JP2012245778A - Production equipment and process of fiber-reinforced resin sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide production process and equipment of a fiber-reinforced resin sheet capable of impregnating a matrix resin sufficiently to a reinforcing fiber substrate.SOLUTION: The production process of fiber-reinforced resin sheet includes the step of: impregnating a matrix resin M to a reinforcing fiber F by feeding the reinforcing fiber substrate F that remains pulled and aligned in one direction and matrix resin P that remains fluidizable through the pair of pressing members 11, 12; and by pressing the reinforcing fiber substrate F and matrix resin P with a pair of pressing members. The matrix resin P is impregnated to the reinforcing fiber substrate F by pressing the reinforcing fiber substrate F through the pair of pressing members 11, 12 while loosening the reinforcing fibers with a plurality of projections 11a, using a pressing member the surface of which has a plurality of projections 11a formed at least as a pressing member 11 of the pair of pressing members 11, 12.

Description

  The present invention relates to an apparatus and a method for manufacturing a fiber reinforced resin sheet that can suitably impregnate a matrix resin in a fluid state between fibers of a reinforced fiber base material aligned in one direction.

  Conventionally, a fiber reinforced composite material (fiber reinforced resin material) in which a matrix resin made of a thermosetting resin or a thermoplastic resin is impregnated into a reinforced fiber base material made of reinforced fiber is lighter and more expensive than a metal material. Since it is elastic and has a higher strength than the polymer resin alone, it is a material that is attracting attention for the application of vehicle members and the like.

  In order to take advantage of the high strength and high elasticity characteristics of tensile strength, which are the original characteristics of reinforcing fibers, reinforcing fibers that are aligned in one direction are used as the reinforcing fiber base, and the reinforcing fiber base is preliminarily polymer resin. Is generally impregnated or semi-impregnated and used as a prepreg sheet (fiber reinforced resin sheet).

  As a method of impregnating such a matrix resin, for example, there is a method of associating a molten band-like matrix resin with an opened sheet-like reinforcing fiber base material and impregnating the reinforcing fiber base material with the matrix resin. It has been proposed (see, for example, Patent Document 1).

JP-A-2005-29912

  However, even if an attempt is made to impregnate the spread reinforcing fiber base material with the matrix resin using the impregnation method shown in Patent Document 1, the reinforcing fiber base material is not sufficiently impregnated with the matrix resin, and the reinforcing fiber and the matrix are not impregnated. In some cases, the resin was not sufficiently mixed. In particular, when the matrix resin is a thermoplastic resin, even if it is in a molten state, its viscosity is higher than that of an uncured thermosetting resin, and thus this phenomenon is more remarkable.

  This invention is made in view of such a point, and it is providing the manufacturing method and manufacturing apparatus of the fiber reinforced resin sheet which can impregnate a reinforced fiber base material with a matrix resin satisfactorily.

  As a result of intensive investigations by the inventors to solve the above-mentioned problems, the reinforcing fiber and the matrix resin of the reinforcing fiber base material are actively moved in the width direction and the thickness direction during the impregnation, thereby strengthening. Air bubbles existing between the fibers were degassed, and a new finding was obtained that the matrix fibers could be suitably impregnated between the reinforcing fibers.

  The present invention is based on this new finding, and the method for producing a fiber-reinforced resin sheet according to the present invention includes a reinforcing fiber base material in which reinforcing fibers are aligned in one direction between a pair of pressing members. The fiber reinforcement that supplies the matrix resin in a state in which the matrix fiber is impregnated into the reinforcing fiber base by supplying the matrix resin in a flowable state and pressing the reinforcing fiber base and the matrix resin with the pair of pressing members A method for producing a resin sheet, wherein a pressing member having a plurality of protrusions formed on a surface is used as at least one pressing member of the pair of pressing members, and the reinforcing fiber base is interposed between the pair of pressing members. By pressing a material, the matrix resin is impregnated between the reinforcing fibers while the reinforcing fibers are loosened by the plurality of protrusions.

  According to the present invention, the reinforcing fibers of the reinforcing fiber base material aligned in one direction are dispersed (moved) in the width direction and the thickness direction by the plurality of protrusions formed on the surface of the pressing member when pressed by the pressing member. ), The air bubbles existing between the reinforced fibers are degassed by the pressing force of the pressing member, and the matrix resin in a flowable state enters between the reinforced fibers. Thereby, the fiber reinforced resin sheet in which the matrix resin is impregnated between the reinforced fibers can be obtained.

