JP2016130011A - Processing method and processing device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a technique which can well impregnate an opened belt-like one-directional reinforced fiber bundle with resin.SOLUTION: A belt-like fiber bundle B* on which a resin film S is overlapped passes through between a pressing face 135a of a hone 135 of an impregnation device 7 and a support face 21 of a supporter 2, and supersonic vibration is applied from a pressing face 135a. Thus, the belt-like fiber bundle B* is impregnated with the melted resin of the resin film S, forming a prepreg P.SELECTED DRAWING: Figure 5

Description

  The present invention relates to a treatment method and a treatment apparatus for impregnating a spread belt-shaped unidirectional reinforcing fiber bundle with a resin.

  Conventionally, unidirectional reinforcing fiber bundles such as carbon fiber, glass fiber, aramid fiber, etc. are spread and widened to form a flat fiber bundle in a flat state, epoxy resin, unsaturated polyester resin, etc. There are provided unidirectional prepregs impregnated with a matrix resin such as a thermosetting resin, a thermoplastic resin such as a polyolefin resin, an aliphatic polyamide resin, or a polyethylene terephthalate resin. In order to form a high-quality unidirectional prepreg, it is necessary to open the unidirectional reinforcing fiber bundle with high accuracy, and various techniques for opening the unidirectional reinforcing fiber bundle have been proposed. For example, in Patent Documents 1 and 2, the unidirectional reinforcing fiber bundle is passed through the unidirectional reinforcing fiber bundle in a direction intersecting the traveling direction while the unidirectional reinforcing fiber bundle is traveling in the longitudinal direction. A technique for spreading the fiber in the width direction is disclosed.

International Publication No. 97/41285 (pages 13 to 14, FIG. 2, abstract, etc.) Japanese Patent Laid-Open No. 11-200136 (paragraph 0025, FIG. 1, abstract, etc.)

  In the techniques disclosed in Patent Documents 1 and 2, since the unidirectional reinforcing fiber bundle is widened and opened by an air flow, a strong tension cannot be applied to the unidirectional reinforcing fiber bundle during opening. Therefore, it has been difficult to stably process the unidirectional reinforcing fiber bundle at high speed.

  This invention is made | formed in view of an above-described subject, and it aims at providing the technique which can impregnate resin satisfactorily to the strip-shaped unidirectional reinforcement fiber bundle opened.

  In order to achieve the above-described object, the processing method according to the present invention is opened between the support surface of the support and the pressing surface of the pressing body that ultrasonically vibrates in the pressing direction orthogonal to the support surface. In a state where the belt-shaped unidirectional reinforcing fiber bundle and the resin film are overlapped and sandwiched, the pressing portion of the unidirectional reinforcing fiber bundle by the pressing surface is moved along the longitudinal direction of the unidirectional reinforcing fiber bundle. The unidirectional reinforcing fiber bundle is impregnated with a resin of the resin film.

  Further, the processing apparatus according to the present invention includes a support having a support surface, a press having a pressing surface, and a vibration unit that applies ultrasonic vibration in a pressing direction perpendicular to the support surface to the pressing body. Between the support surface and the pressing surface of the pressing body that is ultrasonically vibrated in the pressing direction by the vibration means, the opened strip-shaped unidirectional reinforcing fiber bundle and the resin film are overlapped and sandwiched. A moving means for relatively moving the unidirectional reinforcing fiber bundle and the resin film and the pressing body, and the moving means allows the pressing portion of the unidirectional reinforcing fiber bundle to be pressed by the pressing surface. The unidirectional reinforcing fiber bundle is moved along the longitudinal direction of the unidirectional reinforcing fiber bundle, and the resin of the resin film is impregnated into the unidirectional reinforcing fiber bundle.

  In the invention configured as described above, since the impregnation treatment is performed by applying ultrasonic vibration, the reaction at the bonding interface between each filament of the reinforcing fiber and the resin can be promoted to obtain a good bonded state. The resin of the resin film can be satisfactorily impregnated into the belt-shaped unidirectional reinforcing fiber bundle.

  Moreover, it is good to move the said press location, pressing the said unidirectional reinforcing fiber bundle with the predetermined pressing force with respect to the said support surface with the said press surface.

  In this way, the unidirectional reinforcing fiber bundle is pressed with a predetermined pressing force set in advance according to the thickness of the unidirectional reinforcing fiber bundle to be processed or the target value of the width of the fiber bundle after the fiber opening process. While opening the fiber bundle, the width of the fiber bundle after opening can be adjusted with high accuracy.

