JP2012110935A - Apparatus and method for manufacturing fiber reinforced resin sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method and an apparatus for manufacturing a fiber reinforced resin sheet, by which a reinforcing fiber base material is satisfactorily impregnated with thermoplastic resin.SOLUTION: In the method for manufacturing the fiber reinforced resin sheet S by introducing a sheet-like reinforcing fiber base material F and the thermoplastic resin P between a pair of rolls 10, 20 and impregnating the reinforcing fiber bass material F with the thermoplastic resin P while rotating the pair of rolls, by using a main roll 10 made of metal and a press roll 20 made of metal as the pair of rolls 10, 20 and pressing the press roll 20 against the main roll 10, the reinforcing fiber base material F is impregnated with the thermoplastic resin P while deforming the peripheral surface 21 of the press roll 20 so that the peripheral surface of the press roll 20 follows the shape of the peripheral surface of the main roll 10.

Description

  The present invention provides a fiber-reinforced resin sheet manufacturing apparatus and a fiber in which a sheet-like reinforcing fiber base material and a thermoplastic resin are introduced between a pair of rolls, and the reinforcing fiber base material can be suitably impregnated with the thermoplastic resin. The present invention relates to a method for producing a reinforced resin sheet.

  Conventionally, a fiber reinforced composite material (fiber reinforced resin material) using a thermosetting resin or a thermoplastic resin as a matrix resin is lighter and more elastic than a metal material, and higher in strength than a resin material alone. Therefore, it is a material that is attracting attention for the application of members for vehicles.

  In order to make use of the characteristics of the high strength and high elasticity against tension, which are the original characteristics of the reinforcing fiber, a reinforcing fiber such as a long fiber is used as a reinforcing fiber substrate, and this reinforcing fiber substrate is impregnated with a matrix resin in advance, or It is generally semi-impregnated and used as a prepreg sheet (fiber reinforced resin sheet).

  On the other hand, fiber reinforced resin sheets impregnated with a thermoplastic resin as a matrix resin are attracting attention as a value-added material because of their characteristics of thermoplastic resins, which are excellent in toughness, short-time moldability, storage stability, recyclability, etc. Yes.

  However, the thermoplastic resin generally has a higher viscosity than the thermosetting resin, and it is necessary to heat it to a high temperature when molding the thermoplastic resin. Even if the thermoplastic resin is simply formed into a film having a uniform thickness, the forming is not easy. For example, as such a technique, a sheet-shaped molten resin extruded by an extruder is introduced between a metal main roll and a metal pressing roll, and the thin outer cylinder of the pressing roll is placed around the main roll. There is a technique in which a film-like thermoplastic resin is formed by, for example, a film-like thermoplastic resin by being clamped while cooling the resin between these rolls while being deformed so as to follow the surface shape (see, for example, Patent Document 1).

  As described above, it is not easy to mold a thermoplastic resin into a film shape. In addition, it is more difficult to manufacture a fiber reinforced resin sheet using a thermoplastic resin as a matrix resin than a thermosetting resin. It is a more difficult technology. And various researches are made | formed with respect to these techniques (for example, refer nonpatent literature 1).

  For example, as a method of manufacturing a fiber reinforced resin sheet by impregnating a reinforcing fiber base material with a thermoplastic resin, a softened thermoplastic resin film is pressed and impregnated on a reinforcing fiber base material with a pair of metal pressure rolls. And a method of impregnating a reinforcing fiber base material with a thermoplastic resin between these rolls using a metal roll and a rubber roll (for example, see Patent Document 3), etc. ing.

JP 11-235747 A JP-A-7-016936 JP-A-7-016835

Fukui Industrial Technology Center 2000 Research Report No. 17 “Simulation of thermoplastic resin impregnation to develop thermoplastic resin prepreg equipment, Kazumasa Kawamata et al.

  By the way, as shown in the said nonpatent literature 1, inventors have performed analysis of how a thermoplastic resin is impregnated in a reinforced fiber bundle. There, a simple modeling is performed for a process in which a thermoplastic resin is impregnated in a reinforcing fiber bundle, and a basic theoretical formula for impregnation is derived. According to this theoretical formula, when (1) the thickness of the reinforcing fiber bundle is thin, (2) the molding pressure (pressure during impregnation) is high, and (3) the melt viscosity of the thermoplastic resin is low, It has been found that the impregnation time of the thermoplastic resin into the resin is shortened (it is easy to impregnate the reinforcing fiber base material with the thermoplastic resin). In the case of a thermoplastic resin, since the melt viscosity is higher than that of a thermosetting resin, the impregnation state of the resin depends on conditions such as melting temperature, molding pressure, fiber bundle thickness (base material thickness), molding time, etc. Compared with curable resin, it changes greatly.

  In view of such knowledge of the inventors, for example, as in Patent Document 2, when a pair of metal pressure rolls are used, a linear pressure is applied to the thermoplastic resin and the reinforcing fiber substrate between the rolls. The time during which the pressure is applied is instantaneous, and the reinforcing fiber base material may not be sufficiently impregnated with the thermoplastic resin. In addition, when linear pressure is applied, pressure unevenness tends to occur in the roll width direction, and the thermoplastic resin may not be uniformly impregnated into the reinforcing fiber base.

  On the other hand, when a metal roll and a rubber roll are used as in Patent Document 3, a surface pressure can be applied to the thermoplastic resin and the reinforcing fiber base between the rolls. However, when a rubber roll is used, the heat resistant temperature of the rubber is about 200 ° C., so that the reinforcing fiber base material is impregnated with the thermoplastic resin in a high temperature condition (lower viscosity). There are things that cannot be done.

  The present invention has been made in view of these points, and provides a method for manufacturing a fiber reinforced resin sheet and a manufacturing apparatus for the fiber reinforced resin sheet that can satisfactorily impregnate a reinforced fiber base material with a molten thermoplastic resin. It is in.

  In order to solve the above-mentioned problems, a method for producing a fiber-reinforced resin sheet according to the present invention introduces a sheet-like reinforcing fiber base material and a thermoplastic resin between a pair of rolls, and rotates the pair of rolls. However, it is premised on a method of manufacturing a fiber reinforced resin sheet by impregnating the molten thermoplastic resin with the molten thermoplastic resin.

  In the case of the first invention, a metal main roll and a metal pressing roll are used as the pair of rolls, and the pressing roll is pressed against the main roll. The reinforcing fiber base material is impregnated with the thermoplastic resin while the peripheral surface of the pressing roll is deformed so that the peripheral surface of the main roll follows the shape of the peripheral surface of the main roll. On the other hand, in the case of the second invention, a metal main roll is used as the pair of rolls, and the pair of rolls are pressed against each other, whereby the opposing circumferential surfaces of both rolls are deformed into a flat shape. However, the reinforcing fiber base material is impregnated with the thermoplastic resin.

  According to the first invention, by pressing the pressing roll against the main roll, the peripheral surface of the pressing roll is deformed so that the peripheral surface of the pressing roll follows the peripheral surface shape of the main roll. A surface pressure can be applied to a certain thermoplastic resin and the reinforcing fiber substrate. According to the second invention, by pressing the pair of rolls, the opposing circumferential surfaces of both rolls are deformed into a flat shape, so that similarly, the thermoplastic resin and the reinforcing fiber base between the rolls are used. A surface pressure can be applied to the surface.

