll 26 can be used without limitation, such as metal, resin, rubber, etc., and the release film of the belt 21 and the roll 26 is reduced in order to reduce unevenness of the release film due to reduced pressure. The contact surface may be machined with a mirror surface, embossing or a small groove. When the diameter of the opening of the belt or roll is preferably φ50 mm or less, it is difficult to make unevenness or the like on the surface of the release film when sucked and held. Further, it is preferable that the opening portion of the release film contact surface of the vacuum suction gripping means has an area of 10 to 70% because good suction gripping is possible.
The installation position of the vacuum suction gripping means is before and after the resin is applied to the release film, for example, in the apparatus illustrated in FIG. 1, between the roll body 1 that is the unwinding of the release film and the winder 7. Any one may be used, and a suitable installation position that can be held and conveyed while reducing the unevenness in the running speed of the release film may be selected. Further, the backup roll 4 itself may be a vacuum suction gripping means as shown in FIGS. Further, a plurality of these may be used.
In the present invention, when the release film runs on such a vacuum suction gripping means, the release film can be stably run and coated, and as a result, resin coating spots on the release film can be suppressed. become able to. As an indication of the stability of the release film running, if the relationship between the release film running speed F and the backup roll speed B is 0.9 ≦ F / B ≦ 1.1, resin coating spots are further suppressed. Therefore, it is preferable.
In the present invention, it is preferable to heat the release film when coating the release film with the resin because the viscosity of the resin can be lowered. FIG. 1 shows an example in which a heater 9 is installed in the vicinity of the backup roll 4 to heat the release film in a non-contact manner, but the backup roll 4 itself is heated to heat the release film in a contact type. May be.
FIG. 10 shows a method of manufacturing a reinforcing fiber prepreg using the reinforcing fiber prepreg manufacturing resin film manufactured as described above. The reinforcing fiber bundle 32 drawn out from the package 31 of the plurality of reinforcing fiber bundles is a reinforcing fiber in which the plurality of reinforcing fiber bundles 32 are aligned in parallel with each other through the alignment rolls 33 and 34 and the comb 35. It is in the form of a sheet 36. The upper release film 40 drawn from the upper release film roll body 37 with respect to the reinforcing fiber sheet 36 is disposed on the upper surface side of the reinforcing fiber sheet 36 via the introduction rolls 38 and 39, and A lower release film 44 drawn from the roll body 41 of the release film on the side is disposed on the lower surface side of the reinforcing fiber sheet 36 via the introduction rolls 42 and 43. As described above, the resin is applied and supported on at least one of the upper and lower release films 40 and 44. In this embodiment, the resin is applied and supported on at least the upper release film 40. However, a resin may be applied and supported on both release films 40 and 44.

In this way, the reinforcing fiber sheet 36 sandwiched between the release films 40 and 44 from both sides is heated by the heater 45 and the resin applied to the release film is heated and softened, and is nipped by the impregnation rolls 46 and 47. By being pressurized, the resin is impregnated into the reinforcing fiber sheet 36. The reinforcing fiber sheet 36 impregnated with the resin is wound up and collected as the roll body 53 at the position of the take-up rolls 48 and 49, and the upper release film 50 after the resin is transferred to the reinforcing fiber sheet 36 side. . The reinforcing fiber sheet 36 impregnated with the resin is wound up as a roll body 52 as the reinforcing fiber prepreg 51. In this embodiment, the lower release film 44 is also wound together with the reinforcing fiber prepreg 51, and functions as a release material when the reinforcing fiber prepreg 51 is unwound and used for molding a composite material.
Since the resin film produced in this way has small coating spots and is coated with a more uniform basis weight, the reinforced fiber prepreg produced using the resin film has defects and no resin on the surface formed by the coating spots. In addition, since spotted spots are suppressed, a product with good quality is obtained, which is preferable.

The result of manufacturing the resin film for manufacturing reinforcing fiber prepreg and the reinforcing fiber prepreg using the apparatus as described above will be described.
Example 1
As the coating apparatus, the knife coater shown in FIGS. 1 and 3 was used. As the vacuum suction gripping means, the suction belt device shown in FIGS. 6 and 7 was used, and this was installed between the backup roll 4 and the winder 7. The resin to be applied was prepared in advance with the following composition, and a resin composition having a minimum viscosity of 25 poise and a minimum viscosity temperature of 120 ° C. was used. Here, the resin viscosity is RDA-II type apparatus manufactured by Rheometrix Co., Ltd., operation mode: dynamic, vibration 3.14 radians / second, heating rate: 1.5 ° C./min, plate: parallel plate (radius 25 mm ), Gap: measured under the condition of 1.0 mm.