  Moreover, you may move the said press location in the state which has arrange | positioned the said press surface at predetermined gaps from the said support surface.

  In this case, the pressing surface is arranged by opening a predetermined gap from the support surface according to the thickness of the unidirectional reinforcing fiber bundle to be processed or the target value of the thickness of the fiber bundle after the fiber opening process. By opening the unidirectional reinforcing fiber bundle in the state, the thickness of the fiber bundle after opening can be adjusted with high accuracy.

  According to the present invention, since the ultrasonic vibration is applied and the impregnation treatment is performed, the reaction of the bonding interface between each filament of the reinforcing fiber and the resin can be promoted to obtain a good bonded state. The film resin can be satisfactorily impregnated into the band-shaped unidirectional reinforcing fiber bundle.

It is a front view which shows the processing apparatus concerning 1st Embodiment of this invention. It is the principal part enlarged view which looked at the processing apparatus of FIG. 1 from the left side surface side. It is a perspective view which shows the principal part of FIG. It is a front view which shows the processing apparatus concerning 2nd Embodiment of this invention. It is a perspective view which shows the principal part of the processing apparatus concerning 3rd Embodiment of this invention. It is a cross-sectional view which shows the unidirectional reinforcing fiber bundle and resin sheet which are processed in the processing apparatus concerning 4th Embodiment of this invention.

<First Embodiment>
A processing apparatus according to a first embodiment of the present invention will be described with reference to FIGS. 1 is a front view showing a processing apparatus according to a first embodiment of the present invention, FIG. 2 is an enlarged view of a main part of the processing apparatus of FIG. 1 viewed from the left side, and FIG. 3 is a perspective view showing the main part of FIG. FIG. In FIG. 3, the resin film S and the support 2 disposed on the lower surface side of the unidirectional reinforcing fiber bundle B are not shown. 1 to 3 show only main components according to the present invention, and other components are not shown in order to simplify the description. 4 to 6 referred to in the following description, only the main components are shown in the same manner as in FIGS. 1 to 3, but the description thereof is omitted in the following description.

(Processing equipment)
1 and 2 is a unidirectional reinforcing fiber bundle between a support surface 21 of a support 2 and a pressing surface 35a of a horn 35 that ultrasonically vibrates in a pressing direction Z orthogonal to the supporting surface 21. By moving the unidirectional reinforcing fiber bundle B in the longitudinal direction Y while sandwiching B, the pressing location of the unidirectional reinforcing fiber bundle B by the pressing surface 35a is moved along the longitudinal direction Y of the unidirectional reinforcing fiber bundle B. The unidirectional reinforcing fiber bundle B is continuously opened along the longitudinal direction Y by applying ultrasonic vibration in the pressing direction Z from the pressing surface 35a along the longitudinal direction Y to the unidirectional reinforcing fiber bundle B. It is something that is delicate.

  Further, in this embodiment, the processing apparatus 1 is configured such that the unidirectional reinforcing fiber bundle B (resin) is disposed in a state where the unidirectional reinforcing fiber bundle B is disposed so as to overlap the resin film S between the support surface 21 and the pressing surface 35a. By running the film S) in the longitudinal direction Y, the unidirectional reinforcing fiber bundle B is opened while melting and impregnating the resin film S superposed on both surfaces of the unidirectional reinforcing fiber bundle B by ultrasonic vibration. . Therefore, when the processing device 1 processes the unidirectional reinforcing fiber bundle B on which the resin films S are overlapped, the filaments of the reinforcing fibers of the opened unidirectional reinforcing fiber bundle B are drawn in one direction with a predetermined width. A unidirectional prepreg P formed by impregnating the resin of the resin film S into the aligned flat fiber bundles B * (see FIG. 3) is formed.

  The processing apparatus 1 drives the support 2, the head unit 3 including the resonator 31 that applies ultrasonic vibration in the pressing direction Z to the unidirectional reinforcing fiber bundle B, and the resonator 31 supported by the support means 33. A pressure unit 4 that reciprocates in the pressing direction Z, a supply unit 5 that supplies a unidirectional reinforcing fiber bundle B in which the resin film S is overlapped on both sides between the stage 2 and the head unit 3, and a processing And a control device (not shown) that controls each part of the device 1. The unidirectional reinforcing fiber bundle B is formed of reinforcing fibers such as carbon fiber, glass fiber, and aramid fiber, and the resin film S constituting the matrix resin is a thermosetting resin such as an epoxy resin or an unsaturated polyester resin, It is formed of a thermoplastic resin such as a polyolefin resin, an aliphatic polyamide resin, or a polyethylene terephthalate resin. Further, as shown in FIG. 3, the resin film S is formed in a tape shape whose width Ws is slightly wider than the width Wb of the strip-shaped fiber bundle B * formed by opening the unidirectional reinforcing fiber bundle B. Has been.