  In this way, the pressure acting on the reinforcing fiber base is different from the linear pressure acting when using a simple metal roll so far, so that it becomes a surface pressure, so that an excessive stress is applied to the reinforcing fiber base. The reinforcing fiber base material can be impregnated with the thermoplastic resin uniformly and stably. In addition, by applying a surface pressure while rotating the roll, the impregnation time is not instantaneous as in the past, and further, the air intervening between the fibers of the reinforcing fiber base is suitably deaerated during the impregnation. A fiber-reinforced resin sheet having a uniform thickness with no stepped streaks in the width direction can be obtained.

  In particular, in the case of the second invention, the thermoplastic fiber and the reinforcing fiber base are impregnated with the thermoplastic resin while the peripheral surfaces of both rolls facing each other are deformed into a flat shape. And uniform stress can be applied to both sides. Thereby, the uniform fiber reinforced resin sheet of uniform thickness can be obtained.

  Furthermore, in any invention, since the pair of rolls are metal rolls, the temperature of the thermoplastic resin is higher than when the rubber roll is used (for example, the temperature at which the thermoplastic resin melts (for example, 200 ° C.). ˜420 ° C.)). As a result, compared with the case where a metal roll and a rubber roll are used, it is possible to make the thermoplastic resin have a lower viscosity and pressurize this to impregnate the reinforcing fiber base. In this manner, among the thermoplastic resins, it is possible to produce a fiber reinforced resin sheet even for a thermoplastic resin having a high impregnation temperature (molding temperature) and a high melt viscosity.

  For any of the inventions, as a preferred embodiment, the thermoplastic resin is heated by heating the pair of rolls and supplying the thermoplastic resin to the peripheral surface of the heated at least one roll. The molten thermoplastic resin is impregnated while the heated thermoplastic resin is conveyed between the pair of rolls by the rotation of the pair of rolls.

  According to this aspect, the thermoplastic resin is supplied to the peripheral surface of at least one heated roll and receives heat generated from the roll on the peripheral surface of the roll until it is conveyed between the rolls. Here, when the thermoplastic resin to be supplied is heated until it is melted in advance, the temperature of the thermoplastic resin can be suppressed by the heat of the roll until it reaches between the rolls. This suppresses the increase in viscosity of the thermoplastic resin. For example, when a powdery thermoplastic resin or a film-like thermoplastic resin is supplied, the thermoplastic resin can be melted before reaching between the rolls.

  Here, the arrangement of the pair of rolls is not particularly limited as long as the thermoplastic resin can be supplied to the roll surface and supplied between the rolls together with the reinforcing fiber base. However, more preferably, the pair of rolls are arranged side by side in the horizontal direction, and the peripheral surface for supplying the thermoplastic resin may be a peripheral surface on the upper side of the roll. According to this aspect, the thermoplastic resin can be supplied to the peripheral surface on the upper side of the roll by its own weight, and the supplied thermoplastic resin is heated on the roll surface until the roll is rotated approximately one quarter. Can be introduced between the rolls.

  As a more preferable embodiment, the reinforcing fiber base is wound around one of the pair of rolls, and the thermoplastic resin is supplied to the surface of the reinforcing fiber base wound around the roll. .

  According to this aspect, the reinforcing fiber resin base material wound around the roll is heated by the heat of the roll, and the heated thermoplastic resin is supplied to the reinforcing fiber base material. The heat of the roll can be used to supply both the preheated substrate and resin between the rolls.

  The press roll of the first invention and the pair of rolls used in the second invention need only be made of at least a metal material, and can be deformed so as to exert a surface pressure on the thermoplastic resin and the reinforcing fiber substrate. If so, for example, a metal material that can be more elastically deformed than a general metal material such as a β-type Ti alloy so-called rubber metal may be used for these rolls.

  However, as a more preferable aspect, as the pressing roll of the first invention, there is a thin metal outer cylinder that deforms following the shape of the peripheral surface of the main roll by the pressing, and a cylindrical space inside the thin metal outer cylinder. A roll having at least a shaft core inserted into the thin-walled metal outer cylinder so as to be formed is used. On the other hand, as a pair of rolls of the second invention, the thin metal outer cylinder is formed so that a thin metal outer cylinder deformed following the planar shape by the pressing and a cylindrical space is formed inside the thin metal outer cylinder. A roll provided with at least an axial core inserted in a cylinder is used.

  By using rolls having such a structure, not only can surface pressure be applied to the thermoplastic resin and the reinforcing fiber base, but the rolls themselves can be utilized by utilizing the cylindrical space formed inside the roll. Can be suitably heated. Here, in order to obtain a more preferable deformation of the roll, when the thickness t of the thin metal outer cylinder of the deformed portion and the roll radius (radius of the outer diameter of the thin metal outer cylinder) are r, t / r It is preferable that the relationship of ≦ 0.03 is satisfied.

  When these rolls are heated, the roll surface may be heated using, for example, an infrared heater. However, as a preferable aspect, in the case of the first invention, a press roll is provided by supplying a heated medium into a cylindrical space formed between the thin metal outer cylinder and the shaft core. In the case of the second invention, both the pair of rolls are heated. Thereby, the thermoplastic resin introduced between the pair of rolls can be efficiently heated.

  As another preferred aspect, an induction heating coil is disposed so as to be wound around the shaft core body in the cylindrical space, and an alternating current is passed through the induction heating coil to heat the pressing roll. Also good. Even with this method, the thermoplastic resin between the pair of rolls can be efficiently heated. If the thin metal outer cylinder is made of a magnetic material and the core is made of a conductive material, the thin metal outer cylinder can be directly heated by the induction heating coil.

  Moreover, when supplying a thermoplastic resin, it is more preferable to supply the molten thermoplastic resin between said pair of rolls continuously in a sheet form. Since the molten thermoplastic resin is formed into a sheet and continuously supplied, the reinforcing fiber base material can be impregnated with the thermoplastic resin.

  Thus, in both the first and second inventions, the number of the pair of rolls is not particularly limited as long as the thermoplastic resin can be suitably impregnated. However, as a more preferable aspect, a plurality of pairs of rolls are arranged along the conveying direction of the reinforcing fiber base, and the reinforcing fiber base is sequentially passed between the plurality of pairs of rolls, thereby A fiber base material is impregnated with the thermoplastic resin. Thus, since the impregnation of the resin can be performed a plurality of times between the rolls, the reinforcing fiber base material can be more reliably impregnated with the thermoplastic resin.

  In particular, in the case of the first invention, as the plurality of pairs of rolls, impregnation is performed using rolls arranged so that the arrangement of the main roll and the pressing roll along the conveying direction is alternated. Since the reinforcing fiber base material is not bent only in one direction at the time of impregnation, a more uniform fiber reinforced resin sheet can be obtained.

  As another aspect of the first invention, a plurality of the pressing rolls are arranged around the main roll, and the main roll and each pressing roll are wound while the reinforcing fiber base is wound around the main roll. It is preferable that the reinforcing fiber base material is sequentially passed between and the reinforcing fiber base material is impregnated with the thermoplastic resin. Thereby, since the impregnation of the resin can be performed a plurality of times between the rolls using one main roll, the apparatus can be made compact.

