JP2018027836A - Method for producing resin-impregnated fiber bundle wound body - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for producing a resin-impregnated fiber bundle wound body which suppresses an increase in tension of a fiber bundle and can improve operability, can leave an adjustment width even on winding tension around a winding core, and can improve quality.SOLUTION: A method for producing a resin-impregnated fiber bundle wound body 304 includes: an unwinding step 100 of unwinding a fiber bundle 1 from a bobbin; a winding step 300 of winding the fiber bundle around a winding core 301 rotating on a fixed shaft to obtain a product; and a guiding step 200 having a guide member that guides the fiber bundle unwound from the unwinding step to the winding step and resin adhesion means 210 that bonds a resin to the fiber bundle, between the unwinding step and the winding step, where among the guide members arranged in the guiding step, one or more guide members are driving and guiding members rotationally driven by external power, and the driving and guiding members further have a torque meter that detects a rotational resistance torque value and further includes adjustment means which adjusts a rotational driving force by the external force based on the rotational resistance torque value detected by the torque value.SELECTED DRAWING: Figure 9

Description

  The present invention relates to a method for producing a resin-impregnated fiber bundle wound body for producing a fiber reinforced plastic (FRP) container or the like.

  FRP is a composite material in which a resin is reinforced with reinforcing fibers and is widely used because it is lighter than metal materials such as iron and aluminum but can exhibit strength and rigidity equal to or higher than that of metal materials. .

  In FRP production, at the raw material stage, fiber bundles composed of a plurality of single fibers and liquid resin are generally in separate forms, and the fiber bundle and resin are combined by various production means. It is necessary to make it.

  For example, in the filament winding (FW) molding method, a fiber bundle wound in a bobbin shape is continuously unwound, the fiber bundle is combined with a resin, and the product is then wound on a core. It is a construction method to obtain. In the method of manufacturing the FRP product by continuously unwinding the fiber bundle as in this method, the fiber bundle is stabilized in the process, for example, twisting (twisting) of the fiber bundle does not occur. It is often important to equalize the fiber density in the product, and various techniques have been developed focusing on the frictional force and tension applied to the fiber bundle in order to solve the problem.

  For example, in Patent Document 1, in order to prevent twisting of the fiber bundle in the process, the roller is driven by external power so that a difference occurs between the winding speed of the fiber bundle and the rotational speed of the roller. The fiber bundle is prevented from being twisted by applying vibration in parallel to the central axis direction of the fiber and applying a frictional force to the fiber bundle.

  In Patent Document 2, the fiber bundle shape is stabilized by applying tension when the fiber bundle is unwound from the bobbin, and the product quality is improved by adjusting the tension to an appropriate range.

  In Patent Document 3, the tension for winding the fiber bundle around the winding core is adjusted to an appropriate value corresponding to the winding step by a method of adjusting the speed of the roller driven by external power installed in the process. Sequential adjustments are made to prevent a decrease in product strength.

  In Patent Document 4, in order to maintain the winding tension for winding the fiber bundle around the winding core in an appropriate range, the positional relationship between the fiber bundle and the guide member is sequentially changed to achieve stable product quality.

JP 2005-161797 A JP 2008-290381 A JP 2001-260240 A JP 2011-245780 A

By the way, in the FRP manufacturing method for continuously unwinding the fiber bundle as exemplified, it is general to include a step of compounding the fiber bundle and the resin (resin impregnation step). There are various methods for the resin impregnation process. For example, in the FW molding method, as shown in FIG. 2, the lower part of the roller member is passed through the resin, and the excess resin is scraped off by the scraping member. A technique (impregnation roller type) in which a resin film having a constant thickness is formed and a fiber bundle is brought into contact with the resin film to impregnate the resin is sometimes used. In this method, the roller member rotates in the direction DR by the winding force of the fiber bundle, and the resin is continuously supplied onto the roller surface. However, the viscosity of the resin used and the depth at which the roller is immersed in the resin are adjusted. in response, the resin resistance R _V of a resin viscosity occurs during rotation of the roller, the tension F of the fiber bundle is increased in accordance with the magnitude of the resin resistance R _V.

