JP2010095734A - Method for producing metal-hybrid prepreg - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for producing a metal-hybrid prepreg which gives a prepreg product excellent in strength, appearance, and touch feeling in use. <P>SOLUTION: There is provided the method for producing the metal-hybrid prepreg in which a reinforcing fiber prepreg of a 5-30 μm fiber diameter is made a base layer, metal wires 5-100 μm in thickness, 0.1-100 mm in width, and 2-100 in width/thickness ratio are arranged at 0.1-100 mm intervals on the surface of the base layer, the reinforcing fiber prepreg of a 5-30 μm fiber diameter is laminated as a transparent cover layer on the metal wires. In the method for producing the metal-hybrid prepreg by drum winding, the brake of a winding out bobbin is controlled by the detected tension of the metal wires, and the tension of the metal wires is kept constant within a range of 40-400 gf/strand. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method for producing a metal hybrid prepreg using a flat metal wire.

  In recent years, prepregs using carbon fibers and various reinforcing fibers have been widely used in various technical fields, and are also widely used for the production of sports and leisure goods because they are lightweight and have high mechanical strength. Very good results. However, the conventional prepreg is desired to be further improved in terms of strength and elastic modulus, or in terms of feel during use. In addition, it is often preferred to have a metallic luster aesthetically.

  In order to meet these demands, hybrid prepregs that use prepreg reinforcing fibers and different types of fibers, such as carbon prepregs, in combination with boron fibers, titanium fibers, amorphous fibers, stainless steel fibers, glass fibers, various organic fibers, etc. Proposed.

  For example, a hybrid prepreg comprising a reinforcing fiber having a fiber diameter of 5 to 30 μm and different fibers having a fiber diameter of 50 to 500 μm arranged at predetermined intervals in the same direction as the reinforcing fiber is improved in mechanical strength while being thin. Has also been improved (Japanese Patent Laid-Open No. 3-199109). In addition, in order to prevent breakage of processed products, matrix resin in reinforcing fibers is provided on at least one side of the foil-like expanded metal layer with improved mechanical properties such as tensile strength, compressive strength, elastic modulus, and stickiness. There has been proposed a prepreg in which a fiber-reinforced composite resin layer impregnated with or a resin layer having no reinforcing fiber is disposed (Japanese Patent Laid-Open No. 5-8224). As a method for producing these hybrid prepregs, a drum winder is generally used (Japanese Patent Laid-Open No. Hei 3-199109). Japanese Patent Application Laid-Open No. 2-193686 proposes a golf shaft using metal fiber and carbon fiber prepregs in order to give a sense of bending similar to that of a steel shaft. Japanese Patent Application Laid-Open No. 6-225668 proposes a tubular body using a sheet-like titanium material as reinforcing fibers in order to improve corrosion resistance and glitter.

Japanese Patent Laid-Open No. 3-199209 JP-A-5-8224 JP-A-2-193686 JP-A-6-225668 Japanese Patent Laid-Open No. 3-65328 JP-A-6-269522

  In sport and leisure goods, further thinning and weight reduction are desired, but these conventional hybrid prepregs have been difficult to reduce in thickness and weight without impairing mechanical properties. In the hybrid prepreg manufacturing method, a constant tension is applied to the metal wire wound around the drum winder by always applying a constant brake to the metal wire bobbin, but the tension applied to the metal wire depending on the winding state of the metal wire bobbin. However, it was difficult to maintain a constant tension. Therefore, an object of the present invention is to provide a prepreg product that is excellent in strength and aesthetics and has a good feel during use, and a metal hybrid prepreg that can provide such a product. It is another object of the present invention to provide a method of manufacturing a metal hybrid prepreg that is less likely to cause problems such as disorder of the pitch arrangement of the metal wires and bending / cutting of the metal wires themselves.