  Further, as a preferred embodiment, in both cases of the first and second inventions, the reinforcing fiber base is disposed on the surface of a pair of rolls while disposing a release material that can be released from the thermoplastic resin. The material is impregnated with the thermoplastic resin. By using a release material, a fiber reinforced resin sheet can be produced without the thermoplastic resin melted and softened adhering to the roll surface.

  In this application, the manufacturing apparatus for implementing suitably the manufacturing method which concerns on the 1st and 2nd invention mentioned above as this invention is also disclosed. The apparatus for producing a fiber-reinforced resin sheet according to the present invention introduces a sheet-like reinforcing fiber base material and a thermoplastic resin between a pair of rolls, and rotates the pair of rolls to the reinforcing fiber base material. A device for manufacturing a fiber-reinforced resin sheet by impregnating the molten thermoplastic resin, the manufacturing device supplying a reinforcing fiber substrate for supplying the reinforcing fiber substrate introduced between the pair of rolls On the premise of a device configuration including a resin supply unit that supplies the thermoplastic resin introduced between the pair of rolls, and a pressing unit that presses the pair of rolls, and further includes the following characteristic configuration ing.

  That is, the pair of rolls of the manufacturing apparatus (hereinafter referred to as the first apparatus invention) corresponding to the manufacturing method according to the first invention is composed of a metal main roll and a metal pressing roll, The pressing roll of the manufacturing apparatus according to the invention is characterized in that the peripheral surface of the pressing roll is deformed following the peripheral surface shape of the main roll by the pressing force of the pressing portion. On the other hand, a pair of rolls of a manufacturing apparatus (hereinafter referred to as a second apparatus invention) corresponding to the manufacturing method according to the second invention is a metal roll, and both the rolls are pressed by the pressing force of the pressing portion. It is characterized in that the opposed peripheral surfaces are configured to be deformed into a flat shape.

  In either case of the first and second device inventions, the surface pressure is applied to the thermoplastic resin and the reinforcing fiber base between the rolls while rotating the pair of rolls, and the air between the fibers is blown. While degassing, the reinforcing fiber base material can be uniformly and stably impregnated with a thermoplastic resin melted at a higher temperature than before.

  As a more preferable aspect of these inventions, the manufacturing apparatus includes a heating unit that heats the pair of rolls, and the resin supply unit includes a peripheral surface of at least one of the pair of rolls, It arrange | positions so that the said thermoplastic resin may be supplied toward the surrounding surface which can convey the said thermoplastic resin between a pair of said roll by rotation of a pair of said roll.

  According to this aspect, the thermoplastic resin is supplied to the peripheral surface toward the peripheral surface of at least one of the heated rolls and generates heat from the roll on the roll peripheral surface until it is conveyed between the rolls. It receives heat and can impregnate the reinforcing fiber substrate.

  The arrangement of the pair of rolls is not particularly limited as long as the thermoplastic resin can be supplied to the roll surface and supplied between the rolls together with the reinforcing fiber base. However, a more preferable aspect is that the pair of rolls are arranged side by side in the horizontal direction, and the peripheral surface to which the thermoplastic resin is supplied is a peripheral surface on the upper side of the roll. According to this aspect, as described above, the thermoplastic resin supplied to the peripheral surface of the roll can be more efficiently heated on the roll surface and introduced between the rolls.

  Furthermore, as a more preferable aspect, the reinforcing fiber base is wound around one of the pair of rolls, and the thermoplastic resin is supplied to the surface of the reinforcing fiber base wound around the roll.

  According to this aspect, the reinforcing fiber resin base material wound around the roll is heated by the heat of the roll, and the heated thermoplastic resin is supplied to the reinforcing fiber base material. The heat of the roll can be used to supply both the preheated substrate and resin between the rolls.

  The pressing roll according to the first device invention has a thin metal outer cylinder that deforms in accordance with the shape of the peripheral surface of the main roll by the pressing force of the pressing portion, and a cylindrical space inside the thin metal outer cylinder. It is preferable to include at least an axial core inserted into the thin metal outer cylinder so as to be formed. On the other hand, both of the pair of rolls according to the second device invention include a thin metal outer cylinder that deforms following the planar shape of the main roll by the pressing force of the pressing portion, and a cylindrical shape inside the thin metal outer cylinder. It is preferable to include at least a shaft core inserted in the thin metal outer cylinder so that a space is formed. Thereby, these rolls themselves can be suitably heated using the cylindrical space formed inside the rolls.

  In the case of the first invention, the heating unit that heats the pressing roll and in the case of the second invention preferably supplies the heated medium into the cylindrical space. As an aspect of the above, it is preferable that the heating unit includes at least an induction heating coil wound around the shaft core in a cylindrical space, and a power source that supplies an alternating current to the induction heating coil. In the latter case, if the thin metal outer cylinder is made of a magnetic material and the core is made of a conductive material, it is more preferable because the thin metal outer cylinder can be directly heated by the induction heating coil.

  Moreover, as a preferable aspect, the resin supply unit according to the first and second device inventions is configured to continuously supply a molten thermoplastic resin in the form of a sheet as the thermoplastic resin. For example, it can be realized by using a die having slit holes, a die having a plurality of holes formed in a line at equal intervals, etc., in the resin discharge portion of the extrusion molding machine.

  In a more preferred embodiment of the first and second device inventions, a plurality of pairs of rolls are arranged along the conveying direction of the reinforcing fiber substrate. Accordingly, the reinforcing fiber base can be sequentially passed between the plurality of pairs of rolls, so that the step of impregnating the thermoplastic resin into the reinforcing fiber base can be continuously performed a plurality of times. .

  In particular, in the case of the first invention, the plurality of pairs of rolls are preferably arranged so that the arrangement of the main rolls and the pressing rolls along the conveying direction is alternated. A homogeneous fiber-reinforced resin sheet can be obtained.

  When the plurality of pairs of rolls are used in this manner, as a more preferable aspect, the roll peripheral surface is separated from the thermoplastic resin so that the plurality of rolls having the same rotation direction are connected. A belt that can be molded is wrapped around. By using the belt material, the fiber-reinforced resin sheet can be continuously produced without the thermoplastic resin melted and softened adhering to the roll surface.

  Further, in the case of the first invention, as another preferred embodiment, a plurality of pressing rolls are arranged around the main roll, whereby a homogeneous fiber-reinforced resin sheet can be obtained with a compact device configuration.

  According to the present invention, the reinforcing fiber base material can be satisfactorily impregnated with the thermoplastic resin.