  The support body 2 is disposed below the head portion 3 and has a planar shape in which the unidirectional reinforcing fiber bundle B in a state where the resin film S is superimposed on both surfaces is sandwiched between the pressing surface 35a of the horn 35 provided in the head portion 3. The support surface 21 is provided.

  The head unit 3 includes a resonator 31 having a vibrator 32 (vibration means) that applies ultrasonic vibration in the pressing direction Z to the resonator 31 connected to one end thereof, and a support means 33 that supports the resonator 31. When the vibrator 32 ultrasonically vibrates the resonator 31 (horn 35), ultrasonic vibration is applied from the pressing surface 35a to the unidirectional reinforcing fiber bundle B (resin film S).

  Specifically, the resonator 31 resonates with the ultrasonic vibration generated by the vibrator 32 controlled by the control device and vibrates in the direction of the central axis (pressing direction Z). 34 and a horn 35, and the other end of the booster 34 and one end of the horn 35 are connected by a headless screw so that their central axes are coaxial.

  In this embodiment, for example, the booster 34 is formed to have a length of one wavelength of the resonance frequency so that the substantially center position in the direction of arrow Z in FIG. Yes. At this time, two positions that are a quarter wavelength away from each maximum amplitude point in the arrow Z direction correspond to the first and second minimum amplitude points of the booster 34, respectively. Moreover, the booster 34 is formed in the column shape whose cross-sectional shape is circular. The vibrator 32 is connected to one end of the booster 34 by a headless screw so as to be coaxial with the central axis of the booster 34.

  In addition, concave grooves are formed along the respective circumferential directions on the outer peripheral surface of the booster 34 at positions corresponding to the first and second minimum amplitude points, whereby the booster 34 (resonator 31) is supported by the support means 33. A gripped portion is formed to be gripped. In this embodiment, the gripped portion is formed so that the cross-sectional shape substantially orthogonal to the central axis of the booster 34 is an octagonal shape, but the cross-sectional shape is a circular shape or other polygonal shape. A gripped portion may be formed.

  The horn 35 (corresponding to the “pressing body” of the present invention) has a flat pressing surface 35 a that presses the unidirectional reinforcing fiber bundle B (resin film S) in a pressing direction Z perpendicular to the supporting surface 21 of the supporting body 2. The ultrasonic vibration is applied to the unidirectional reinforcing fiber bundle B (resin film S) from the pressing surface 35a by resonating with the vibration of the vibrator 32 and ultrasonically vibrating. The horn 35 is formed to have a half wavelength length of the resonance frequency so that both end positions in the arrow Z direction in FIG. 2 are maximum amplitude points, for example. At this time, the substantially center position of the horn 35 in the arrow Z direction corresponds to the third minimum amplitude point. As shown in FIGS. 2 and 3, the horn 35 is formed in a rectangular parallelepiped shape. And the pressing surface 35a of the horn 35 is formed wide in the width direction X substantially orthogonal to the pressing direction Z and the longitudinal direction Y with respect to the resin film S (band-shaped fiber bundle B * after opening). (Width Wh of horn 35 ≧ width Ws of resin film S ≧ width Wb of band-like fiber bundle B *).

  In this embodiment, the resonator 31 has a resonance frequency of about 15 kHz to about 60 kHz, and a vibration amplitude (amplitude of expansion and contraction in the arrow Z direction) of about 2 μm to about 300 μm. The resonator 31 resonates with the ultrasonic vibration generated by the child 32 and ultrasonically vibrates, so that the unidirectional reinforcing fiber bundle B (resin film S) is pressed from the pressing surface 35a of the horn 35 in the pressing direction Z. Sonic vibration is applied.

  The support means 33 includes a base portion 36 and a clamp means 37, and supports the resonator 31 by holding the gripped portion of the booster 34 with the clamp means 37. The base portion 36 includes the pressurizing means 4. A screw hole to be screwed into the ball screw 42 is formed in the arrow Z direction.