  The “fiber reinforced resin sheet” as used in the present invention is a composite material comprising a reinforcing fiber base material and a matrix resin impregnated in the reinforcing fiber base material, and maintains a predetermined strength together with the reinforcing fibers. If it is possible, the type is not particularly limited. Further, the “reinforcing fiber substrate” in the present invention refers to a reinforcing fiber bundle that is aligned in one direction.

  The “matrix resin” refers to a polymer resin for connecting the reinforcing fibers, and as the matrix resin, either a thermosetting resin or a thermoplastic resin may be used. The “matrix resin in a flowable state” means a thermoplastic resin that is softened by heating in the case of a thermoplastic resin, and an uncured state in the case of a thermosetting resin. It refers to the thermosetting resin.

  In such a pair of pressing members, a plurality of protrusions are formed on either surface so as to impregnate a flowable matrix resin between the reinforcing fibers of the reinforcing fiber base, and the gap between the pair of pressing members In addition, the pressing member is not particularly limited as long as the supplied reinforcing fiber substrate and the matrix resin can be pressed and impregnated with the matrix resin. For example, a flat pressing member, a roll pressing member, or any pressing member may be used. Moreover, you may form such a processus | protrusion by surface-treating mechanically or chemically to this press member.

  However, as a preferable aspect, a member in which a sheet material on which the plurality of protrusions are formed is arranged on the surface of the pressing base material is used as the pressing member on which the protrusions are formed. A sheet material on which the plurality of protrusions are formed by attaching hard particles that are harder than the reinforcing fibers of the reinforcing fiber base to the surface is used.

  According to this aspect, by using a sheet material on which a plurality of protrusions are formed, the surface of the pressing base material can be used regardless of whether the shape of the pressing base material is a flat plate shape or a roll shape. The protrusion can be formed on the surface of the pressing member. Further, by using the sheet material, it is possible to prevent the matrix resin from adhering to the surface of the pressing base material.

  For example, when a roll-shaped pressing base material is used, the sheet material may be formed into a belt shape and wound around the surface of the pressing base material. Furthermore, since the plurality of protrusions are formed by dispersing and adhering the above-described hard particles on the surface of the sheet base material, the sheet material, depending on the fiber diameter of the reinforcing fiber, the material of the reinforcing fiber, etc. The particle size and material of the hard particles can be selected and dispersed on the surface of the sheet base material.

  For example, the pressing base material is a base material for a pressing member made of metal or the like, and has a rigidity so as not to be plastically deformed at the time of pressing, for example, a flat or roll metal base material. Can be mentioned.

  The sheet base material is a base material for the sheet material, and examples thereof include paper and cloth. The hard particles are attached to the sheet base material through an adhesive or the like. Examples of the hard particles include ceramic particles such as aluminum oxide, silicon carbide, aluminum nitride, and boron nitride. Therefore, for example, abrasive paper, abrasive cloth, etc. may be used as the sheet material.

  In a more preferred embodiment, the center line average roughness Ra of the surface of the pressing member on which the protrusion is formed is 8 μm or more. By setting the surface of the pressing member to such a surface roughness, the matrix resin can be impregnated between the reinforcing fibers while loosening the reinforcing fibers of the reinforcing fiber base with a plurality of protrusions. That is, when the center line average roughness Ra of the surface of the pressing member on which the protrusion is formed is less than 8 μm, the reinforcing fiber cannot be sufficiently loosened by the protrusion at the time of pressing, and thus the matrix resin cannot be impregnated between the reinforcing fibers. Sometimes.

  Even more preferably, the reinforcing fiber substrate is supplied so that the reinforcing fiber substrate contacts the surface side of the pressing member on which the protrusion is formed. According to this aspect, since the reinforcing fiber base is supplied to the surface of the pressing member on which the protrusion is formed, the reinforcing fiber of the reinforcing fiber base is brought into direct contact with the plurality of protrusions to loosen the reinforcing fiber. be able to.

  Moreover, in this application, the manufacturing apparatus of a fiber reinforced resin sheet is also disclosed. The apparatus for producing a fiber-reinforced resin sheet according to the present invention includes the reinforcing fiber substrate supplied to impregnate a reinforcing fiber substrate in which reinforcing fibers are aligned in one direction with a flowable matrix resin. A fiber-reinforced resin sheet manufacturing apparatus including a pair of pressing members that press against a matrix resin, and the surface of at least one pressing member of the pair of pressing members is between the pair of pressing members, A plurality of protrusions for loosening the reinforcing fibers are formed by pressing the reinforcing fiber substrate.