The typical conceptual diagram of the manufacturing apparatus of the fiber reinforced resin sheet which concerns on 1st Embodiment of 1st invention. The typical perspective view of the resin impregnation part of the fiber reinforced resin sheet manufacturing apparatus shown in FIG. It is a typical conceptual diagram for demonstrating the press state of a pair of rolls of the fiber reinforced resin sheet manufacturing apparatus shown in FIG. 1, (a) is a state before pressing by a press part, (b) By a press part The figure for demonstrating the state pressed. The typical sectional view in the horizontal direction containing the axis of rotation of a pair of rolls shown in FIG. Typical sectional drawing which showed the resin impregnation part of the manufacturing apparatus of the fiber reinforced resin sheet which concerns on the modification of 1st Embodiment shown in FIG. Typical sectional drawing which showed the resin impregnation part of the manufacturing apparatus of the fiber reinforced resin sheet which concerns on another modification of 1st Embodiment shown in FIG. The typical perspective view of the press roll concerning a 2nd embodiment of the 1st invention. Typical sectional drawing which showed the resin impregnation part of the manufacturing apparatus of the fiber reinforced resin sheet which concerns on 3rd embodiment of 1st invention. Typical sectional drawing which showed the resin impregnation part of the manufacturing apparatus of the fiber reinforced resin sheet which concerns on the modification of 3rd Embodiment shown in FIG. Typical sectional drawing which showed the resin impregnation part of the manufacturing apparatus of the fiber reinforced resin sheet which concerns on another modification of 3rd Embodiment shown in FIG. Typical sectional drawing which showed the resin impregnation part of the manufacturing apparatus of the fiber reinforced resin sheet which concerns on 4th Embodiment of 1st invention. Typical sectional drawing which showed the resin impregnation part of the manufacturing apparatus of the fiber reinforced resin sheet which concerns on the modification of 4th Embodiment shown in FIG. Typical sectional drawing which showed the resin impregnation part of the manufacturing apparatus of the fiber reinforced resin sheet which concerns on another modification of 4th Embodiment shown in FIG. The typical sectional view showing the resin impregnation part of the manufacture device of the fiber reinforced resin sheet concerning the embodiment of the 2nd invention. The typical sectional view in the horizontal direction containing the axis of rotation of a pair of rolls of Drawing 14. The typical sectional view showing the resin impregnation part of the manufacture device of the fiber reinforced resin sheet concerning the modification of the embodiment shown in FIG. The typical sectional view showing the resin impregnation part of the manufacture device of the fiber reinforced resin sheet concerning another modification of the embodiment shown in FIG.

  Below, based on drawing, several embodiment which can implement suitably the manufacturing method of the fiber reinforced resin sheet which concerns on this invention is described.

  FIG. 1 is a schematic conceptual diagram of a fiber-reinforced resin sheet manufacturing apparatus according to the first embodiment of the first invention, and FIG. 2 is a schematic diagram of a resin-impregnated portion of the fiber-reinforced resin sheet manufacturing apparatus shown in FIG. FIG. FIG. 3 is a schematic conceptual diagram for explaining a pressed state between a pair of rolls of the fiber-reinforced resin sheet manufacturing apparatus shown in FIG. 1, (a) is a state before being pressed by a pressing portion, (b ) It is a figure for demonstrating the state pressed by the press part. 4 is a schematic cross-sectional view in the horizontal direction including the rotation shafts of the pair of rolls shown in FIG.

  The fiber reinforced resin sheet manufacturing apparatus 1 according to the present embodiment is an apparatus for manufacturing a fiber reinforced resin sheet. The manufacturing apparatus 1 introduces a sheet-like reinforcing fiber base F and a thermoplastic resin P into a pair of rolls 10 and 20 described later, and heats the reinforcing fiber base F while rotating the pair of rolls. It is an apparatus intended to produce a fiber reinforced resin sheet S by being impregnated with a plastic resin P.

  As shown in FIG. 1, the manufacturing apparatus 1 which concerns on this embodiment is the reinforcement fiber supply part 2 which supplies the reinforcement fiber base material F introduced between a pair of rolls of the resin impregnation part 4 mentioned later, and a pair of rolls. And a resin supply unit 3 for supplying a thermoplastic resin P introduced therebetween.

  The reinforcing fiber supply unit 2 supplies a reinforcing fiber base F in which continuous fibers are aligned in one direction in a sheet shape, and the reinforcing fiber base F before the supply is wound in a coil shape. 2a. Conveying rolls 2b and 2c are arranged in the reinforcing fiber supply unit 2 so that the sheet-like reinforcing fiber substrate F unwound from the wound body 2a can be introduced between the rolls 10 and 20 described later. Yes.

  On the other hand, in the present embodiment, as an example, the resin supply unit 3 melts the thermoplastic resin pellets Pa above the softening point, and melts the sheet-like heat through a die (nozzle) 3a that is a resin discharge port. This is a biaxial extrusion molding apparatus for continuously molding the plastic resin P. The die 3a is disposed above the pair of rolls 10 and 20, and the die 3a has a plurality of holes formed at equal intervals along the width direction, and is melted through the plurality of holes. Is extruded continuously in the form of a sheet.

  And as shown to Fig.3 (a), the die | dye 3a of the resin supply part 3 is a pair of thermoplastic resin in a surrounding surface by rotation of a pair of rolls among the surrounding surfaces 21 of the pressing roll 20 mentioned later. It arrange | positions so that the thermoplastic resin P may be supplied toward the surrounding surface which can be conveyed between these rolls 10 and 20. FIG. This peripheral surface to which the thermoplastic resin P is supplied is preheated by the heat generated from the peripheral surface of the pressing roll 20 during the transport before being introduced between the rolls. It is the surrounding surface in the position which can do. Therefore, in this embodiment, since a pair of rolls 10 and 20 are arrange | positioned along with the horizontal direction so that it may mention later, the surrounding surface which supplies the thermoplastic resin P is among the surrounding surfaces 21 of the pressing roll 20. The upper peripheral surface 21a is used.

  The resin impregnation unit 4 impregnates the thermoplastic resin P that is supplied in this way and heated while being wound around the peripheral surface 21 of the pressing roll 20. Here, the resin impregnation part 4 is provided with a pair of rolls 10 and 20 for impregnating the thermoplastic resin P with the reinforcing fiber base F as shown in FIGS. Specifically, the pair of rolls 10 and 20 includes a main roll 10 and a pressing roll 20, and these rolls are arranged side by side in the horizontal direction.

  As shown in FIG. 4, the main roll 10 is a rigid roll made of metal such as steel or aluminum having higher rigidity than the press roll 20, and one end of the main roll 10 is connected to the motor 30 via a coupling 31. It is connected to the. Further, the main roll 10 has a cylindrical space S1 formed therein. A heated medium (for example, water) M is introduced from the heating unit 40 through the medium introduction port 13a formed in the shaft 13 into the cylindrical space S1, passes through the inside of the main roll 10, and is discharged. The medium M is connected to the heating unit 40 so that it circulates. Thereby, the peripheral surface 11 of the main roll 10 can be heated.

  The pressing roll 20 is a roll that presses the main roll 10, and is connected to a pressing portion 50 that presses the pair of rolls, that is, the main roll 10 and the pressing roll 20. Specifically, the pressing unit 50 includes a piston 51 and a cylinder 52 connected to the shafts 23 on both sides of the pressing roll 20, and if the pressing described later can be performed, the operating pressure for pressing is: Either air pressure or hydraulic pressure may be used.

  With the pressing force of the pressing portion 50, the pressing roll 20 is deformed when the peripheral surface 21 of the pressing roll 20 follows the shape of the peripheral surface 11 of the main roll 10 and there is no supply between the rolls. These rolls are configured to be surface-bonded. In the case of the present embodiment, specifically, the pressing roll 20 includes a thin metal outer cylinder 24 that deforms according to the shape of the peripheral surface 11 of the main roll 10 by the pressing force of the pressing portion 50, and a thin metal outer cylinder. The shaft core body 27 is inserted into the thin metal outer cylinder 24 so that the cylindrical space S <b> 2 is formed in the interior of the outer wall 24. In this way, the main roll 10 has higher rigidity on the roll surface than the pressing roll 20, and the pressing roll 20 has higher flexibility on the roll surface than the main roll 10.