  The clamping means 37 is provided at two locations on the base portion 36 so that the two gripped portions formed on the booster 34 can be gripped. The clamp means 37 holds the gripped portions of the booster 34 respectively. Two members are provided. Specifically, the first and second members of the clamping means 37 are provided with recesses having shapes that can be engaged with the cross-sectional shape of the gripped portion. And the 1st and 2nd of the clamp means 37 supported by the base part 36 in the concave groove | channel which forms a to-be-held part so that the to-be-held part of the booster 34 may be pinched by the recessed part of a 1st and 2nd member. The members are inserted and the first and second members are fixed with bolts, whereby the gripped portion of the booster 34 is gripped by the clamp means 37.

  Note that the configuration of the support means 33 that supports the resonator 31 is not limited to the clamp means 37 that is fixed with bolts while holding (clamping) the gripped portion formed on the booster 34 as described above. Any configuration that can support the gripped portion of the booster 34, such as a mechanical clamping mechanism configured to be electrically controlled or a clamping mechanism that can be attached with one touch, may be used.

  The position of the gripped portion formed in the resonator 31 is not limited to the minimum amplitude point, and the gripped portion may be formed at an arbitrary position of the resonator 31. The configuration of the gripped portion is not limited to a configuration in which a concave groove is formed along the circumferential direction on the outer peripheral surface of the resonator 31. For example, a convex shape along the circumferential direction is formed on the outer peripheral surface of the resonator 31. As long as it can be gripped by the support means 33, such as a configuration in which a flange is formed, the gripped portion may be configured in any shape. Further, the gripped portion may be supported by the support means 33 via an elastic member such as an O-ring or a diaphragm.

  The pressurizing unit 4 drives the resonator 31 supported by the support unit 33 in the pressing direction Z so that the pressing surface 35 a of the horn 35 faces the support surface 21 of the support 2, or approaches the support 2. It is separated from the support 2 and includes a drive motor 41 and a ball screw 42. In addition, a guide 43 is coupled to a support (not shown) standing on a gantry (not shown), and the pressurizing means 4 is connected to the support and the guide 43 via a frame 44.

  Then, when the drive motor 41 rotates under the control of the control device, the convex rail 43a provided on the guide 43 in the arrow Z direction and the guide (not shown) provided on the support means 33 are in sliding contact. The support means 33 screwed into the ball screw 42 moves up and down in the movement direction Z, so that the resonator 31 supported by the support means 33 approaches or is separated from the support body 2.

  Further, the pressurizing unit 4 adjusts the driving torque of the driving motor 41 based on the control by the control device, thereby bringing the resonator 31 supported by the support unit 33 close to the support 2 with a predetermined pressurizing force. It is configured to be able to. Further, the support column is provided with a linear encoder (not shown), whereby the height of the head portion 3 in the arrow Z direction (pressing direction) is detected and driven by the control device based on the detection signal of the linear encoder. By controlling the motor 41, the height of the head unit 3 can be adjusted.

  The direction of the center axis of the resonator 31 is substantially the same as the screw hole formed in the base portion 36, that is, the direction of the center axis of the resonator 31 and the moving direction of the resonator 31 by the pressing means 4 (pressing direction Z ) Are substantially in the same direction, and the resonator 31 is supported by the support means 33 so that the pressing surface 35a of the horn 35 faces the support 2. Accordingly, when the base portion 36 is moved downward by the pressurizing means 4, the resonator 31 (horn 35) is driven in the pressing direction Z so as to be integrally close to the support body 2, thereby Pressure is applied to the unidirectional reinforcing fiber bundle B (resin film S) supported by the support surface 21 of the support 2 from the pressing surface 35a. That is, by being controlled by the pressurizing means 4, the unidirectional reinforcing fiber bundle B (resin film S) is pressed against the support surface 21 of the support 2 by the pressing surface 35 a of the horn 35 that vibrates ultrasonically. Pressed.