  According to the present invention, the reinforcing fiber substrate and the flowable matrix resin are supplied between the pair of pressing members, and the reinforcing fiber substrate and the matrix resin are pressed by the pair of pressing members. Thus, the matrix resin can be impregnated between the reinforcing fibers while loosening the reinforcing fibers with a plurality of protrusions formed on the surface of the pressing member.

  As a more preferred aspect, the pressing member having the protrusion is a member in which a sheet material in which the plurality of protrusions are formed is arranged on the surface of the pressing base material, and the sheet material is on the surface of the sheet base material, The plurality of protrusions are formed by attaching hard particles that are harder than the reinforcing fibers of the reinforcing fiber base. According to this aspect, it is possible to prevent the matrix resin from adhering to the surface of the pressing base material. Further, the combination of the hard particles and the sheet base is as described above.

  Furthermore, as a more preferable aspect, the center line surface roughness Ra of the surface of the pressing member on which the protrusion is formed is 8 μm or more. By setting the surface of the pressing member to such a surface roughness, the matrix resin can be impregnated between the reinforcing fibers while loosening the reinforcing fibers of the reinforcing fiber base with a plurality of protrusions.

  Moreover, as a preferable aspect, it is comprised so that the said reinforced fiber base material may be supplied so that the said reinforced fiber base material may contact the surface of the press member in which the said protrusion was formed. According to this aspect, the reinforcing fibers of the reinforcing fiber base can be directly brought into contact with the plurality of protrusions to loosen the reinforcing fibers.

  According to the present invention, the reinforcing fiber base material can be satisfactorily impregnated with the matrix resin by the pressing member.

BRIEF DESCRIPTION OF THE DRAWINGS It is a typical conceptual diagram of the manufacturing apparatus of the fiber reinforced resin sheet which concerns on 1st Embodiment of this invention, (a) is a typical perspective view of the manufacturing apparatus at the time of manufacture of a fiber reinforced resin sheet, (b) is The fragmentary sectional view of (a), (c) is a conceptual diagram for demonstrating the impregnation of the matrix resin between reinforcement fibers. It is typical sectional drawing which showed another form of the manufacturing apparatus shown in FIG. 1, (a) is typical partial sectional drawing of the manufacturing apparatus of the fiber reinforced resin sheet which concerns on 2nd Embodiment, (b) is The fragmentary sectional view which showed the modification. It is typical sectional drawing which showed another form of this invention, (a) is a fragmentary sectional view of the manufacturing apparatus of the fiber reinforced resin sheet which concerns on 3rd Embodiment, (b) is the modification. The fragmentary sectional view shown. Typical sectional drawing of the manufacturing apparatus of the fiber reinforced resin sheet which concerns on 4th Embodiment. It is the result of having measured the surface roughness of the press member (sheet material) which concerns on Example 1, 2 and a comparative example, (a) is the figure which showed the measurement result of the surface roughness of the press member which concerns on Example 1. (B) is the figure which showed the measurement result of the surface roughness of the press member which concerns on Example 2, (c) is the figure which showed the measurement result of the surface roughness of the press member which concerns on the comparative example 2. FIG. It is sectional photograph figure of the fiber reinforced resin sheet which concerns on Example 1, 2 and a comparative example, (a) is sectional photograph figure of the fiber reinforced resin sheet which concerns on Example 1, (b) concerns Example 2. The cross-sectional photograph figure of a fiber reinforced resin sheet concerning a comparative example 2, and (d) is the cross-sectional photograph figure of the fiber reinforced resin sheet concerning comparative example 2.

  Below, based on drawing, some embodiment of the manufacturing apparatus which can manufacture the fiber reinforced resin sheet which concerns on this invention suitably is described.

  FIG. 1 is a schematic conceptual diagram of a fiber-reinforced resin sheet manufacturing apparatus according to a first embodiment of the present invention, and (a) is a schematic perspective view of the manufacturing apparatus at the time of manufacturing a fiber-reinforced resin sheet. b) is a sectional view of (a), and (c) is a conceptual diagram for explaining impregnation of a matrix resin between reinforcing fibers.

  As shown in FIG. 1, the manufacturing apparatus 10 of the fiber reinforced resin sheet which concerns on this embodiment is equipped with a pair of flat pressing members 11 and 12, and a pressing member consists of metals, such as steel and aluminum. One (upper) pressing member 11 of the pressing members 11 and 12 is connected to a pressing means 13 including a cylinder and a piston, and the lower pressing member 12 is fixed. Here, the lower pressing member 12 is fixed, but may be connected by pressing means having the same configuration as the upper pressing member 11.