  Therefore, if the resin used has a high viscosity in the first place, or if the resin-derived resistance increases due to temperature increase or resin aging, the appropriate range of fiber bundle tension in the process will be exceeded. There is a risk of adversely affecting operability such as thread breakage, and there is a risk that product quality will deteriorate due to exceeding the appropriate range of winding tension around the core. The main measures were time-consuming and time-consuming work such as replacement, leaving room for efficiency.

  Also, when there is a roller member (free roller) that rotates due to the tension of the fiber bundle during the process, the moment of inertia related to the rotation axis of the roller is large (for example, when the diameter is large or solid) ), A large rotational resistance is generated until a predetermined rotational speed is reached, and as a result, a high tension is temporarily applied to the fiber bundle, exceeding the appropriate range of the tension in the process or the winding tension around the core. There was room for improvement.

  Therefore, the present invention can contribute to the improvement of operability by suppressing an increase in the tension of the fiber bundle, and can also leave an adjustment range to an appropriate range with respect to the winding tension around the core. Another object of the present invention is to provide a method for producing a resin-impregnated fiber bundle wound body that can contribute to improvement in product quality.

The above problems are solved by the following invention.
(1) At least a unwinding step of unwinding the fiber bundle from the bobbin;
A winding step in which a winding head freely moves with respect to a core that rotates on a fixed shaft, and a product is obtained by winding a fiber bundle on the core;
Between the unwinding step and the winding step, a guide member that guides the fiber bundle fed out from the unwinding step to the winding step, and a resin attachment unit that attaches resin to the fiber bundle. A guidance process;
A method for producing a resin-impregnated fiber bundle wound body comprising:
Among the guide members arranged in the guiding step, at least one guide member is a drive guide member that is rotationally driven by external power, and the drive guide member includes a torque meter that detects a rotational resistance torque value. In addition,
A method for producing a resin-impregnated fiber bundle winder, further comprising adjusting means for adjusting a rotational driving force by the external power based on the rotational resistance torque value detected by the torque meter.
(2) The rotational driving force by the external power is always controlled using the rotational resistance torque value detected by the torque meter as a control parameter, and the resin-impregnated fiber bundle winder according to (1) Manufacturing method.
(3) The resin-impregnated fiber bundle winding according to (2), wherein the rotational driving force by the external power is controlled so that the rotational resistance torque value is 0.0001 N · m or more and 1 N · m or less. Manufacturing method of the body.
(4) The resin adhering means is an impregnating roll type in which a fiber bundle passes on the surface of a guide member whose surface is coated with a resin, according to any one of (1) to (3) A method for producing a resin-impregnated fiber bundle wound body.

  According to the present invention, it is possible to suppress the increase in the tension of the fiber bundle and contribute to the improvement of operability, and it is possible to leave an adjustment range to an appropriate range with respect to the winding tension around the core. In addition, it is possible to provide a method for producing a resin-impregnated fiber bundle wound body that can contribute to improvement of product quality.

It is a figure which shows an outline about an example of the manufacturing process of the resin impregnation fiber bundle winding body which concerns on this invention. It is a figure which shows the outline of an example (impregnation roller type) of a resin adhesion means. It is a figure which shows the example of a general guide member. It is a figure explaining the fiber bundle which runs orthogonally to a guide member. It is a figure which shows the passage form of the desirable fiber bundle in a guide member. It is a figure which shows an example of the guide driven with the external power which concerns on this invention. It is a figure explaining the example of the effect acquired by this invention. It is a figure which shows an example regarding the installation position of a drive guide. It is a figure which shows another example regarding the installation position of a drive guide. It is a figure which shows an outline about another example of the manufacturing process of the resin impregnation fiber bundle winding body which concerns on this invention.

  Hereinafter, the present invention will be described in detail.