  The thin-walled metal outer cylinder 24 is a thin-walled cylinder made of metal such as steel or aluminum with both sides tapered, and flanges 28 are attached to both sides, and these are fixed. The flange 28 is supported by shafts 23 formed at both ends of the shaft core body 27 via bearings 29.

  With such a structure, the pressing roll 20 (specifically, the thin metal outer cylinder 24) rotates together with the main roll 10 by the rotation of the motor 30 connected to the main roll 10 at the time of pressing. However, without using the bearing 29, the pressing roll 20 together with the shaft 23 may be connected to another motor so as to rotate in synchronization with the main roll 10.

  Here, as for the press roll 20, the roll diameter r of the trunk | drum which deform | transforms facing the main roll 10 is 200-500 mm, The effective width (width which can contact the main roll 10) L is 500 mm- It is composed of about 1600 mm. The main roll 10 is also substantially equivalent.

  Further, when the thickness of the thin metal outer cylinder 24 is t and the roll radius is r, it is preferable that the relationship of t / r ≦ 0.03 is satisfied, and the smaller the ratio, the smaller the thickness of the thin metal outer cylinder 24. The flexibility of the peripheral surface portion is increased. For example, when the roll diameter r is 200 to 500 mm as described above and the roll diameter of the main roll 10 is also equal, the contact width between the rolls shown in FIG. 3B is about 2 mm to 5 mm.

  Further, in the cylindrical space S <b> 2 formed between the thin metal outer cylinder 24 and the shaft core body 27, the heated medium M is heated from the heating unit 40 through the medium introduction port 23 a formed in the shaft 23. (For example, water or the like) is introduced and connected to the heating unit 40 so that the medium discharged through the inside of the pressing roll 20 circulates. Thereby, the surrounding surface 21 of the thin metal outer cylinder 24 (pressing roll 20) can be heated.

  Here, the heating unit 40 heats the medium M inside so that the roll surface temperature is equal to or higher than the softening point temperature of the thermoplastic resin P that passes between the rolls. It is configured to be pressure-fed to the rolls 10 and 20 by using a device such as a pump so as to heat both of the holding rolls 20. Thereby, between the rolls 10 and 20, the thermoplastic resin P supplied to the upper peripheral surface 21 is softened. As a result, the thermoplastic resin P is easily impregnated into the reinforcing fiber base F. Here, although the shaft core body 27 is a solid cylinder, for example, as shown in Patent Document 1 described above, the medium M is loaded from one side of the shaft using a cylindrical shaft core body. It may be circulated.

  Further, a plurality of transport rolls are arranged further downstream of the pair of rolls 10 and 20 of the resin impregnation unit 4 (see FIG. 1), and the apparatus 1 is a fiber-reinforced resin sheet obtained by the resin impregnation unit 4. The winding part 5 for further winding the is disposed.

  The manufacturing method of the fiber reinforced resin sheet using the manufacturing apparatus comprised in this way is demonstrated below. First, as the reinforcing fiber substrate F, a reinforcing fiber substrate in which continuous fibers are aligned in one direction and wound in a coil shape is prepared. Here, as the reinforcing fiber base material, a base material aligned in one direction was used. For example, if it can be a sheet-like reinforcing fiber base material, long fibers that are not aligned, or Cloth-like fibers such as woven fabric and non-woven fabric may be used. In the case of a woven fabric, the weaving method may be any of woven structures such as plain weave, twill weave, satin weave, etc., and is a sheet-like thermoplastic resin between rolls described later while being continuously conveyed. The state of the fiber is not particularly limited as long as it can be impregnated with P.

  The reinforcing fiber is a resin reinforcing fiber for reinforcing the mechanical strength of the fiber reinforced resin sheet. For example, glass fiber, carbon fiber, natural fiber, aramid fiber, alumina fiber, boron fiber, steel fiber, PBO fiber Or fibers such as high-strength polyethylene fibers.

  On the other hand, the thermoplastic resin pellet Pa is introduced into the resin supply unit 3, and the molten sheet-like thermoplastic resin P is discharged from the die 3a. As such a thermoplastic resin, a crystalline thermoplastic resin or an amorphous thermoplastic resin can be used. For example, an olefin resin such as a nylon resin, a polycarbonate resin, a polyamide resin, a polypropylene resin, an acrylic resin, etc. Examples thereof include a resin or an ABS resin, and may be a thermoplastic resin having a higher melting point (higher softening point) than these.

  Then, the sheet-like reinforcing fiber base F and the molten sheet-like thermoplastic resin P are introduced between the pair of rolls 10 and 20, and the pair of rolls 10 and 20 are rotated by the driving force of the motor 30. The fiber reinforced resin sheet is manufactured by impregnating the reinforced fiber base F with the thermoplastic resin P.

  Specifically, by pressing the pressing roll 20 against the main roll 10, the peripheral surface 21 of the pressing roll 20 is deformed so that the peripheral surface 21 of the pressing roll 20 follows the shape of the peripheral surface 11 of the main roll 10. (See FIG. 3B).

  In this state, as shown in FIG. 4, the medium M heated to the cylindrical space S <b> 1 and the cylindrical space S <b> 2 is supplied by the heating roll 40 to heat the main roll 10 and the pressing roll 20. And the thermoplastic resin P is heated by supplying the thermoplastic resin P toward the surrounding surface of the pressing roll 20. While the heated thermoplastic resin P is transported between the pair of rolls 10 and 20 by the rotation of the pair of rolls 10 and 20, the thermoplastic resin P is heated between the rolls 10 and 20. Then, the reinforcing fiber base F is impregnated with the thermoplastic resin P.

  In this way, by pressing the pressing roll 20 against the main roll 10, the peripheral surface 21 of the pressing roll 20 is deformed so that the peripheral surface 21 of the pressing roll 20 follows the shape of the peripheral surface 11 of the main roll 10. Therefore, the surface pressure can be applied to the thermoplastic resin P and the reinforcing fiber base F. The pressure acting on the reinforcing fiber base F becomes a surface pressure unlike the linear pressure acting when using a conventional rigid metal roll so far, and it is necessary to apply excessive stress to the reinforcing fiber base F. There is no.

  And the thermoplastic resin P is supplied to the upper peripheral surface 21a of the heated pressing roll 10 by its own weight, and is conveyed between the rolls 10 and 20 (until the pressing roll 20 rotates approximately one-fourth. ), The heat generated from the roll 10 is received on the upper peripheral surface 21a. Here, since the supplied thermoplastic resin P is heated until it is melted in advance, the temperature of the thermoplastic resin can be suppressed by the heat of the roll until it reaches between the rolls. , The increase in the viscosity of the resin is suppressed.

  As described above, the reinforcing fiber base F can be uniformly and stably impregnated with the molten thermoplastic resin P between the rolls using the heat of the pressing roll 20. Further, by applying a surface pressure while rotating the pair of rolls 10 and 20, the impregnation time can be maintained longer than that of the conventional rolls, and between the fibers of the reinforcing fiber base F during the impregnation. Air can be suitably degassed, and furthermore, a fiber-reinforced resin sheet having a uniform thickness with no stepped streaks in the width direction can be obtained.