  Furthermore, on the surface (opposing surface) of the pressing member 11, a plurality of protrusions (minutes) for loosening the reinforcing fibers f by pressing a reinforcing fiber substrate F described later between the pair of pressing members 11, 12. Projections) 11a,... Are formed. Moreover, the center line average roughness Ra of the surface of the pressing member 11 on which the protrusions 11a are formed is 8 μm or more. The surface roughness of the pressing member 11 can be obtained by mechanical surface treatment such as discharge dull machining or shot blasting, or chemical surface treatment by etching.

  Further, the opposing surface of the lower pressing member 12 is a flat surface having no projections (a surface whose surface roughness is smaller than the surface roughness of the upper pressing member 11), such as the pressing member 11, and the pressing member. Inside 12, heating means (not shown) such as a heater is provided.

  When a thermoplastic resin is used for the matrix resin by this heating means, the thermoplastic resin can be heated during pressing (during impregnation) and softened to a fluid state. On the other hand, when a thermosetting resin is used, it can be cured by heating after impregnating an uncured thermosetting resin between the reinforcing fibers.

  In addition, although the opposing surface of the lower pressing member 12 is a flat surface here, as long as the reinforcing fiber described later can be loosened, even if the surface property is the same as that of the upper pressing member 11. Good.

  The fiber reinforced resin sheet S is manufactured using such a manufacturing apparatus 10. First, a reinforcing fiber base F in which reinforcing fibers are aligned in one direction and a sheet-like matrix resin P are prepared. The reinforcing fiber base F may be a fiber bundle itself made of reinforcing fibers for reinforcing the fiber-reinforced resin sheet, and more preferably is an opened reinforcing fiber bundle. Furthermore, in order to loosen the fibers suitably and to function as reinforcing fibers for the fiber reinforced resin sheet, the fiber diameter of the reinforcing fibers of the reinforcing fiber base F is preferably in the range of 5 to 15 μm. The thickness is preferably in the range of 20 to 300 mm.

  Examples of the reinforcing fiber constituting the reinforcing fiber base F include glass fiber, carbon fiber, aramid fiber, alumina fiber, boron fiber, steel fiber, PBO fiber, organic fiber, or high-strength polyethylene fiber. Can be mentioned.

  The sheet-like matrix resin P is a polymer resin for connecting the reinforcing fibers, and the thickness thereof is preferably in the range of 20 to 300 mm. In this embodiment, a thermoplastic resin is prepared as the matrix resin P. However, it may be a thermosetting resin. In the case of a thermosetting resin, an uncured thermosetting resin is prepared.

  As the thermoplastic resin, a crystalline thermoplastic resin or an amorphous thermoplastic resin can be used. For example, an olefin resin such as nylon resin, polycarbonate resin, polyamide resin, polypropylene resin, acrylic resin, or Examples thereof include ABS resins, and thermoplastic resins having higher melting points (higher softening points) may be used. Examples of the thermosetting resin include vinyl ester resins, epoxy resins, fiber reinforced resins, unsaturated polyester resins, and the like.

  The reinforcing fiber base F and the matrix resin P thus prepared are arranged between the pair of pressing members 11 and 12. At this time, the reinforcing fiber base F is disposed on the surface side so that the reinforcing fiber base F is in direct contact with the surface on which the protrusions 11a of the pressing member 11 are formed during pressing. Here, the manufacturing apparatus 10 supplies (arranges) the reinforcing fiber base F to the surface side of the pressing member 11 on which the protrusions 11a are formed by using a generally known conveying means (not shown) or the like. ) May be configured.

  Next, the reinforcing fiber base F and the matrix resin P that are arranged are pressed using the pressing means 13. At this time, when the matrix resin P is a thermoplastic resin, the matrix resin is heated and softened by the heating means of the lower pressing member 12.

  Thus, as shown in FIG.1 (c), at the time of the press by the press member 11, the reinforcement | strengthening of the reinforced fiber base material arranged in one direction with the some protrusion 11a formed in the surface of the press member 11 is carried out. The reinforcing fibers f are loosened so that the fibers f are dispersed (moved) in the width direction and the thickness direction of the fiber reinforced resin sheet. Then, air bubbles between the loosened reinforcing fibers f and f are sent out to the outside, and a flowable matrix resin P enters between the reinforcing fibers f and f. Thereby, the fiber reinforced resin sheet in which the matrix resin is impregnated between the reinforcing fibers f and f can be obtained.