<Process outline>
A method for producing a resin-impregnated fiber bundle wound body according to the present invention will be described using the embodiment shown in FIG. This manufacturing method is a downstream process of at least the unwinding step 100 for unwinding the fiber bundle 1 from the fiber bundle bobbin 101 to which no resin is adhered and the fiber bundle 1 unwound in the unwinding step. Winding on a winding core 301 via a winding head 302 and a guiding step 200 having at least a guiding guide 201 for guiding to the winding step 300 and a resin adhering means 210 for adhering resin to the fiber bundle 1 And a winding step 300 for obtaining a resin-impregnated fiber bundle wound body.

<Outline of guide member>
Hereinafter, the “guide” or “guide member” (for example, expressed as the unwinding guide 102 or the guide guide 201) appearing in the present specification refers to the fiber bundle 1 fed out from the fiber bundle bobbin 101. A generic term for members that are used in contact with each other and are arranged for the purpose of guiding the fiber bundle 1 to the core while changing the height and direction without giving unnecessary twisting or folding to the fiber bundle 1 and winding it around the core. It is.

  FIG. 3 shows general shapes 11, 12, 13, and 14 of the guide member. The shape of the guide members 11 to 14 is a rod-like member elongated in one direction, and a rotationally symmetric shape with a long axis (center axis 21) as the rotation axis is preferable. More specifically, it may be a shape (11) that is uniform in the direction of the central axis 21 or a shape that includes a portion that changes continuously or discontinuously (12, 13, 14).

  The guide member is disposed so that the central axis 21 and the traveling direction of the fiber bundle 1 are substantially orthogonal to each other, and the fiber bundle 1 travels while being in contact with the rotationally symmetrical outer peripheral surface. It is possible to restrict the position of 1 to a predetermined position. The “orthogonal” state in the present invention indicates that the angle θ formed by the central axis 21 of the guide member and the traveling direction M of the fiber bundle 1 is θ = 90 ° as shown in FIG. A range of 90 ° ± 5 ° may be included.

  Preferably, the width direction of the fiber bundle 1 is aligned with the direction of the central axis 21 of the guide member (in the example of FIG. 5, the guide member 11) so that the ideal passing state of the fiber bundle 1 is shown in FIG. 5. By running, a reaction force can be applied not in the width direction of the fiber bundle 1 but in the thickness direction, and as a result, the fiber bundle can be made less likely to be twisted or folded.

  The portion where the fiber bundle 1 contacts is configured to be able to run the fiber bundle 1 without giving excessive resistance by allowing the fiber bundle 1 to follow the fiber bundle 1 as a roller member that can rotate around the central axis 21. As a fixed guide bar member that cannot rotate around the central axis 21, it may be configured such that the fiber bundle 1 can run with resistance. It is possible to select according to a predetermined purpose to be fulfilled by the guide member arranged in each process.

<Unpacking process>
The unwinding process 100 includes at least a fiber bundle bobbin 101 and a unwinding guide 102.

  The number of unwinding guides 102 for guiding the fiber bundle 1 unwound from the fiber bundle bobbin 101 to the guiding process 200 is an optimum number for each manufacturing process from the viewpoint of manufacturing facility layout constraints and economy. Selected. The axial direction of the unwinding guide 102 is important to be orthogonal to the traveling direction of the fiber bundle 1 (the direction in which the fiber bundle 1 is wound and advanced), and the axial direction of the fiber bundle bobbin 101 matches the axial direction. They may be orthogonal to each other, or may be arranged at a twisted position.

<Fiber>
As the reinforcing fiber used in this production method, various kinds of reinforcing fibers such as inorganic fibers such as glass fibers generally used as reinforcing fibers for FRP, organic fibers such as carbon fibers and aramid fibers, or a plurality of kinds thereof are used. However, it is preferable to use carbon fiber or glass fiber because the rigidity and strength of the resulting resin-impregnated fiber bundle wound body can be increased.

<Induction process>
The guiding process 200 includes a guiding guide 201 for guiding the fiber bundle 1 unwound in the unwinding process to a winding process 300 that is a downstream process, and a resin that attaches resin to the fiber bundle 1. And an attaching means 210.