  Furthermore, since the pair of rolls 10 and 20 are metal rolls, the thermoplastic resin P can be heated to a higher temperature than conventional rubber rolls. As a result, compared with the case where a metal roll and a rubber roll are used, it is possible to make the thermoplastic resin P have a lower viscosity and pressurize it to impregnate the reinforcing fiber base F. In this manner, among the thermoplastic resins P, the fiber-reinforced resin sheet S can be manufactured even for thermoplastic resins having a high impregnation temperature (molding temperature) and a high melt viscosity.

  Then, the fiber reinforced resin sheet S obtained in this way is passed through a transport roll, and is wound up in a coil shape by the winding unit 5. In the present embodiment, the thermoplastic resin P is directly supplied to the upper peripheral surface 21a of the press roll 20, but the thermoplastic resin may be supplied to the upper peripheral surface of the main roll 10, and the upper side of both of them. You may supply the thermoplastic resin P to a surrounding surface.

  5 and 6 are schematic cross-sectional views showing a resin-impregnated portion of a fiber-reinforced resin sheet manufacturing apparatus according to a modification of the first embodiment shown in FIG. The modified example shown in FIG. 5 is different from the winding state of the fiber reinforced base material in the position of the die, the modified example shown in FIG. 6 is different in the position of the die, and other configurations are shown in FIGS. It is the same as the device configuration. Therefore, this difference will be described below.

  As shown in FIG. 5, the reinforcing fiber supply unit 2 arranges a transport roll (not shown) on the upstream side of the main roll 10 so that the reinforcing fiber base F wraps around the circumferential surface of the half circumference of the main roll 10. is doing. Further, the die 3 b of the resin supply unit 3 is arranged so as to supply a molten sheet-shaped resin toward the upper peripheral surface 11 a of the main roll 10. Therefore, when the reinforcing fiber base F is wound around the main roll 10, the die 3 b of the resin supply unit 3 is arranged so that the thermoplastic resin P is supplied to the surface of the reinforcing fiber base F. Yes.

  Thus, since it can wind around the main roll 10 and the contact area of the reinforcing fiber base F with the main roll 10 can be increased, the reinforcing fiber base F is heated more efficiently by the heat of the main roll 10. . Further, since the thermoplastic resin P is supplied to the heated reinforcing fiber base F, the thermoplastic resin P is applied to the preheated reinforcing fiber base F more efficiently by using the heat of the heated roll. Can be fed between rolls 10,20.

  Further, as shown in FIG. 6, the die 3 c of the resin supply unit 3 is arranged so that a melted sheet-shaped resin can be supplied toward a portion where the main roll 10 and the pressing roll 20 are in contact with each other. Also good. In the case of this modification, it is preferable to bring the die 3c closer to each other so that a higher temperature sheet-like resin is supplied between the rolls.

  FIG. 7 is a schematic perspective view of a pressing roll according to the second embodiment of the first invention. The second embodiment is different from the first embodiment in the structure for heating the pressing roll, and the other parts are the same. Therefore, the same reference numerals are given to members having the same configuration in the first embodiment, and details of this point will be described below.

  As shown in FIG. 7, the induction heating coil 41 is disposed in the cylindrical space S2 of the presser roll 20A according to the second embodiment, and the other structures are the same. The heating unit 40A that heats the pressing roll 20A has the induction heating coil 41 wound around a shaft body 27 made of a conductive material in the cylindrical space S2, and is provided at both ends of the induction heating coil. A power supply 42 for supplying an alternating current I is connected. As in the first embodiment, the shaft core 27 supports the thin metal outer cylinder 24 on the outer periphery of both ends thereof via a bearing so that the thin metal outer cylinder 24 is made of iron. Made of magnetic material.

  Thus, by supplying an alternating current to the induction heating coil 41, the thin metal outer cylinder 24 of the pressing roll can be directly heated by the principle of induction heating. Moreover, since the distance between the thin metal outer cylinder 24 and the induction heating coil 41 becomes closer due to the deformation of the thin metal outer cylinder 24 at the time of holding, this deformed portion (that is, the thermoplastic resin between the rolls) becomes another portion. Heating is more efficient than that. Thereby, the viscosity of a thermoplastic resin can be reduced more effectively and the reinforced fiber base material F can be impregnated with the thermoplastic resin P.

  FIG. 8 is a schematic cross-sectional view showing a resin-impregnated portion of a fiber-reinforced resin sheet manufacturing apparatus according to the third embodiment of the first invention. 9 and 10 are schematic cross-sectional views showing a resin-impregnated portion of a fiber-reinforced resin sheet manufacturing apparatus according to a modification of the third embodiment shown in FIG. The third embodiment is different from the first embodiment in that the number of a pair of rolls and their arrangement state and a release belt are used, and other configurations are the same as those in the first embodiment. is there. Therefore, the same reference numerals are given to members having the same configuration in the first embodiment, and details of this point will be described below.

  As shown in FIGS. 8 to 10, two rolls each having a pair of the main roll 10 and the pressing roll 20 are disposed along the conveying direction of the reinforcing fiber base F. Moreover, the main roll 10 and the pressing roll 20 which rotate in the same direction are arrange | positioned alternately along the conveyance direction. A heater 45 for heating the thermoplastic resin is disposed between the plurality of pairs of rolls.

  Further, a release belt 61 that can be released from the thermoplastic resin P is wound around the roll peripheral surface so as to connect a plurality of rolls having the same rotation direction among these rolls. . The release belt 61 is wound around the roll with an appropriate tension so as to move between the rolls in the same rotation direction together with the reinforcing fiber base F when impregnated with the resin.

  The release belt 61 is a resin belt such as a polyimide resin or polyethylene terephthalate, or a resin obtained by adding a release material such as a silicone resin, a melamine resin, a polyolefin resin, or wax on a sheet of paper or the like. For example, a belt formed by laminating a release layer or the like, or a belt made of polyolefin resin or the like can be used.

  In addition, the die 3a of the apparatus shown in FIG. 8 is arranged so as to supply the thermoplastic resin P to the upper peripheral surface of the pressing roll 20 as in the apparatus shown in FIG. The apparatus shown in the figure is similar to the apparatus shown in FIG. 5, in which the die 3 b of the resin supply unit 3 is thermoplastic on the reinforcing fiber base F wound around the main roll 10 toward the upper peripheral surface 11 a of the main roll 10. It arrange | positions so that resin P may be supplied. Furthermore, the apparatus shown in FIG. 10 which is another modified example is the same as the apparatus shown in FIG. 6, and the die 3 c of the resin supply unit 3 faces the portion where the main roll 10 and the pressing roll 20 come into contact with each other. It arrange | positions so that the molten sheet-like resin can be supplied.

  In such a state, the thermoplastic resin P is preheated in either the main roll 10 or the pressing roll 20 and the heated thermoplastic resin P is sequentially placed between the plurality of pairs of rolls, and the reinforcing fiber base F is sequentially placed. The reinforcing fiber base F is impregnated with the thermoplastic resin P by passing through. Thereby, since the sheet | seat material which consists of the reinforced fiber base material F and the thermoplastic resin P can be pressurized and heated in multiple times between rolls, the reinforced fiber base material F is more reliably impregnated with the thermoplastic resin P. be able to.