  That is, the present invention detects the tension of the metal wire when winding the metal wire on the surface side of the base layer by drum winding so that the metal wires are arranged at regular intervals, and controls the brake of the unwinding bobbin by the detected tension. A method for producing a metal hybrid prepreg, wherein the tension of the metal wire is kept constant in the range of 40 to 400 gf / strand.

  In the present invention, a prepreg using reinforcing fibers having a fiber diameter of 5 to 30 μm is used as a base layer, and on the surface side of the base layer, a thickness of 5 to 100 μm, a width of 0.1 to 100 mm, and a width and thickness A metal wire or foil having a ratio of 2 to 100 is arranged at intervals of 0.1 to 100 mm, and a prepreg using reinforcing fibers having a fiber diameter of 5 to 30 μm is further laminated thereon as a transparent cover layer. In the method of manufacturing a metal hybrid prepreg, when winding the metal wire around the surface of the base layer by drum winding so that the metal wires are arranged at regular intervals, the tension of the metal wire is detected, and the unwinding bobbin brake is applied by the detected tension. It is a method for producing a metal hybrid prepreg characterized by controlling and keeping the tension of the metal wire constant in the range of 40 to 400 gf / strand. Here, the fiber diameter of the reinforcing fiber of the base layer and / or the reinforcing fiber of the transparent cover layer is preferably 0.1 to 0.5 times the thickness of the metal wire or foil, and the metal wire or foil is round. It is preferable that the die-shaped metal wire is rolled or drawn or a metal foil is stamped.

  The method for producing a metal hybrid prepreg according to the present invention can advantageously produce a thinned prepreg without impairing mechanical properties and feel during use as compared with a conventional hybrid prepreg. In addition, processed products such as fishing rods, golf shafts, and rackets using this metal hybrid prepreg have excellent mechanical properties, are thin and lightweight, and improve the feel during use.

It is sectional drawing which shows the structure of a metal hybrid prepreg. It is a perspective view explaining the manufacturing method of the metal hybrid prepreg of this invention. It is sectional drawing of the tubular product using a metal hybrid prepreg.

  FIG. 1 is a cross-sectional view showing a layer structure of a metal hybrid prepreg manufactured by the manufacturing method of the present invention. The metal hybrid prepreg 1 uses a prepreg using reinforcing fibers having a fiber diameter of 5 to 30 μm as a base layer 2, and has a thickness of 5 to 100 μm, a width of 0.1 to 100 mm, and a width and thickness on the surface side of the base layer 2. Metal wires 3 with a ratio of 2 to 100 (unless metal wires and foils are used separately, metal wires are used to include foil) are arranged at regular intervals, and reinforcing fibers with a fiber diameter of 5 to 30 μm are used. The prepreg thus prepared is used as a cover layer 4 and bonded together. Compared with the conventional hybrid prepreg using metal fibers having a fiber diameter of 50 to 500 μm, the metal hybrid prepreg having such a configuration may be made thinner because the metal wire 3 is thinner and wider. It becomes possible and adhesion with the reinforcing fiber is improved, and the mechanical properties are not impaired.

Examples of the prepreg used for the base layer 2 include a unidirectional prepreg, a woven prepreg, a yarn prepreg, and a mat prepreg, and a unidirectional prepreg or a woven prepreg is preferable. Examples of the prepreg used for the cover layer 4 include a unidirectional prepreg, a woven prepreg, a yarn prepreg, and a mat prepreg. The prepreg is preferably a woven prepreg and transparent. Further, the prepreg manufacturing method may be a wet method or a dry method.
Examples of reinforcing fibers used in the prepreg include inorganic fibers such as carbon fibers, boron fibers, alumina fibers, glass fibers, silicon carbide fibers, and silicon nitride fibers, and organic fibers such as aramid fibers, polyarylate fibers, polyester fibers, and polyethylene fibers. In addition, one or two or more types selected from metal fibers such as titanium fibers, amorphous fibers, and stainless steel fibers can be used, and carbon fibers are excellent for prepreg of the base layer. The reinforcing fibers may be arranged in one direction or may be used as a cloth (woven fabric). In order to obtain a thin prepreg, the reinforced fiber has a fiber diameter of 5 to 30 μm, preferably 6 to 15 μm. In order to obtain a transparent prepreg, glass fiber, aramid fiber, or the like is used, but glass fiber is excellent for use in the prepreg of the cover layer.