  FIG. 2 is a schematic cross-sectional view showing another form of the manufacturing apparatus shown in FIG. 1, (a) is a schematic partial cross-sectional view of the apparatus for manufacturing a fiber-reinforced resin sheet according to the second embodiment, (B) is the fragmentary sectional view which showed the modification.

  The manufacturing apparatus shown in FIG. 2 (a) is different from the manufacturing apparatus shown in FIG. 1 in the upper pressing member, and the manufacturing apparatus shown in FIG. 2 (b) is different from the manufacturing apparatus shown in FIG. The point is a pair of pressing members. Therefore, only the following differences will be described, and detailed description of members having the same configuration will be omitted.

  As shown in FIG. 2A, the upper pressing member 11 </ b> A of the manufacturing apparatus 10 </ b> A according to the second embodiment has a plurality of protrusions. Specifically, a plurality of protrusions are formed on the surface of the pressing base material 15. This is a member in which the sheet material 16 on which the protrusions are formed is disposed. The sheet material 16 is a sheet material in which a plurality of protrusions are formed by attaching hard particles 16b that are harder than the reinforcing fibers of the reinforcing fiber base material to the surface of the sheet base material 16a. Further, the center line average roughness Ra of the sheet material 16 is 8 μm or more.

  The pressing base material 15 is a base material made of metal or the like, has a rigidity that does not plastically deform when pressed, and is a flat base material, for example. Further, examples of the hard particles 16b include ceramic particles such as aluminum oxide, silicon carbide, aluminum nitride, and boron nitride, and are preferably harder than the reinforcing fibers. Examples of the sheet base material 16a include flexible base materials such as cloth and paper, and the hard particles are attached to the sheet base material 16a via an adhesive or the like.

  According to this aspect, by using the sheet material 16 on which a plurality of protrusions are formed, the sheet material 16 can be disposed on the surface of the pressing base material 15, and the protrusions are formed on the surface of the pressing member 11A. Can do. Further, the use of the sheet material 16 can prevent the matrix resin from adhering to the surface of the pressing base material 15.

  Since the sheet material 16 has a plurality of protrusions formed by dispersing and adhering the hard particles 16b to the surface of the sheet base material 16a, the hard particles are formed according to the fiber diameter of the reinforcing fibers, the material of the reinforcing fibers, and the like. Can be selected and dispersed on the surface of the sheet base material 16a.

  Further, as shown in FIG. 2B, the lower pressing member 12A of the manufacturing apparatus 10B has a plurality of protrusions on the surface facing the pressing member 11A, like the pressing member 11A shown in FIG. It may be a member that is formed and has a sheet material 16 in which a plurality of protrusions are formed on the surface of the pressing substrate 15.

  When such a manufacturing apparatus is used, the reinforcing fiber bases F1 and F2 are disposed on the surface sides of the upper and lower pressing members 11A and 12A, and the matrix resin P is interposed between the reinforcing fiber bases F1 and F2. The reinforcing fiber bases F1 and F2 can be brought into direct contact with the pressing members 11A and 12A, and these reinforcing fibers can be loosened directly. Thereby, a reinforced fiber can be loosened suitably and the matrix resin P can be impregnated between reinforced fibers.

  FIG. 3 is a schematic cross-sectional view showing another embodiment of the present invention, (a) is a partial cross-sectional view of a fiber-reinforced resin sheet manufacturing apparatus according to the third embodiment, (b) It is the fragmentary sectional view which showed the modification.

  As shown in FIG. 3A, the fiber-reinforced resin sheet manufacturing apparatus 20 according to the present embodiment includes rolls 21 and 22 using a sheet-like reinforcing fiber substrate F and a matrix resin P as a pair of pressing members. It is an apparatus intended to produce a fiber reinforced resin sheet S by introducing the matrix resin P into the reinforced fiber base F while rotating between a pair of rolls.

  As shown in FIG. 3, the manufacturing apparatus 20 according to this embodiment includes a reinforcing fiber supply unit 31 that supplies a reinforcing fiber base F introduced between a pair of rolls 21 and 22, and a pair of rolls 21 and 22. And a resin supply part 32 for supplying the matrix resin P introduced into the.