  The number and the axial direction of the guides 201 are determined based on the same idea as the unwinding guide 102. That is, as for the number of guides 201, an optimum number is selected for each manufacturing process from the viewpoint of manufacturing facility layout constraints and economical efficiency, and the axial direction of the guides 201 is in the traveling direction of the fiber bundle 1. It is important that they are orthogonal to each other, and the axial direction and the axial direction of the fiber bundle bobbin 101 arranged in the unwinding step 100 may be the same, or may be orthogonal, and the position of the twist May be arranged.

  In the impregnation roller type illustrated in FIG. 1 with respect to the resin adhering means 210, the fiber bundle 1 passes through the guide guide 201 and then passes over the impregnation roller 212 which is a kind of guide member, and another guide guide 201 is passed through. Passed and sent downstream. The impregnation bath 211 containing the impregnation roller 212 is filled with the resin 2, and the resin adheres to the surface of the impregnation roller 212 by arranging the lower part of the impregnation roller 212 to pass through the resin 2. After the excess resin on the impregnation roller 212 is scraped off by the scraping member 213, the fiber bundle 1 passes over the impregnation roller 212, so that the resin 2 adheres to the fiber bundle 1.

  The impregnation process by the impregnation roller method is only an example of the impregnation method. For example, a dip method in which the fiber bundle is directly passed through the resin, a fixed discharge that draws the fiber bundle into the impregnation die and discharges a separately measured resin inside the die. Various means can be applied as long as the purpose is to attach and impregnate a predetermined amount of resin to the fiber bundle.

<Resin>
The resin 2 is preferably in a liquid form, and a thermosetting resin such as epoxy or unsaturated polyester, or a thermoplastic resin such as polyamide is selected according to the use of the final product, the specification environment, and the required product characteristics. There are no restrictions. From the viewpoint of workability and energy consumption, a thermosetting resin such as an epoxy resin is preferable because the impregnation process can be carried out with the resin temperature being generally low, and workability is good.

  About the viscosity of the impregnated resin, from the viewpoint of impregnation, it is better to be small, but if it is too low, the resin may drip before sufficiently impregnating into the fiber bundle, and there is a possibility that the predetermined resin content cannot be maintained. A suitable viscosity is necessary. Specifically, it is preferably in the range of 10 to 2000 mPa · s. More preferably, it is the range of 100-1100 mPa * s.

<External power drive and adjustment means>
The method for producing a resin-impregnated fiber bundle wound body according to the present invention is characterized by having at least one drive guide 204 that is a guide member driven by external power during the induction process 200. As shown in FIG. 6, the drive guide 204 includes at least a free roller 205 that can freely rotate, an external power source 206, and a torque meter 207.

FIG. 7 shows the effect of the drive guide 204. Various resistances R act on the free roller 205 rotated by the tension F of the fiber bundle. For example, inertial resistance R _I due to the inertia moment which is determined by the shape and weight of the free rollers 205 itself, the viscous resistance due to the resin is a free roller that rotates while soak in the resin as impregnation roller included in the impregnating roller impregnated means _RV is further generated. As a result, since a larger force is required to rotate, the tension F of the fiber bundle increases, and there is a possibility that the proper tension range in the process or the proper range with respect to the tension at the time of winding the core is exceeded. Paying attention to this point, the driving guide 204 can cancel the resistance R by applying the driving torque T by the external power when the free roller 205 rotates, thereby suppressing an excessive increase in the tension F of the fiber bundle. it can.