  Examples of the matrix resin used for the prepreg include one or more of thermosetting resins such as epoxy resins, unsaturated polyester resins, polyurethane resins, diallyl phthalate resins, and phenol resins. Epoxy resins are excellent. You may mix | blend a hardening | curing agent and another imparting agent, for example, a flexibility imparting agent, etc. with a matrix resin so that hardening temperature may be 50-200 degreeC.

  Preferred examples of the matrix resin include glycidyl ether type epoxy resins such as bisphenol A, F, and S type epoxy resins, novolak type epoxy resins, brominated bisphenol A type epoxy resins, cycloaliphatic epoxy resins, glycidyl, and the like. 1 type or 2 or more types, such as ester type epoxy resin, glycidyl amine type epoxy resin, tetraglycidyl diaminodiphenylmethane, triglycidyl p-aminophenol, heterocyclic epoxy resin, and other epoxy resins, and more Preferably, bisphenol A, F, S type epoxy resin, and glycidylamine type epoxy resin are used. Examples of the curing agent include amine-based curing agents such as dicyandiamide (DICI), diaminodiphenylsulfone (DDS), and diaminodiphenylmethane (DDM), and examples include hexahydrophthalic anhydride (HHPA) and methylhexahydrophthalic anhydride (MHHPA). 1) or 2 or more types such as acid anhydride curing agents such as), and preferably amine curing agents.

  In the production method of the present invention, a metal wire or foil having a thickness of 5 to 100 μm, a width of 0.1 to 100 mm, and a width to thickness ratio of 2 to 100 is used. If the ratio of width to thickness is smaller than 2, improvement of mechanical properties and thinning of the hybrid prepreg cannot be achieved. Preferably, the thickness is 30 to 80 μm, the width is 0.4 to 4 mm, and the ratio of width to thickness is 5 to 80.

  This flat-shaped metal wire can be manufactured, for example, by rolling or drawing a round metal wire. Examples of such metal wires include one or more selected from stainless steel, high-strength steel, titanium, amorphous alloy, and the like, but iron alloy or titanium is corrosion resistance and strength. It is advantageous in terms of improvement effect and its metallic luster. In order to improve the appearance, it is also advantageous to perform a surface treatment and gloss treatment.

  The metal foil is obtained by cutting or punching a metal foil having a predetermined thickness, and has the above thickness and width. Here, in the case of punching, an elongated slit, preferably a slit having a width of 0.1 to 100 mm, may be formed. It is also possible to improve the aesthetics by changing the shape of the punching die to make the cut surface corrugated. As the material of the metal foil, the same material as the metal wire is used.

  A flat metal wire 3 is wound around the surface side of the base layer 2 made of prepreg by drum winding and arranged at regular intervals. It is preferable that the metal wires 3 have an interval of 0.1 to 100 mm and are oriented in the same or substantially orthogonal direction as the prepreg reinforcing fibers. That is, it is preferably oriented in substantially the same direction with respect to the reinforcing fibers of the base layer, and preferably oriented in substantially the same direction and substantially orthogonal directions with respect to the reinforcing fibers (glass cloth) of the transparent cover layer. If the distance is too narrow, the adhesive strength between the base layer and the cover layer is lowered. If the distance is too wide, not only is the strength improved, but also the appearance is inferior. It is good to set the interval of about.

  In order to keep the tension of the metal wire constant by drum winding, a constant brake is applied to the unwinding bobbin in the conventional method, but the tension control method is adopted in the present invention. The tension control method will be described with reference to FIG.