  Moreover, since the thermoplastic resin impregnated with the pair of upstream rolls can be heated by the heater 45, the viscosity of the thermoplastic resin P before being introduced into the pair of downstream rolls is increased. Can be suppressed. Furthermore, since the arrangement along the conveyance direction of the main roll 10 and the pressing roll 20 is alternated, the reinforcing fiber base material is not bent in only one direction at the time of impregnation, so that a more uniform fiber reinforced resin sheet S can be obtained. Obtainable.

  FIG. 11 is a schematic cross-sectional view showing a resin-impregnated portion of a fiber-reinforced resin sheet manufacturing apparatus according to the fourth embodiment of the present invention, and FIGS. 12 and 13 are views of the fourth embodiment shown in FIG. It is typical sectional drawing which showed the resin impregnation part of the manufacturing apparatus of the fiber reinforced resin sheet which concerns on a modification. The fourth embodiment differs from the first embodiment in that the number of pressing rolls and a release sheet are used during impregnation, and other configurations are the same as those in the first embodiment.

  As shown in FIGS. 11 to 13, in the fiber reinforced resin sheet manufacturing apparatus according to the fourth embodiment, the two pressing rolls 20 and 20 are arranged around the main roll so as to sandwich the main roll 10 from the horizontal direction. It arrange | positions and the press part 50 is connected with both of these pressing rolls 20 and 20 similarly to 1st Embodiment. Moreover, the method of heating the pressing rolls 20, 20 is the same as that in the first or second embodiment.

  In addition, the die 3a of the apparatus shown in FIG. 11 is arranged to supply the thermoplastic resin P to the upper peripheral surface of the pressing roll 20 in the same manner as the apparatus shown in FIG. In the apparatus shown, as in the apparatus shown in FIG. 5, the die 3 b of the resin supply unit 3 faces the upper peripheral surface 11 a of the main roll 10, and the thermoplastic fiber base F wound around the main roll 10 is thermoplastic. It arrange | positions so that resin P may be supplied. Furthermore, the apparatus shown in FIG. 13 which is another modified example is the same as the apparatus shown in FIG. 6, and the die 3 c of the resin supply unit 3 faces the portion where the main roll 10 and the pressing roll 20 are in contact with each other. It arrange | positions so that the molten sheet-like resin can be supplied.

  At the time of impregnation with the thermoplastic resin P, the release sheet 62 is placed such that the thermoplastic resin P and the reinforcing fiber base F heated in advance by the heat of the roll are sandwiched between the rolls by the release sheet (release material) 62. Introduce. Thereby, the release sheet 62 is disposed on the peripheral surfaces 11 and 21 of the rolls 10 and 20. The release sheet 62 is made of the same material as the release belt of the third embodiment.

  Further, while winding the reinforcing fiber base F around the main roll 10, the reinforcing fiber base F is sequentially passed between the main roll 10 and the press rolls 20 and 20, and the thermoplastic resin is passed through the reinforcing fiber base. Impregnate. Thereby, since the impregnation of the thermoplastic resin P can be performed a plurality of times between the rolls using one main roll 10, the apparatus can be made more compact than the third embodiment.

  In this embodiment, the number of pressing rolls 20 arranged around the main roll 10 is not limited, and the pressing force and heating temperature applied to these pressing rolls 20 are adjusted according to the impregnation conditions. May be.

  FIG. 14 is a schematic cross-sectional view showing a resin-impregnated portion of the apparatus for manufacturing a fiber-reinforced resin sheet according to the embodiment of the second invention, and FIG. 15 includes the rotation shafts of the pair of rolls in FIG. It is typical sectional drawing in a horizontal direction. FIG.16 and FIG.17 is typical sectional drawing which showed the resin impregnation part of the manufacturing apparatus of the fiber reinforced resin sheet which concerns on the modification of embodiment shown in FIG.

  Moreover, this embodiment is different in that a pressing roll is used instead of the main roll 10 of the first embodiment of the first invention of FIG. Therefore, other configurations are the same as those of the first embodiment, and members having the same functions as those of the first embodiment in FIGS. 14 to 17 are denoted by the same reference numerals, and the details of this point will be described below. To do.

  As shown in FIGS. 14-17, a pair of roll 20A, 20B which concerns on this embodiment is a metal roll of the same structure as the pressing roll 20 which concerns on 1st Embodiment. Each of the rolls 20A and 20B is configured such that the opposing circumferential surfaces of both the rolls 20A and 20B are deformed into a flat shape by the pressing force of the pressing portion 50, and surface pressing is performed when there is no supply between the rolls. Yes. That is, here, the thin metal outer cylinder 24 of one roll 20A (20B) is deformed into a flat shape with respect to the peripheral surface of the other roll 20B (20A) by the pressing force of the pressing portion 50.

  14 is arranged so as to supply the thermoplastic resin P to the upper peripheral surface of the pressing roll 20A. In the modified apparatus shown in FIG. The third die 3b is arranged so that the thermoplastic resin P is supplied to the reinforcing fiber base F wound around the pressing roll 20B toward the upper peripheral surface of the pressing roll 20B. Furthermore, the apparatus shown in FIG. 17, which is another modified example, can supply the molten sheet-shaped resin toward the portion where the pressing rolls 20A and 20B are in contact with the die 3c of the resin supply unit 3. It is arranged.

  In this way, by pressing the pair of rolls 20A and 20B, the circumferential surfaces 21 of both rolls facing each other are deformed into a flat shape, so that the thermoplastic resin P and the reinforcing fiber base F are similarly formed. Surface pressure can be applied. Thereby, the thermoplastic fiber P can be uniformly and stably impregnated into the reinforcing fiber base F, and furthermore, the air between the fibers of the reinforcing fiber base F can be suitably deaerated during the impregnation.

  Further, since the reinforcing fiber base F is impregnated with the thermoplastic resin P while deforming the opposing peripheral surfaces 21 of both rolls 20A, 20B into a flat shape, the thermoplastic resin P and the reinforcing fiber base F A uniform stress can be applied to both sides. A uniform fiber-reinforced resin sheet S having a uniform thickness can be obtained.

  Although the embodiments of the present invention have been described in detail above, the present invention is not limited to the above-described embodiments, and various designs can be made without departing from the spirit of the present invention described in the claims. It can be changed.

  For example, in the embodiment shown in FIGS. 14 to 17, a pair of rolls is used, but a plurality of these may be arranged as in the third embodiment of the first invention. As in the fourth embodiment, a plurality of rolls having the same structure may be arranged around one roll. Moreover, you may heat these rolls using induction heating like 2nd Embodiment of 1st invention.

  In addition, the distance between the die according to these embodiments and the roll to which the thermoplastic resin is supplied from the die may be made closer than illustrated. Thereby, the temperature fall of the molten thermoplastic resin can be suppressed and the resin can be effectively heated by the heat of the roll.