  In this embodiment, the drive motor 41 is controlled by the control device so that the unidirectional reinforcing fiber bundle B (resin film S) is pressed against the support surface 21 with a predetermined constant pressure by the pressing surface 35a. The Further, the height position of the resonator 31 (base portion 36) in the pressing direction Z is such that the distance between the pressing surface 35a and the support surface 21 when the resonator 31 extends to the maximum as shown by the arrow L in FIG. When the position H that reaches the predetermined gap G is reached, the drive motor 41 is controlled by the control device so that the resonator 31 does not move beyond the position H to the support 2 side. In addition, the magnitude of the pressure applied to the unidirectional reinforcing fiber bundle B by the pressing surface 35a and the size of the gap G between the pressing surface 35a and the support surface 21 are the width and thickness of the strip-shaped fiber bundle B * after opening, What is necessary is just to set an optimal value suitably according to the width | variety and thickness of the unidirectional prepreg P. FIG. For example, by repeatedly performing a processing test on the unidirectional reinforcing fiber bundle B and the resin film S, the optimum pressure and the value of the gap G may be set.

  As shown in FIG. 1, the supply means 5 (corresponding to the “moving means” in the present invention) has a first supply roller 51 that winds and holds the unidirectional reinforcing fiber bundle B, and a resin film S that is wound. Second and third supply rollers 52 and 53, a drawing roller 54, a tension adjusting roller 55, and a storage roller 56 are provided. The unidirectional reinforcing fiber bundle B and the both resin films S are pulled out from the supply rollers 51 to 53 by being nipped by the driving roller 54a and the driven roller 54b rotating in the direction of the arrow of the drawing roller 54, and both resins The unidirectional reinforcing fiber bundle B sandwiched between the films S is supplied between the pressing surface 35 a of the horn 35 and the support surface 21 of the support 2.

  At this time, the unidirectional reinforcing fiber bundle B in which the resin films S are overlapped on both surfaces is rotated by the driving roller 55a and the driven roller 55b that rotate in the direction of the arrow of the tension adjusting roller 55 disposed on the downstream side of the head portion 3. When the nip is applied, the belt travels in the longitudinal direction Y while being sandwiched between the pressing surface 35a and the support surface 21 while adjusting the tension. Therefore, in this embodiment, since the unidirectional reinforcing fiber bundle B (resin film S) and the horn 35 move relatively in the longitudinal direction Y, the unidirectional reinforcing fiber bundle B (resin film S) is moved by the pressing surface 35. A portion pressed with a predetermined constant pressing force moves along the longitudinal direction Y of the unidirectional reinforcing fiber bundle B. The unidirectional prepreg P formed by passing the unidirectional reinforcing fiber bundle B in which the resin film S is overlapped on both surfaces passes between the pressing surface 35a of the horn 35 and the supporting surface 21 of the support 2, It is wound around the storage roller 56 and stored. Note that the resin film S may be overlapped only on one side of the unidirectional reinforcing fiber bundle B by providing only one of the second and third supply rollers 52 and 53.

(Opening and impregnation treatment)
Next, an example of the fiber opening / impregnation process performed in the processing apparatus 1 will be described.

  First, a unidirectional reinforcing fiber bundle B made of an aggregate of predetermined reinforcing fibers is prepared. The unidirectional reinforcing fiber bundle B is applied to the support surface 21 of the support 2 by the pressing surface 35a of the horn 35 that ultrasonically vibrates in a state where the resin film S having a predetermined thickness is superimposed on both surfaces. By running in the longitudinal direction Y while pressing with pressure, as shown in FIG. 3, the width of the unidirectional reinforcing fiber bundle B is expanded to the width Wb, and the thickness is formed to be a predetermined thickness. A unidirectional prepreg P formed by impregnating the resin film S with the strip-shaped fiber bundle B * is formed.

  As described above, in this embodiment, the unidirectional reinforcing fiber bundle B is interposed between the support surface 21 of the support 2 and the pressing surface 35a of the horn 35 that ultrasonically vibrates in the pressing direction Z orthogonal to the supporting surface 21. The unidirectional reinforcing fiber bundle B can be opened by moving the pressing portion of the unidirectional reinforcing fiber bundle B by the pressing surface 35a along the longitudinal direction Y of the unidirectional reinforcing fiber bundle B in a state of sandwiching it can. Therefore, for example, when comparing conventional techniques using airflow, a strong tension can be applied to the unidirectional reinforcing fiber bundle B when opening, so that the unidirectional reinforcing fiber bundle B can be stably processed at high speed. Can be opened.