  Further, the torque meter 207 is installed on the rotation shaft of the free roller 205 to detect the rotational resistance torque value, and the resistance R is adjusted by adjusting the driving torque T by the external power according to the detected rotational resistance torque value. Can be canceled more accurately and the influence on the tension F of the fiber bundle can be minimized. In the present invention, the adjustment of the driving torque T by the external power is an important factor in managing the tension F of the fiber bundle, and hence the adjustment of the driving torque T is hereinafter defined as the adjusting means. As an implementation method of the adjusting means, a torque meter 207 for each driving guide 204 is prepared in advance for each manufacturing condition (for example, process speed, moment of inertia of the roller, resin viscosity, depth at which the roller is immersed in the resin, etc.). The rotation resistance torque value may be measured and recorded by the method, and a method of manually adjusting the driving torque T by the external power at an appropriate timing according to the progress of production may be selected. As a more preferable method, It is preferable to use continuous adjustment means for controlling the obtained rotational resistance torque value as a control parameter, always reflecting the driving torque T by external power. For example, the resistance R can be canceled quickly and accurately by controlling the driving torque T by external power by feedback control, feedforward control, or the like. More preferably, the value of the rotational resistance torque is controlled to be 0.0001 N · m or more and 1 N · m or less, so that an increase in tension due to the passage of the guide member can be almost zero.

  Regarding the selection of the external power source 206, there is no particular limitation as long as it has a driving torque sufficient to cancel the resistance R, but control using the rotational resistance torque detected by the torque meter 207 was considered. In this case, it is preferable to use an external power source that can easily control the torque, for example, a servo motor or a stepping motor.

  Regarding the selection of the torque meter 207, any type of torque meter such as a contact type or a non-contact type can be applied as long as the rotational resistance torque during the rotation of the free roll 205 can be measured.

  The arrangement position of the drive guide 204 is not particularly limited, and can be determined from the viewpoint of the layout of the manufacturing process. Especially, it is effective to apply to the free roller 205 which requires a large force to rotate. For example, as shown in FIG. 8, the large-diameter free roller in the process is used as the drive guide 204, or the impregnation roll in the resin bath is used as the drive guide 204 as shown in FIG. It is preferable because the effect can be maximized.

<Impregnation promotion process>
Further, as shown in FIG. 10, the guiding process 200 may include a plurality of impregnation guides 220 (ironing bars) installed for the purpose of further promoting resin impregnation. The impregnation guide 220 is usually installed in a state in which the rotation around the central axis of the guide is constrained, and when the fiber bundle 1 passes over the impregnation guide 220, the fiber bundle 1 is separated from the impregnation guide 220 with respect to its thickness direction. Receive reaction force. Due to this reaction force, further impregnation (penetration) of the resin 2 adhered to the fiber bundle 1 into the fiber bundle by the resin adhesion means 210 is promoted, and the void remaining in the fiber bundle 1 is replaced with the resin 2. In the configuration including the squeezing bar, it is unavoidable that the tension of the fiber bundle increases due to the passage of the squeezing bar, and the increase in the tension of the fiber bundle can be suppressed by the installation of the drive guide according to the present invention. The effect of installing the drive guide 204 can be further increased.

<Winding process>
In the winding process 300, the winding core 301 that is the winding object, the winding head 302 that is freely movable with respect to the winding core 301, and the fiber bundle 1 sent from the guiding process 200 are guided to the winding core 301. And a winding guide 303 for performing at least.

  In the winding process 300, the fiber bundle 1 sent from the guiding process 200 passes through a winding guide 303 fixed to the winding head 302, and can be rotated on an axis fixed in space. 301 is wound around. The winding head 302 performs winding on the core 301 while moving its position freely according to the fiber bundle winding amount and winding angle designed in advance according to the required characteristics of the product. Thus, the resin-impregnated fiber bundle wound body 304 is manufactured.

  The number and axial directions of the winding guides 303 are determined based on the same idea as the unwinding guide 102 and the guide guide 201. That is, as for the number of winding guides 303, an optimal number is selected for each manufacturing process from the viewpoints of manufacturing facility layout constraints and economy, and the fiber bundle 1 travels in the axial direction of the winding guides 303. It is important that the direction is perpendicular to the direction, and the axial direction of the core 301 may coincide with the axial direction, may be orthogonal, or may be arranged at a twisted position. .