  The reinforcing fiber supply unit 31 supplies the reinforcing fiber base F in which the continuous fibers are aligned in one direction in a sheet shape along the transport direction T, and the reinforcing fiber base F before the supply is coiled. It is said that it is a wound body. Further, in the reinforcing fiber supply unit 31, a sheet-like reinforcing fiber base material F unwound from the wound body is arranged so as to be in direct contact with the roll 21 side among the rolls 21 and 22, which will be described later. .

  On the other hand, in the present embodiment, as an example, in the present embodiment, when a thermoplastic resin is used as the matrix resin, the resin supply unit 32 melts the resin above the softening point, and a die (nozzle) that is a resin discharge port is provided. A sheet-like molten matrix resin P is continuously formed through the sheet. The resin supply unit 32 is disposed above the pair of rolls 21 and 22 so that the molten sheet-like thermoplastic resin can be supplied between the pair of rolls 21 and 22.

  Here, the pair of rolls 21 and 22 are arranged side by side in the horizontal direction, in which a cylindrical space is formed, and a heated medium (for example, water) is introduced. Thereby, the surrounding surface of a pair of rolls 21 and 22 can be heated.

  Moreover, on the surface of the roll 21, a plurality of protrusions (not shown) for loosening the reinforcing fibers are formed by pressing the reinforcing fiber base F in the same manner as shown in FIG. The centerline average roughness Ra of the surface is 8 μm or more. Further, the other roll 22 has the same surface roughness as that of the lower pressing member 12 shown in FIG. 1. The roll 22 is connected to pressing means 23 including a cylinder and a piston, and the roll 21 is fixed. Yes.

  With such a configuration, the reinforcing fiber base F is in contact with the roll 21 on which the protrusions are formed, and the reinforcing fiber base F is aligned in one direction with a plurality of protrusions formed on the surface. The reinforcing fibers are continuously loosened so that the reinforcing fibers are dispersed (moved) in the width direction and the thickness direction. Then, the bubbles between the loosened reinforcing fibers are sent out by the pressure at the time of pressing, and the softened matrix resin P enters the sent-out location. Thereby, the fiber reinforced resin sheet S in which the matrix resin is impregnated between the reinforced fibers can be obtained.

  FIG.3 (b) is the modification which has arrange | positioned a pair of roll continuously. Components having the same functions as those shown in FIG. 3A are denoted by the same reference numerals, and detailed description thereof is omitted. As shown in FIG. 3B, in the manufacturing apparatus 20 </ b> A, two pairs of rolls 25 and 25 as pressing base materials are arranged in the transport direction T, and each roll 25 arranged in the transport direction T. , 25, the sheet material 26 is wound around the belt. The sheet material 26 has the same configuration as that of the sheet material shown in FIGS. Further, the two reinforcing fiber supply units 31 are arranged so that the supplied reinforcing fiber base F is in direct contact with the surface of the sheet material 26.

  When such a manufacturing apparatus 20A is used, reinforcing fiber base materials F1 and F2 are supplied to the surface of each sheet material 26, and by arranging the matrix resin P between the reinforcing fiber base materials F1 and F2, Since the reinforcing fiber bases F1 and F2 can be in direct contact with the pressing member 11A, the reinforcing fibers can be suitably loosened and the matrix resin P can be impregnated between the reinforcing fibers.

  FIG. 4 is a schematic conceptual diagram of a fiber-reinforced resin sheet manufacturing apparatus according to the fourth embodiment. The manufacturing apparatus shown in FIG. 4 differs from the manufacturing apparatus shown in FIG. 3A in the shape of one of the pair of rolls. Therefore, the same functional components as those of the manufacturing apparatus of FIG. 3A are denoted by the same reference numerals, and detailed description thereof is omitted.

  As shown in FIG. 4, the roll (pressing roll) 42 of the fiber reinforced resin sheet manufacturing apparatus 40 is a roll that presses the roll (main roll) 21. By the pressing force of the pressing means 23, the pressing roll 42 is When the peripheral surface of the pressing roll 42 is deformed following the shape of the peripheral surface of the main roll 21 and there is no supply between the rolls, these rolls are configured to be pressure-bonded to each other. Moreover, the surface roughness of the pressing roll 42 is equivalent to the surface roughness of the roll 22 shown in FIG.