  In general, the strip-shaped fiber bundle B * after opening is unstable and easily entangled, but the unidirectional reinforcing fiber bundle B and the resin film S are overlapped between the support surface 21 and the pressing surface 35a. The unidirectional reinforcing fiber bundle B (resin film S) is run in the longitudinal direction Y in a state where the unidirectional reinforcing fiber bundle B is opened, and at the same time, the resin in which the resin film S is melted is strip-shaped fiber. The bundle B * can be impregnated. Therefore, the impregnation apparatus which has been conventionally required is unnecessary, and the unidirectional prepreg P can be formed in one process, so that the processing cost of the unidirectional reinforcing fiber bundle B can be reduced. Further, the physical ultrasonic vibration is applied from the horn 35 and the resin of the resin film S comes into contact with the belt-like fiber bundle B *, thereby promoting the reaction at the bonding interface between the filaments of the reinforcing fibers and the resin. In this way, the resin film S can be satisfactorily impregnated into the band-like fiber bundle B *. Therefore, the physical properties of a molded product using the unidirectional prepreg P can be improved. In addition, since the band-like fiber bundle B * is impregnated with the resin simultaneously with the opening, there is no possibility of fluffing and the like in the band-like fiber bundle B * after opening, and the fiber bundle B * after opening is handled. Is easy.

  Further, the unidirectional reinforcing fiber is set with a predetermined pressure set in advance according to the thickness of the unidirectional reinforcing fiber bundle B to be processed and the target value of the width Wb and thickness of the strip-shaped fiber bundle B * after the fiber opening process. By opening the bundle B while pressing it, the width Wb and thickness of the fiber bundle B * after opening can be adjusted with high accuracy.

  In addition, the support surface 21 is more than the predetermined gap G set in advance according to the target value of the thickness of the unidirectional reinforcing fiber bundle B to be processed, the thickness of the band-like fiber bundle B * after the fiber opening process, and the width Wb. By opening the unidirectional reinforcing fiber bundle B in a state where the pressing surface 35a is arranged so that the distance between the two is not narrowed, the thickness and width Wb of the strip-like fiber bundle B * after opening can be adjusted with high accuracy. it can. In a state where the resonator 31 is fixedly disposed at the position H in the pressing direction Z so that the distance between the pressing surface 35a and the support surface 21 at the time of maximum extension of the ultrasonically vibrating horn 35 is always the predetermined gap G ( 2), the unidirectional reinforcing fiber bundle B (resin film S) may be run in the longitudinal direction Y. Even in this way, the thickness and width Wb of the strip-shaped fiber bundle B * after opening can be adjusted with high accuracy.

Second Embodiment
A processing apparatus according to a second embodiment of the present invention will be described with reference to FIG. FIG. 4 is a front view showing a processing apparatus according to the second embodiment of the present invention.

  The processing apparatus 1a shown in FIG. 4 differs from the first embodiment described above in that the impregnation process is performed in the impregnation apparatus 6 as shown in FIG. That is, after the unidirectional reinforcing fiber bundle B is opened by passing between the pressing surface 35a and the support surface 21 in a state where the resin film S is not superposed, the resin film S is applied to the belt-like fiber bundle B *. And the impregnation process is performed in the impregnation apparatus 6. Since other configurations and operations are the same as those of the first embodiment described above, the description of the configurations and operations is omitted by citing the same reference numerals.

  As shown in FIG. 4, the impregnation device 6 is configured to be able to press a belt-like fiber bundle B * having a resin film S superimposed on both sides from above and below, and rotates in the direction of the arrow in the figure. Units 61 and 62, and a heating mechanism 63 and a cooling mechanism 64 disposed inside the belt units 61 and 62 are provided. The heating mechanism 63 is disposed on the upstream side, and the cooling mechanism 64 is disposed on the downstream side. In the impregnation apparatus 6 configured as described above, when the belt-like fiber bundle B * with the resin film S superimposed on both sides passes, the heating mechanism 63 is pressurized while being pressurized by the belt units 61 and 62 on the upstream side. The belt-shaped fiber bundle B * is impregnated with the resin of the resin film S melted by heating. Then, on the downstream side, the resin impregnated in the fiber bundle B * is solidified by being cooled by the cooling mechanism 64 while being pressurized by the belt units 61 and 62, and the unidirectional prepreg P is formed. Note that, similarly to the first embodiment described above, the tension adjusting roller 55 may be further provided at an optimal place as appropriate.

  Even if comprised in this way, like the above-mentioned 1st Embodiment, by passing between the press surface 35a and the support surface 21, the unidirectional reinforcement fiber bundle B is opened, and thereby the unidirectional reinforcement fiber The bundle B can be stably processed at high speed and opened. In addition, by stably opening the unidirectional reinforcing fiber bundle B, the thickness of the strip-like fiber bundle B * impregnated with the resin (impregnation distance: the number of reinforcing fiber filaments) can be reduced. Thus, the fiber bundle B * can be impregnated with the resin, the generation of voids can be suppressed, and incomplete impregnation can be prevented. Therefore, the physical properties of a molded product using the unidirectional prepreg P can be improved.