  A flat metal wire 12 is pulled out from the unwinding bobbin 11 and wound around a drum 13. In the tension control method, the tension applied to the metal wire 12 is detected by the detector 14, and if the tension is excessively applied, the brake 15 of the unwinding bobbin 11 is weakened. Conversely, if the tension is weakened, the brake 15 is strengthened. In this method, the tension of the metal wire is kept constant by applying strength to the brake 15 of the unwinding bobbin 11 so that the tension is kept constant in the range of 40 to 400 gf / strand.

  By this tension control method, it is possible to manufacture a metal hybrid prepreg having an excellent appearance without being affected by the winding state of the unwinding bobbin and without disturbing the metal wire pitch arrangement. In addition, the flat metal wire used in the present invention is likely to be cut, stretched, or broken, but the tension control method is very effective because an abnormal tension is not applied to the metal wire in the production of the metal hybrid prepreg. If the metal foil is also linear, it can be similarly arranged on the base layer.

  By the way, in order to improve the adhesion between the base layer and / or the transparent cover layer and the metal wire or foil, the fiber diameter of the reinforcing fiber of the base layer and / or the transparent cover layer is 0. It is preferable to make it 1 to 0.5 times.

  In this way, the metal wires 3 are wound around the surface side of the base layer 2 by means such as drum winding, arranged at regular intervals, and further provided with a cover layer 4 made of prepreg, and these are crimped to form a metal hybrid. A prepreg can be manufactured.

  The metal hybrid prepreg obtained by the production method of the present invention is finished to be thin and lightweight without impairing mechanical properties, and is suitable as a prepreg used for processed products such as fishing rods, golf shafts and rackets. In this case, if the cover layer is wound so as to be on the outside, the metallic luster such as a metal wire enhances the beauty.

  FIG. 3 is a cross-sectional view of a tubular product such as a fishing rod, a handle of a racket such as a golf shaft, a tennis racket, or a badminton racket. The tubular product 21 includes an inner layer 22 having at least one prepreg layer, and an outer layer 23 formed by winding a metal hybrid prepreg on the outer side of the inner layer 22 so that the cover layer is on the outer side. And are integrally formed. Since the surface A of the outer layer 23 is transparent, the metal wire of the metal hybrid prepreg is visible from the outside. Further, it is preferable to change the thickness ratio of the inner layer 22 and the outer layer 23 of the tubular product 21 and the angle in the longitudinal direction of the metal wire or the like included in the outer layer 23 with respect to the axial direction in accordance with the application. The angle of the metal wire in the longitudinal direction relative to the axial direction can be changed by winding the metal hybrid prepreg serving as the outer layer 23 spirally at a predetermined angle with respect to the prepreg serving as the inner layer 22 in the manufacturing process of the tubular product 21. .

  In a fishing rod using a metal hybrid prepreg, the thickness ratio of the outer layer / inner layer is 50/50 to 10/90, preferably 20/80 to 10/90, and the longitudinal direction of the metal wire is 0 with respect to the product axis direction. It is good to be-± 90 degrees, preferably 0- ± 10 degrees, ± 80- ± 90 degrees. In the golf shaft, the thickness ratio of the outer layer to the inner layer is 20/80 to 4/96, preferably 15/85 to 5/95, and the longitudinal direction of the metal wire is ± 10 to ± 90 degrees with respect to the product axis direction. , Preferably ± 10 to ± 20 degrees and ± 80 to ± 90 degrees. In the racket, the thickness ratio of the outer layer to the inner layer is 20/80 to 4/96, preferably 15/85 to 5/95, and the longitudinal direction of the metal wire is 0 to ± 90 degrees with respect to the axial direction. The angle is preferably 0 to ± 10 degrees and ± 80 to ± 90 degrees.