  DESCRIPTION OF SYMBOLS 1: Fiber reinforced resin sheet manufacturing apparatus, 2: Reinforcement fiber supply part, 2a: Roll body, 2b, 2c: Conveyance roll, 3: Resin supply part, 3a, 3b, 3c: Die (nozzle), 4: Resin impregnation part 5: winding part, 10: main roll, 11: peripheral surface, 11a: upper peripheral surface, 20: pressing roll, 20A, 20B: a pair of rolls, 21 peripheral surfaces, 21a, 21b: upper peripheral surface, 23: Shaft, 24: Thin metal outer cylinder, 27: Shaft core, 28: Flange, 29: Bearing, 30: Motor, 31: Coupling, 40, 40A: Heating part, 41: Induction heating coil, 42: Power supply, 50 : Pressing part, 51: Piston, 52: Cylinder, 61: Release belt, 62: Release sheet, F: Reinforcing fiber substrate, M: Medium, P: Thermoplastic resin, Pa: Thermoplastic resin pellet, S: Fiber reinforced resin sheet, S1: cylinder During, S2: tubular space

Claims (18)

By introducing a sheet-like reinforcing fiber base material and a thermoplastic resin between a pair of rolls and being impregnated with the thermoplastic resin melted in the reinforcing fiber base material while rotating the pair of rolls, A method for producing a fiber reinforced resin sheet,
As the pair of rolls, a metal main roll and a metal pressing roll are used,
By pressing the pressing roll against the main roll, the peripheral surface of the pressing roll is deformed so that the peripheral surface of the pressing roll follows the shape of the peripheral surface of the main roll. A method for producing a fiber-reinforced resin sheet, comprising impregnating a reinforcing fiber substrate. Heating the pair of rolls;
Heating the thermoplastic resin by supplying the thermoplastic resin toward the peripheral surface of the heated at least one roll;
2. The fiber reinforcement according to claim 1, wherein the thermoplastic resin is impregnated while the heated thermoplastic resin is conveyed toward the pair of rolls by rotation of the pair of rolls. Manufacturing method of resin sheet.   3. The thermoplastic resin is supplied to the surface of the reinforcing fiber base wound around the roll by winding the reinforcing fiber base around one of the pair of rolls. The manufacturing method of the fiber reinforced resin sheet of description.   As the pressing roll, a thin metal outer cylinder that deforms following the peripheral surface shape of the main roll by the pressing, and a cylindrical space is formed inside the thin metal outer cylinder. A roll comprising at least an inserted shaft core is used. The method for producing a fiber-reinforced resin sheet according to any one of claims 1 to 3.   The induction heating coil is disposed so as to be wound around the shaft core body in the cylindrical space, and the pressing roll is heated by applying an alternating current to the induction heating coil. The manufacturing method of the fiber reinforced resin sheet of description.   The method for producing a fiber-reinforced resin sheet according to any one of claims 1 to 5, wherein a molten thermoplastic resin is continuously supplied in the form of a sheet as the thermoplastic resin.   A plurality of the pair of rolls are arranged along the conveyance direction of the reinforcing fiber base so that the arrangement along the conveyance direction of the main roll and the pressing roll is alternate, and the plurality of pairs The fiber reinforced resin according to any one of claims 1 to 6, wherein the reinforcing fiber base material is sequentially passed between the rolls of the material to impregnate the reinforcing fiber base material with the thermoplastic resin. Sheet manufacturing method.   A plurality of the pressing rolls are arranged around the main roll, and the reinforcing fiber base material is sequentially passed between the main roll and each pressing roll while the reinforcing fiber base material is wound around the main roll. The method for producing a fiber-reinforced resin sheet according to any one of claims 1 to 7, wherein the thermoplastic fiber is impregnated in the reinforcing fiber base. By introducing a sheet-like reinforcing fiber base material and a thermoplastic resin between a pair of rolls, the reinforcing fiber base material is impregnated with the thermoplastic resin while rotating the pair of rolls. A method for producing a reinforced resin sheet,
As the pair of rolls, a metal roll is used,
By pressing the pair of rolls, the reinforcing fiber substrate is impregnated with the thermoplastic resin while deforming the opposing peripheral surfaces of both rolls into a flat shape. Production method. Heating the pair of rolls;
Heating the thermoplastic resin by supplying the thermoplastic resin toward the peripheral surface of the heated one roll;
The fiber-reinforced fiber according to claim 9, wherein the thermoplastic resin is impregnated while the heated thermoplastic resin is conveyed toward the pair of rolls by rotation of the pair of rolls. Manufacturing method of resin sheet. By introducing a sheet-like reinforcing fiber base material and a thermoplastic resin between a pair of rolls and being impregnated with the thermoplastic resin melted in the reinforcing fiber base material while rotating the pair of rolls, An apparatus for producing a fiber reinforced resin sheet,
The manufacturing apparatus includes a reinforcing fiber supply unit that supplies the reinforcing fiber base introduced between the pair of rolls, a resin supply unit that supplies the thermoplastic resin introduced between the pair of rolls, A pressing portion that presses between the pair of rolls,
The pair of rolls includes a metal main roll and a metal pressing roll, and the pressing roll is configured so that the peripheral surface of the pressing roll follows the peripheral surface shape of the main roll by the pressing force of the pressing portion. An apparatus for manufacturing a fiber reinforced resin sheet, wherein the apparatus is configured to deform. The manufacturing apparatus includes a heating unit that heats the pair of rolls,
The resin supply unit is configured such that, among the peripheral surfaces of at least one of the pair of rolls, the rotation of the pair of rolls toward the peripheral surface where the thermoplastic resin can be conveyed between the pair of rolls. It is arrange | positioned so that a thermoplastic resin may be supplied, The manufacturing apparatus of the fiber reinforced resin sheet of Claim 11 characterized by the above-mentioned.   The pressing roll includes the thin-walled metal outer cylinder that deforms following the shape of the peripheral surface of the main roll by the pressing force of the pressing portion, and the thin-walled wall so that a cylindrical space is formed inside the thin-walled metal outer cylinder. The apparatus for producing a fiber-reinforced resin sheet according to claim 11 or 12, comprising at least an axial body inserted in a metal outer cylinder.   The heating unit that heats the presser roll includes at least an induction heating coil wound around the shaft core body in a cylindrical space, and a power source that supplies an alternating current to the induction heating coil. Item 14. A device for producing a fiber-reinforced resin sheet according to Item 13.   The plurality of pairs of rolls are arranged in the conveyance direction of the reinforcing fiber base so that the arrangement along the conveyance direction of the main roll and the pressing roll is alternate. The manufacturing apparatus of the fiber reinforced resin sheet as described in any one of 11-14.   The said press roll is arrange | positioned around the said main roll, The manufacturing apparatus of the fiber reinforced resin sheet as described in any one of Claims 11-14 characterized by the above-mentioned. By introducing a sheet-like reinforcing fiber base material and a thermoplastic resin between a pair of rolls and being impregnated with the thermoplastic resin melted in the reinforcing fiber base material while rotating the pair of rolls, An apparatus for producing a fiber reinforced resin sheet,
The manufacturing apparatus includes: a reinforcing fiber supply unit that supplies the reinforcing fiber base introduced between the pair of rolls; a resin supply unit that supplies a thermoplastic resin introduced between the pair of rolls; A pressing part that presses the rolls of
The pair of rolls is a metal roll, and is configured such that the opposing circumferential surfaces of both rolls are deformed into a planar shape by the pressing force of the pressing portion. Sheet manufacturing equipment. The manufacturing apparatus includes a heating unit that heats the pair of rolls,
The resin supply unit is configured such that, among the peripheral surfaces of at least one of the pair of rolls, the rotation of the pair of rolls toward the peripheral surface where the thermoplastic resin can be conveyed between the pair of rolls. The apparatus for producing a fiber-reinforced resin sheet according to claim 17, wherein the apparatus is arranged to supply a thermoplastic resin.

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