<Third Embodiment>
A processing apparatus according to a third embodiment of the present invention will be described with reference to FIG. FIG. 5 is a perspective view showing a main part of a processing apparatus according to the third embodiment of the present invention. In FIG. 5, as in FIG. 3, the resin film S disposed on the lower surface side of the belt-shaped reinforcing fiber bundle B * and the support 2 are not shown.

  The processing apparatus 1b shown in FIG. 5 is different from the above-described second embodiment in that the configuration of the impregnation apparatus 7 is different as shown in FIG. Since other configurations and operations are the same as those of the first embodiment described above, the description of the configurations and operations is omitted by citing the same reference numerals.

  As shown in FIG. 5, the impregnation apparatus 7 includes a horn 135 having substantially the same configuration as the horn 35 used for the fiber opening process. Then, the band-shaped fiber bundle B * overlaid with the resin film S passes between the pressing surface 135a of the horn 135 of the impregnation device 7 and the support surface 21 of the support body 2, whereby the first embodiment described above is performed. Similarly to the form, the belt-shaped fiber bundle B * is impregnated with the resin of the resin film S melted by applying ultrasonic vibration from the pressing surface 135a, and the prepreg P is formed.

  With this configuration, compared to the configuration of the second embodiment described above, the impregnation time of the impregnation apparatus 7 can be improved while the impregnation time can be further shortened by applying ultrasonic vibration. . Further, as in the first embodiment described above, since the ultrasonic vibration is applied and the impregnation treatment is performed, the reaction at the bonding interface between the filaments of the reinforcing fibers and the resin is promoted to obtain a good bonded state. The belt-shaped fiber bundle B * can be satisfactorily impregnated with the resin of the resin film S. Therefore, the physical properties of a molded product using the unidirectional prepreg P can be improved.

<Fourth embodiment>
A processing apparatus according to a fourth embodiment of the present invention will be described with reference to FIG. FIG. 6 is a cross-sectional view showing a unidirectional reinforcing fiber bundle and a resin sheet processed in the processing apparatus according to the fourth embodiment of the present invention.

  This embodiment is different from the first to third embodiments described above, as shown in FIG. 6, two bundles of unidirectional reinforcing fiber bundles B, or two bundles of strip-like fiber bundles B * after opening. Thus, the impregnation process is performed in a state where the resin film S is sandwiched. Other configurations and operations are the same as the configurations and operations of any of the first to third embodiments described above, and thus the same reference numerals are used to omit the description of the configurations and operations.

  Thus, even if the unidirectional reinforcing fiber bundle B (band-like fiber bundle B *) and the resin sheet S are overlapped as shown in FIG. 6, the same effects as those of the above-described embodiments can be obtained.

  It should be noted that the present invention is not limited to the above-described embodiment, and various modifications other than those described above can be made without departing from the spirit of the present invention. May be combined. For example, by moving the horn 35 (resonator 31) in the longitudinal direction Y, the pressing location of the unidirectional reinforcing fiber bundle B by the pressing surface 35a of the horn 35 may be moved. Further, by moving both the horn 35 (resonator 31) and the unidirectional reinforcing fiber bundle B in the longitudinal direction Y, the pressing location of the unidirectional reinforcing fiber bundle B by the pressing surface 35a of the horn 35 moves. You may do it.

  Moreover, you may make it set the pressurizing force with respect to the unidirectional reinforcement fiber bundle B by the press surface 35a of the horn 35 using a pressure difference of a cylinder by adding a cylinder to the above-mentioned pressurization means 4. FIG.

  In the second and third embodiments described above, the configuration of the impregnation apparatus is not limited to the above-described example, and the impregnation process may be performed by a generally used impregnation apparatus.

  The configuration of the pressing body and the shape of the pressing surface is not limited to the configuration of the horn 35 described above, but has a flat pressing surface and supports the unidirectional reinforcing fiber bundle B at least in the width direction. The pressing body may be configured in any shape as long as it can be pressed against the surface 21 by the pressing surface. For example, the horns 35 and 135 can be configured such that the side view shape tapers in a beak shape toward the pressing surfaces 35a and 135a.