  The pressing roll 42 is formed such that a thin metal outer cylinder 44 that deforms following the shape of the peripheral surface of the main roll 21 by the pressing force of the pressing means 23, and a cylindrical space S <b> 2 is formed inside the thin metal outer cylinder 44. And an axial core body 47 inserted in the thin metal outer cylinder 44. Further, in order to increase the flexibility of the peripheral surface portion of the thin metal outer tube 44, when the thickness of the thin metal outer tube 44 is t and the roll radius is r, the relationship of t / r ≦ 0.03 is satisfied. Preferably it is. A heated medium (for example, water) is introduced into the cylindrical space S2.

  When such a manufacturing apparatus 40 is used, the reinforcing fiber base F is in surface contact between the main roll 21 on which the protrusion is formed and the pressing roll 42 that presses the protrusion, and is formed on the surface of the main roll 21. The reinforcing fibers are continuously loosened so that the reinforcing fibers of the reinforcing fiber base F are dispersed (moved) in the width direction and the thickness direction by the plurality of projections. A softened matrix resin P enters between the loosened reinforcing fibers, and a fiber-reinforced resin sheet in which the reinforcing resin is impregnated with the matrix resin can be obtained.

Examples of the present invention will be described below.
[Example 1]
The example shown below was manufactured using the manufacturing apparatus shown in FIG. Specifically, a 280 mm × 300 mm iron pressing base material is prepared as an upper pressing member, and a polishing paper (#) in which hard particles made of alumina are dispersed in kraft paper as a sheet material on the surface of the pressing base material (# 500) was prepared. In addition, when the surface roughness of the sheet material was measured with a stylus type surface roughness meter, the center line average roughness Ra was 8.04 μm as shown in FIG. The lower pressing base material had a flat surface (centerline average roughness Ra 0.02 μm).

  Next, as a reinforcing fiber substrate, a carbon fiber substrate having a thickness of 20 mm and a fiber diameter of 7 μm in which reinforcing fibers are aligned in one direction and 6-nylon as a matrix resin are prepared, and these are paired pressing members. Before pressing, the reinforcing fiber base material is preheated for 30 seconds at a temperature condition of 300 ° C. and heated at a temperature of 30 ° C. to make the matrix resin flowable, and at a pressure of 6 MPa for 3 seconds. These were pressed to impregnate the matrix fiber with the matrix resin to produce a fiber reinforced resin sheet. And the cross section of this fiber reinforced resin sheet was observed with the microscope. The result is shown in FIG.

[Example 2]
A fiber-reinforced resin sheet was produced in the same manner as in Example 1. The difference from Example 1 is that the size of the hard particles of the sheet material is changed so that the center line average roughness Ra of the sheet material is 20.3 μm (the point where abrasive paper (# 180) is used). (See FIG. 5B). And the cross section of this fiber reinforced resin sheet was observed with the microscope. The result is shown in FIG.

[Comparative Example 1]
A fiber-reinforced resin sheet was produced in the same manner as in Example 1. The difference from Example 1 is that no sheet material was used. That is, the surface of the upper pressing substrate is the same as the lower pressing substrate. And the cross section of this fiber reinforced resin sheet was observed with the microscope. The result is shown in FIG.

[Comparative Example 2]
A fiber-reinforced resin sheet was produced in the same manner as in Example 1. The difference from Example 1 is that the size of the hard particles of the sheet material (abrasive paper) is changed so that the center line average roughness Ra of the sheet material is 3.94 μm (the abrasive paper (# 1000) (Points used) (see FIG. 5C). And the cross section of this fiber reinforced resin sheet was observed with the microscope. The result is shown in FIG.

〔result〕
As shown in FIGS. 6A and 6B, the fiber reinforced resin sheets of Examples 1 and 2 are better impregnated with the matrix resin in the fiber bundle of the reinforced fiber base material than those of Comparative Examples 1 and 2. It had been. Moreover, the thickness of the fiber reinforced resin sheet | seat of Example 1 and 2 exists in the range of 70 micrometers-80 micrometers, and was thin compared with the thing of Comparative Examples 1 and 2 (about 90 micrometers).

  Examples 1 and 2 In the fiber reinforced resin sheet, the resin has penetrated into the fiber bundle. In the case of Example 1, the tendency is particularly remarkable on the abrasive paper side. The resin / fibers tended to be uniform throughout the thickness direction.

  In the fiber reinforced resin sheet of Comparative Example 1, as shown in FIG. 6C, the matrix resin does not uniformly impregnate the reinforced fiber base material, and air bubbles remain between the fibers, and these exist separately. Was confirmed. In the fiber-reinforced resin sheet of Comparative Example 2, as shown in FIG. 6D, the resin did not sufficiently penetrate into the fiber bundle.