The composition of the applied resin is as follows.
Bisphenol A type epoxy resin: 30 parts by weight (Epicoat 828, registered trademark, manufactured by Japan Epoxy Resins Co., Ltd.)
Bisphenol A type epoxy resin: 20 parts by weight (Epicoat 1001, registered trademark, manufactured by Japan Epoxy Resins Co., Ltd.)
Phenol novolac type epoxy resin: 45 parts by weight (Epicoat 154, registered trademark, manufactured by Japan Epoxy Resins Co., Ltd.)
Polyvinyl formal: 5 parts by weight (Vinylec K, trade name, manufactured by Chisso Corporation)
3- (3,4-dichlorophenyl) -1,1-dimethylurea: 10 parts by weight (DCMU99, model number, manufactured by Hodogaya Chemical Co., Ltd.)
As the release film, a carbon fiber prepreg peeling process paper (WBE90R-DT, trade name, manufactured by Lintec Corporation) having a width of 1080 mm was used.

  The temperature of the resin in the resin reservoir 15 was heated to 70 ° C., and the molten resin composition was applied to the release film with a width of 1000 mm under the following conditions. Here, the viscosity at 70 ° C. of the resin composition was 300 poise.

Backup roll speed B: 15 m / min Knife clearance: 30 μm
Suction belt speed S: 15.5 m / min Suction belt suction: ON
When the resin was continuously applied, the release film, that is, the speed F of the resin film was 15 ± 0.5 m / min. Therefore, F / B is 0.97 to 1.03.

  The obtained resin film was excellent in quality with no apparent coating spots and no defects with no resin. This resin film was sampled at a length of 5 m, and the difference R between the individual maximum value and the minimum value when a sample of a 100 mm square sample at the center of the film was measured at 100 mm intervals in the film longitudinal direction was regarded as the basis weight variation and evaluated. . The resin basis weight can be obtained from the weight of the resin scraped off from the release film with a spatula or the like measured with a balance. As a result of measuring the variation in the longitudinal direction of the average resin basis weight and basis weight, the results were as follows. The results are summarized in Table 1.

Average weight: 35.5 g / m ²
Longitudinal variation R: 1.8 g / m ²
Example 2
As the coating apparatus, the reverse roll coater shown in FIGS. 1 and 4 was used. As the vacuum suction gripping means, the suction belt device shown in FIGS. 6 and 7 was used, and this was installed between the backup roll 4 and the winder 7. The same resin and release film as those used in Example 1 were used.

  The surface temperature of the metering roll 17, the coating roll 16, and the backup roll 4 was heated to 70 ° C., and the resin composition in a molten state was applied to the release film with a width of 1000 mm under the following conditions.

Metalling roll speed M: 12 m / min Coating roll speed C: 15.5 m / min Backup roll speed B: 15 m / min Roll clearance: 30 μm
Suction belt speed S: 15.5 m / min Suction belt suction: ON
When the resin was continuously applied, the release film, that is, the speed F of the resin film was 15 ± 0.2 m / min. Accordingly, C / F is 1.02 to 1.05, F / B is 0.99 to 1.01, and F / S is 0.95 to 0.98.

  The obtained resin film was excellent in quality with no apparent coating spots and no defects with no resin. As a result of measuring the average resin basis weight and the variation R in the longitudinal direction of the basis weight in the same manner as in Example 1, this resin film was as follows. The results are summarized in Table 1.

Average weight: 30.4 g / m ²
Longitudinal variation R: 1.3 g / m ²
Example 3
As the coating apparatus, the comma roll coater shown in FIGS. 1 and 5 was used. As the vacuum suction gripping means, the suction belt device shown in FIGS. 6 and 7 was used, and this was installed between the backup roll 4 and the winder 7. Further, the suction roll shown in FIGS. 8 and 9 was used as the backup roll 4. The same resin and release film as those used in Example 1 were used.

  The surface temperature of the comma roll 18, the coating roll 16, and the backup roll 4 is heated to 70 ° C., and the heater 9 is further backed up so that the release film 2 held and conveyed by the backup roll 4 is heated to 70 ° C. It was installed in the vicinity. The molten resin composition was applied to a release film with a width of 1000 mm under the following conditions.