<Core>
The core 301 used can be selected according to the product. For example, in the production of a resin-impregnated fiber bundle (toe prepreg) that has been impregnated into a fiber bundle and then cured at a predetermined level to obtain a semi-cured state and then wound into a bobbin again, A core similar to that used (for example, a paper hollow paper tube) can be used. In the production of hollow pipe members, cylindrical cores that can be decentered after the molded product has been cured, and various types of cores that can be decentered by melting by heating, etc. can be used. is there. In the production of the pressure vessel, various liner members made of metal or resin, which are cores that ensure a sealing property against a predetermined container, can be used.

  For products that require resin curing, such as hollow pipe members and pressure vessels using thermal effect resins, after the completion of winding, through a finishing process consisting of a resin curing process and additional processing for trimming the excess part, etc. The final product. The curing process may be performed at the same place without being moved from the winding process, or may be performed at another place after being moved from the winding process.

<Process speed>
The traveling speed of the fiber bundle 1 is preferably in the range of 0.1 to 300 m / min from the viewpoint of production efficiency. If the running speed is too high, the resin impregnation time cannot be secured and the product quality may be deteriorated. In addition, since the running resistance of the fiber bundle is increased and the amount of running fiber per unit time is increased, the amount of fluff generated is increased, and maintenance may not catch up and may cause trouble such as yarn breakage.

<Tension adjustment mechanism>
Further, another tension adjusting mechanism (not shown) may be further included in the process in order to adjust the tension during the process or the tension during winding to the optimum range. The selection of the tension adjusting mechanism is not particularly limited, and various forms such as a known dancer roll and a guide member height adjusting mechanism can be selected.

  In addition, for the purpose of more accurate tension value control, a known tension sensor or load cell is further included in the process, the tension control mechanism is controlled using the measured value as a control parameter, and the tension value is adjusted within a specified range. It is preferable to stabilize the product quality.

<Other embodiments>
The present invention is not limited only to the embodiments in the description, and can be implemented by changing the selection and arrangement of various members as long as the embodiments are based on the same technical idea.

1: Fiber bundle 2: Resin 11-14: Guide member example 21: Central shaft 100: Unwinding step 101: Fiber bundle bobbin 102: Unwinding guide 200: Guide step 201: Guide guide 204: Drive guide 205: Free roller 206: External power source 207: Torque meter 210: Resin adhesion means 211: Resin bath 212: Impregnation roller 213: Scraping member 220: Impregnation guide 300: Winding step 301: Core 302: Winding head 303: Winding guide 304: Resin-impregnated fiber bundle wound body F: Fiber bundle tension M: Fiber bundle travel direction θ: Angle formed by the central axis of the guide member and the fiber bundle travel direction DR: Rotation direction R: Resistance R _V : Resin Resistance R _I : Inertial resistance T: Driving torque by external power source

Claims (4)

At least the unwinding step of unwinding the fiber bundle from the bobbin;
A winding step in which a winding head freely moves with respect to a core that rotates on a fixed shaft, and a product is obtained by winding a fiber bundle on the core;
Between the unwinding step and the winding step, a guide member for guiding the fiber bundle fed out in the unwinding step to the winding step, and a resin attaching means for attaching a resin to the fiber bundle A guidance process;
A method for producing a resin-impregnated fiber bundle wound body comprising:
Among the guide members arranged in the guiding step, at least one guide member is a drive guide member that is rotationally driven by external power, and the drive guide member includes a torque meter that detects a rotational resistance torque value. In addition,
A method for producing a resin-impregnated fiber bundle winder, further comprising adjusting means for adjusting a rotational driving force by the external power based on the rotational resistance torque value detected by the torque meter. The method for producing a resin-impregnated fiber bundle wound body according to claim 1, wherein the rotational driving force by the external power is constantly controlled using the rotational resistance torque value detected by the torque meter as a control parameter. . 3. The resin-impregnated fiber bundle winder according to claim 2, wherein the rotational driving force by the external power is controlled so that the rotation resistance torque value is 0.0001 N · m or more and 1 N · m or less. Production method. The resin-impregnated fiber bundle winding according to any one of claims 1 to 3, wherein the resin adhering means is of an impregnating roll type in which the fiber bundle passes over the surface of a guide member whose surface is coated with resin. Manufacturing method of the body.