[Discussion]
In the fiber reinforced resin sheets of Examples 1 and 2, a minute pressure gradient acts on the surface due to the plurality of protrusions formed on the surface of the sheet material. As a result, the reinforcing fibers are in the width direction and thickness of the fiber reinforced resin sheet. It is thought that the bubbles moved between the fibers in the direction, and bubbles between the fibers were sent out, and the impregnation of the matrix resin into the reinforcing fiber substrate was promoted. Thereby, it is thought that the thickness of the fiber reinforced resin sheet of Example 1 and 2 became thin compared with the thing of the comparative examples 1 and 2.

  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.

  In the above-described embodiment, the reinforcing fiber base is supplied so as to be in direct contact with the surface side of the pressing member (roll) on which the protrusion is formed, but the reinforcing fiber base is loosened with a plurality of protrusions. If possible, the matrix resin may be supplied so that the matrix resin contacts the surface side of the pressing member (roll) on which the protrusions are formed.

  10, 10A: Fiber reinforced resin sheet manufacturing apparatus, 11, 11A, 12: pressing member, 11a: protrusion, 13: pressing means, 15: pressing substrate, 16: sheet material, 16a: sheet substrate, 16b: hard particles 20, 20A: Fiber reinforced resin sheet manufacturing apparatus, 21, 22: Roll (pressing member), 23: Pressing means, 25: Roll (pressing base material), 26: Sheet material, 31: Reinforcing fiber supply unit, 32: Resin supply part, 40: Fiber reinforced resin sheet manufacturing apparatus, 42: Pressing roll, 44: Thin metal outer cylinder, 47: Shaft core

Claims (8)

A reinforcing fiber base material in which reinforcing fibers are aligned in one direction between a pair of pressing members and a matrix resin in a flowable state are supplied, and with the pair of pressing members, the reinforcing fiber base material and the A method for producing a fiber reinforced resin sheet by impregnating the matrix resin into the reinforcing fiber base by pressing the matrix resin,
As at least one pressing member of the pair of pressing members, a pressing member having a plurality of protrusions formed on the surface is used.
A fiber reinforcement characterized in that the matrix resin is impregnated between the reinforcing fibers while the reinforcing fibers are loosened by the plurality of protrusions by pressing the reinforcing fiber base between the pair of pressing members. Manufacturing method of resin sheet.   A member in which the sheet material on which the plurality of protrusions are formed is disposed on the surface of the pressing base material as the pressing member on which the protrusions are formed, and the reinforcing fiber base is formed on the surface of the sheet base material as the sheet material. The method for producing a fiber-reinforced resin sheet according to claim 1, wherein a sheet material in which the plurality of protrusions are formed by attaching hard particles that are harder than the reinforcing fibers of the material is used.   The method for producing a fiber-reinforced resin sheet according to claim 1 or 2, wherein the center line average roughness Ra of the surface of the pressing member on which the protrusion is formed is 8 µm or more.   The fiber reinforcing material according to any one of claims 1 to 3, wherein the reinforcing fiber base material is supplied so that the reinforcing fiber base material is in contact with the surface side of the pressing member on which the protrusion is formed. Manufacturing method of resin sheet. Provided with a pair of pressing members that press the supplied reinforcing fiber base material and matrix resin so that the reinforcing fiber base material in which the reinforcing fibers are aligned in one direction is impregnated with the matrix resin in a flowable state. An apparatus for manufacturing a fiber reinforced resin sheet,
On the surface of at least one of the pair of pressing members, a plurality of protrusions for loosening the reinforcing fibers is formed by pressing the reinforcing fiber substrate between the pair of pressing members. An apparatus for producing a fiber-reinforced resin sheet, wherein   The pressing member having the protrusion is a member in which a sheet material in which the plurality of protrusions are formed is arranged on the surface of the pressing base material, and the sheet material is formed on the surface of the sheet base material. 6. The apparatus for producing a fiber-reinforced resin sheet according to claim 5, wherein the plurality of protrusions are formed by attaching hard particles that are harder than the reinforcing fibers.   The apparatus for producing a fiber-reinforced resin sheet according to claim 5 or 6, wherein a center line average roughness Ra of a surface of the pressing member on which the protrusion is formed is 8 µm or more.   The structure according to claim 5, wherein the reinforcing fiber base is supplied so that the reinforcing fiber base contacts the surface side of the pressing member on which the protrusion is formed. The manufacturing apparatus of the fiber reinforced resin sheet in any one.

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