Coating roll speed C: 20 m / min Backup roll speed B: 18 m / min Roll clearance: 28 μm
Suction belt speed S: 18.2 m / min Suction belt suction: ON
Suction roll suction: ON
When the resin was continuously applied, the release film, that is, the speed F of the resin film was 18 ± 0.2 m / min. Therefore, C / F is 1.10 to 1.12, F / B is 0.98 to 1.02, and F / S is 0.99 to 1.00.

  The obtained resin film was excellent in quality with no apparent coating spots and no defects with no resin. As a result of measuring the average resin basis weight and the variation R in the longitudinal direction of the basis weight in the same manner as in Example 1, this resin film was as follows. The results are summarized in Table 1.

Average weight: 30.6 g / m ²
Longitudinal variation R: 1.6 g / m ²
Comparative Example 1
The resin, release film, apparatus, roll speed, etc. were the same as in Example 1 and the suction belt was not used, and the results of producing the resin film are summarized in Table 1.

Average weight: 35.7 g / m ²
Variation in longitudinal direction R: 6.4 g / m ²
Comparative Example 2
Table 1 summarizes the results of producing a resin film with the same resin, release film, apparatus, roll speed, etc. as in Example 2 and without using a suction belt.

Average weight: 30.2 g / m ²
Longitudinal variation R: 3.5 g / m ²
Comparative Example 3
The resin, release film, apparatus, roll speed, etc. were the same as in Example 3, a suction belt was not used, and a metal roll having no suction function was used as a backup roll. The results of producing the resin film are summarized in Table 1.

Average weight: 30.8 g / m ²
Variation in longitudinal direction R: 6.9 g / m ²
Example 4
Reinforcing fiber prepregs were manufactured from the resin film and reinforcing fibers obtained in Example 1 using the reinforcing fiber prepreg manufacturing apparatus shown in FIG.

As the reinforcing fibers, 125 carbon fiber bundles (fineness: 0.8 g / m) having an average single fiber diameter of 7 μm, the number of single fibers of 12,000, a tensile strength of 4.9 GPa, and a tensile elastic modulus of 230 GPa were used. The carbon fiber sheet in which these carbon fiber bundles are aligned is pressed against one resin film obtained in Example 1 from below, and a release film not coated with resin is applied from above to sandwich the heater 45, The impregnating rolls 46 and 47 were heated to 130 ° C., pressurized at a speed of 8 m / min and a linear pressure of 4 kg / cm, and the carbon fiber bundle was impregnated with the resin to obtain a carbon fiber prepreg. The carbon fiber prepreg had a prepreg basis weight of 135.7 g / m ² , a fiber basis weight of 100.5 g / m ² , and a weight fiber content of 74.1%.

  This carbon fiber prepreg was sampled at a length of 5 m, and the difference R between the individual maximum value and the minimum value when a sample of a 100 mm square sample at the center of the prepreg was measured at 100 mm intervals in the longitudinal direction was regarded as the basis weight variation and evaluated. The result was as follows. The results are summarized in Table 2.

Longitudinal variation: 1.4 g / m ²
Examples 5-6
Similar to Example 4, the results of producing reinforcing fiber prepregs using the resin films produced in Examples 2 to 3 are summarized in Table 2.
Comparative Examples 4-6
Similar to Example 4, the results of producing the reinforcing fiber prepreg using the resin films produced in Comparative Examples 1 to 3 are summarized in Table 2. On the surface of the prepreg, a portion having no resin on the surface due to the resin coating spots and fluff were generated and the quality was not good.

The present invention can be applied not only to sports and leisure applications such as golf shafts and fishing rods but also to general industrial applications such as aircraft applications and civil engineering construction, but the application range is not limited to these. Absent.