  Further, the pressurizing unit 4 is not limited to the above-described configuration. If the resonator 31 can be moved, the pressurizing unit 4 may be changed by using a known actuator such as a linear motor or a cylinder. It may be configured.

  Further, the arrangement positions of the pressing body and the support body are not limited to the above-described examples arranged in the vertical direction toward the paper surface of FIG. 1, and the vertical positions of the pressing body and the support body are interchanged. Alternatively, the pressing body and the support body may be arranged side by side in the left-right direction toward the paper surface of FIG.

  And this invention can be widely applied to the processing method and processing apparatus which open a unidirectional reinforcement fiber bundle.

DESCRIPTION OF SYMBOLS 1, 1a, 1b ... Processing apparatus 2 ... Support body 21 ... Support surface 32 ... Vibrator (vibration means)
35 ... Horn (pressing body)
35a ... Pressing surface 5 ... Supply means (moving means)
B ... Unidirectional reinforcing fiber bundle G ... Gap S ... Resin film Y ... Longitudinal direction Z ... Pressing direction

In order to achieve the above-described object, the processing method according to the present invention is opened between the support surface of the support and the pressing surface of the pressing body that ultrasonically vibrates in the pressing direction orthogonal to the support surface. belt-like and superposed and unidirectional reinforcing fiber bundle and the resin film look narrow, while maintaining the pressing surface and the supporting surface at a predetermined interval, the unidirectional reinforcing fiber bundle and the resin film in the longitudinal direction of its The unidirectional reinforcing fiber bundle is continuously impregnated with the resin of the resin film by being moved relative to the pressing body and the support .

Further, the processing apparatus according to the present invention includes a support having a support surface, a press having a pressing surface, and a vibration unit that applies ultrasonic vibration in a pressing direction perpendicular to the support surface to the pressing body. A belt-shaped unidirectional reinforcing fiber bundle that has been opened, and a moving means that moves the resin film superimposed on the unidirectional reinforcing fiber bundle relative to the pressing body and the support body along the longitudinal direction, The superimposed unidirectional reinforcing fiber bundle and the resin film are sandwiched between the support surface and the pressing surface of the pressing body that is ultrasonically vibrated in the pressing direction by the vibrating means, and the pressing surface and the while maintaining the support surface at a predetermined interval, wherein the moving means, the unidirectional reinforcing fiber bundle and the resin film by moving the continuously impregnated with resin of the resin film on the unidirectional reinforcing fiber bundle It is characterized by causing.

In the invention configured as described above, since the impregnation treatment is performed by applying ultrasonic vibration, the reaction at the bonding interface between each filament of the reinforcing fiber and the resin can be promoted to obtain a good bonded state. The resin of the resin film can be continuously and satisfactorily impregnated into the belt-shaped unidirectional reinforcing fiber bundle.

Claims (4)

Between the support surface of the support and the pressing surface of the pressing body that vibrates ultrasonically in the pressing direction orthogonal to the support surface, the opened strip-shaped unidirectional reinforcing fiber bundle and the resin film are overlapped and sandwiched In this state, the pressing portion of the unidirectional reinforcing fiber bundle by the pressing surface is moved along the longitudinal direction of the unidirectional reinforcing fiber bundle, and the unidirectional reinforcing fiber bundle is impregnated with the resin of the resin film. A processing method characterized by the above.   The processing method according to claim 1, wherein the pressed portion is moved while pressing the unidirectional reinforcing fiber bundle against the support surface with a predetermined pressing force by the pressing surface.   The processing method according to claim 1, wherein the pressing portion is moved in a state where the pressing surface is arranged with a predetermined gap from the support surface. A support having a support surface;
A pressing body having a pressing surface;
Vibration means for applying ultrasonic vibration in a pressing direction orthogonal to the support surface to the pressing body;
Between the support surface and the pressing surface of the pressing body that is ultrasonically vibrated in the pressing direction by the vibration means, the opened strip-shaped unidirectional reinforcing fiber bundle and the resin film are overlapped and sandwiched. A moving means for relatively moving the unidirectional reinforcing fiber bundle and the resin film and the pressing body,
By the moving means, the pressing portion of the unidirectional reinforcing fiber bundle by the pressing surface is moved along the longitudinal direction of the unidirectional reinforcing fiber bundle, and the unidirectional reinforcing fiber bundle is impregnated with the resin of the resin film. The processing apparatus characterized by the above-mentioned.

Images