Example 1
An epoxy resin is applied to a glass cloth (fiber diameter 13 μm) of 25 g / m ² to obtain a cover layer prepreg. The glass cloth content is 40 wt%. The PE film is taken up as a separator so that the PE film contacts the drum. FIG. 2 As shown in FIG. 2, a metal fiber (elastic modulus: 98 GPa, tensile strength: 980 MPa) made of titanium, 30 μm thick and 1.0 mm wide was wound by a drum winding method. The interval was 2.5 mm, and the direction was approximately 90 ° with respect to the drum axis. At this time, the tension was measured, and the result was fed back to the brake system so that the tension was 130 gf / strand. Next, this was pressurized with a roller, and the metal fiber and the cover layer prepreg were pressure-bonded. Remove this from the roller, bond a unidirectional epoxy resin prepreg (CF content 60 wt%) with a fiber diameter of 7 μm so that the metal fiber side and the fiber direction are almost the same direction as the metal fiber, and after pressure bonding, peel the PE film A metal hybrid prepreg having a thickness of 110 μm was obtained.

Example 2 (reference example)
After applying a release agent to a cored bar having a predetermined outer diameter, three layers of carbon fiber prepreg were wound to form an inner layer, and the metal hybrid prepreg was cut into a predetermined shape on the outer side and wound to form an outer layer. The direction with respect to the fiber axis of the prepreg was appropriately shifted, and the direction with respect to the metal fiber axis was 80 °. A fishing rod having a length of 2 m, an inner diameter of the tip portion of 1.0 mm, an inner diameter of the proximal portion of 15 mm, an inner layer thickness of 0.4 mm, and an outer layer thickness of 0.1 mm was obtained. This fishing rod had an excellent appearance and a good feeling when used.

Example 3 (reference example)
In the same manner as in Example 2, a golf shaft having a length of 1100 mm, a tip inner diameter of 5 mm, a hand inner diameter of 155 mm, an inner layer thickness of 1.2 mm, and an outer layer thickness of 0.1 mm was obtained.

Example 4 (reference example)
In the same manner as in Example 2, a tennis racket handle having an inner diameter of 28 mm, an outer diameter of 30 mm, an inner layer thickness of 0.9 mm, and an outer layer thickness of 0.1 mm was obtained. This had an excellent appearance and a good feel.

1: Metal hybrid prepreg, 2: Base layer, 3, 12: Metal wire, 4: Cover layer, 14: Detector, 15: Brake, 22: Inner layer, 23: Outer layer

Claims (4)

  When winding the metal wire around the surface of the base layer by drum winding so that the metal wires are arranged at regular intervals, the tension of the metal wire is detected, the brake of the unwinding bobbin is controlled by the detected tension, and the tension of the metal wire is reduced to 40. A method for producing a metal hybrid prepreg characterized by being kept constant in a range of ˜400 gf / strand.   A prepreg using reinforcing fibers having a fiber diameter of 5 to 30 μm is used as a base layer, and on the surface side of the base layer, the thickness is 5 to 100 μm, the width is 0.1 to 100 mm, and the width to thickness ratio is 2 to 100. In a method for producing a metal hybrid prepreg, in which a certain metal wire is arranged at intervals of 0.1 to 100 mm, and a prepreg using a reinforced fiber having a fiber diameter of 5 to 30 μm is laminated thereon as a transparent cover layer. When the metal wire is wound around the surface of the base layer by drum winding so that the metal wires are arranged at regular intervals, the tension of the metal wire is detected, and the brake of the unwinding bobbin is controlled by the detected tension to control the tension of the metal wire. A method for producing a metal hybrid prepreg, which is kept constant in a range of 40 to 400 gf / strand.   The method for producing a metal hybrid prepreg according to claim 1 or 2, wherein the fiber diameter of the reinforcing fiber of the base layer and / or the reinforcing fiber of the transparent cover layer is 0.1 to 0.5 times the thickness of the metal wire.   The method for producing a metal hybrid prepreg according to any one of claims 1 to 3, wherein the metal wire is obtained by rolling or drawing a round shape metal wire or punching a metal foil.

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