It is a schematic side view of the apparatus for enforcing the manufacturing method of the resin film for reinforced fiber prepreg manufacture which concerns on one embodiment of this invention. It is a schematic partial side view which shows an example of the resin measurement means of the apparatus of FIG. It is a schematic partial side view which shows an example of the resin measurement means of the apparatus of FIG. It is a schematic partial side view which shows an example of the resin measurement means of the apparatus of FIG. It is a schematic partial side view which shows an example of the resin measurement means of the apparatus of FIG. It is a schematic side view which shows the example of the decompression suction holding means based on one embodiment of this invention. FIG. 7 is a schematic plan view of the vacuum suction gripping means of FIG. 6. It is an expansion schematic partial side view which shows another example of the pressure reduction suction | inhalation holding means of FIG. It is a schematic perspective view of the reduced pressure suction gripping means of FIG. It is a schematic side view of the apparatus for manufacturing the reinforced fiber prepreg which concerns on one embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Roll body of release film 2 Release film 3 Guide roll 4 Backup roll 5 Resin metering means 6 Resin film for reinforcing fiber prepreg 7 Winder 8 Vacuum suction gripping means 9 Heater 11 Die 12 Resin 13 Knife 14 Weir 15 Resin pool 16 Coating roll 17 Metering roll 18 Commer roll 20 Release film 21 Belt 21a Belt opening 22 Drive roll 23 Free roll 24 Housing 25 Suction port 26 Roll 26a Roll opening 31 Reinforcing fiber bundle package 32 Reinforcing fiber bundle 33, 34 Alignment roll 35 Comb 36 Reinforcing fiber sheet 37 Upper release film roll body 38, 39 Introduction roll 40 Upper release film 41 Lower release film roll body 42, 43 Introduction roll 44 Lower side Release film 45 Tar 46,47 impregnation roll 48, 49 take-up rolls 50 above the release film 51 roll of the release film of the roll body 53 above the reinforcing fiber prepreg 52 reinforced fiber prepreg

Claims (15)

  In a method for producing a resin film for producing a reinforced fiber prepreg, in which a resin metered and discharged from a resin supply means is applied to a release film running on a backup roll, the release film runs on a vacuum suction gripping means. A method for producing a resin film for producing reinforced fiber prepreg, which is characterized by the following. In a method for producing a resin film for producing a reinforced fiber prepreg in which a resin measured on a coating roll is applied to a release film that runs on a backup roll by transfer, the release film runs on a vacuum suction gripping means, And the manufacturing method of the resin film for reinforced fiber prepreg manufacture characterized by the coating-roll speed C and the release film speed F having the following relationship.
C / F ≧ 1.0 (1) The method for producing a resin film for reinforcing fiber prepreg according to claim 1, wherein the backup roll speed B and the release film speed F are in the following relationship.
0.9 ≦ F / B ≦ 1.1 (2)   The method for producing a reinforced fiber prepreg resin film according to any one of claims 1 to 3, wherein the resin film is applied to the release film and then continuously wound into a roll by a winder. .   5. The reinforcing fiber prepreg production according to claim 4, wherein after the release film is coated with a resin, the release film is gripped by the reduced-pressure adsorption gripping means before being wound up by a winder. A method for producing a resin film.   6. The resin film for producing a reinforced fiber prepreg according to claim 1, wherein the release film is gripped by a vacuum suction gripping means comprising a driving roll or a driving belt having a plurality of suction ports. Manufacturing method. The method for producing a reinforced fiber prepreg resin film according to any one of claims 1 to 6, wherein the reduced-pressure adsorption gripping means speed S and the release film speed F have the following relationship.
0.9 ≦ F / S ≦ 1.0 (3)   The method for producing a reinforced fiber prepreg resin film according to any one of claims 1 to 7, wherein the resin is a thermosetting resin having a minimum viscosity of 0.1 to 300 poise.   The said resin consists of a resin composition which has an epoxy resin as a main component, The manufacturing method of the resin film for reinforcement fiber prepreg manufacture in any one of Claims 1-8 characterized by the above-mentioned.   The resin film for producing a reinforced fiber prepreg according to any one of claims 1 to 9, wherein the viscosity of the resin when the resin is applied to a release film is kept in a range of 10 to 10000 poise. Method.   The method for producing a reinforced fiber prepreg resin film according to any one of claims 1 to 10, wherein the release film is heated when the resin is applied to the release film.   It manufactures using the resin film for reinforcement fiber prepreg manufacture by the method in any one of Claims 1-11, The manufacturing method of the reinforcement fiber prepreg characterized by the above-mentioned.   Reinforced fiber prepreg manufacturing with a means for vacuum suction and gripping a traveling release film coated with resin or coated with a coater in a resin film manufacturing apparatus for reinforcing fiber prepreg consisting of a coater with a backup roll Resin film manufacturing equipment.   The apparatus for producing a reinforced fiber prepreg for a reinforcing fiber according to claim 12, wherein the reduced-pressure adsorbing and gripping means includes a driving roll or a driving belt having a plurality of suction ports. The resin film manufacturing apparatus for manufacturing a reinforcing fiber prepreg according to claim 12 or 13, wherein heating means is provided in the vicinity of the backup roll and / or the backup roll.

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