JP2019148029A - Manufacturing method and manufacturing apparatus of split yarn of carbon fiber - Google Patents

Abstract

To provide a manufacturing method of a split yarn of a carbon fiber in which a crossover yarn is less likely to be separated, when imparting a sizing agent to the split yarn.SOLUTION: A manufacturing method of a split yarn of a carbon fiber has an opening step for widening and thinning an original yarn A of the carbon fiber, a splitting step for splitting the original yarn A into a plurality of split yarns B along a longer direction, and a post-treatment step for imparting a sizing agent S to the split yarns B, in which, in the post-treatment step, the sizing agent S is imparted to the split yarns B by spraying or dropping the sizing agent S, while exposing the split yarns B to the air by sending the air along a sending direction X of the split yarns B.SELECTED DRAWING: Figure 6

Description

  The present invention relates to a carbon fiber split yarn manufacturing method and manufacturing apparatus.

  Thin carbon fibers are not on the market. This is because the thinner the carbon fiber, the more severe the production conditions, and technical difficulties. In addition, the thinner, the lower the carbon fiber production efficiency and the higher the price.

Japanese Unexamined Patent Publication No. 11-323692

Therefore, Patent Document 1 proposes a method of obtaining a thin divided yarn by dividing a thick carbon fiber yarn. Patent Document 1 proposes that after obtaining a split yarn, the split yarn is guided to a sizing bath in which a sizing agent is stored, and the split yarn is immersed in the bath to apply the sizing agent to the split yarn.
In the split yarn cut along the longitudinal direction after opening the fiber, the so-called transition yarn extending obliquely with respect to the longitudinal direction is subjected to fluid resistance when immersed in a bath, and the other yarn is turned up. It will detach from the thread. Then, I noticed that productivity would be lost by depositing on the bottom of the bath or entangled with the rollers in the bus.

  Accordingly, the present invention provides a method for producing carbon fiber split yarns, in which the transition yarns are not easily detached when a sizing agent is applied to the split yarns.

In order to achieve the above object, according to one aspect of the present invention, the following is provided.
An opening process that widens the width of the carbon fiber yarn and reduces the thickness,
A dividing step of dividing the raw yarn into a plurality of divided yarns along the longitudinal direction;
A post-treatment step of applying a sizing agent to the split yarn,
In the post-processing step, carbon is applied to the split yarn by blowing or dropping the sizing agent while sending air along the feed direction of the split yarn and applying air to the split yarn. A method for producing a split yarn of a fiber.

In order to achieve the above object, according to one aspect of the present invention, the following is provided.
An opening mechanism that widens the width of the carbon fiber yarn and reduces the thickness,
A dividing mechanism for dividing the raw yarn into a plurality of divided yarns along the longitudinal direction;
A post-processing mechanism for applying a sizing agent to the split yarn,
The post-processing mechanism is
A feed mechanism for feeding the split yarn in the feed direction;
An application mechanism for spraying or dropping the sizing agent on the split yarn and applying the sizing agent to the split yarn;
A blower mechanism that applies air to the split yarn,
The blower mechanism is a carbon fiber split yarn manufacturing apparatus that sends air along the feed direction of the split yarn and applies the sizing agent to the split yarn while applying air to the split yarn.

  According to the present invention, when applying a sizing agent to the split yarn, it is possible to make it difficult to separate the transition yarn.

It is the schematic of the manufacturing apparatus concerning this embodiment. It is sectional drawing of a raw yarn and a split yarn. It is a flowchart of the method concerning this embodiment. It is a schematic plan view of a split yarn. It is a figure which shows the post-processing part which concerns on a comparative example, Comprising: (a) is a schematic side view of a post-processing part, (b) is a schematic plan view of a post-processing part. It is a schematic side view which shows the post-processing part which concerns on this embodiment. 10 is a schematic side view showing a post-processing unit according to Modification 1. FIG. 10 is a schematic side view showing a post-processing unit according to Modification 2. FIG.

Embodiments of the present invention will be described in detail with reference to the drawings.
FIG. 1 is a schematic diagram of a manufacturing apparatus 1 according to the present embodiment. 1A is a plan view of the manufacturing apparatus 1, and FIG. 1B is a side view of the manufacturing apparatus 1.
As shown in FIG. 1, the manufacturing apparatus 1 includes a delivery unit 10, a pretreatment unit 20, a fiber opening unit 30, a sizing agent application unit 40, a laser irradiation unit 50, a posttreatment unit 60, and a heating unit 70. And a winding unit 80.

  The delivery unit 10 is a part that delivers the raw yarn A to the downstream side. The delivery unit 10 includes a plurality of dancer rollers 11 and a drive nip roller pair 12. The dancer roller 11 absorbs fluctuations in the tension acting on the raw yarn A that is sent out with the yarn path zigzag so that the tension acting on the raw yarn A is constant. The drive nip roller pair 12 pinches and holds the raw yarn A, and pulls out the raw yarn A from the spool 13 around which the raw yarn A is wound.

  The pre-processing unit 20 is a part for removing the sizing agent for the raw yarn provided to the raw yarn A. The raw yarn A is provided with a sizing agent for raw yarn so as not to be unwound during handling. However, if the sizing agent for raw yarn is still applied, it is difficult to open the fiber in the fiber opening process described later. Therefore, the sizing agent for raw yarn is removed from the raw yarn A by the pretreatment unit 20. For example, the pretreatment unit 20 dissolves and removes the sizing agent for raw yarn with a solvent, melts and removes the sizing agent for raw yarn by heating, or sprays a high-temperature vapor-like solvent for the raw yarn. The sizing agent can be removed by melting and melting.

  The opening part (an example of the opening mechanism) 30 is a part that widens the width of the raw yarn A and reduces the thickness. FIG. 2 shows a cross section of a surface orthogonal to the longitudinal direction of the raw yarn A. FIG. 2A shows the raw yarn A before opening, and FIG. 2B shows the raw yarn A after opening. The opening portion 30 deforms the raw yarn A so as to change from the state shown in FIG. 2A to the state shown in FIG.

  The opening part 30 deforms the raw yarn A by using, for example, a parallel roll, a parallel bar, a drum roll, a counter-rotating roll, a vibrating roll, a liquid flow, an air current, a spray of ultrasonic waves, water vapor, water, hot air, or the like. . The opening portion 30 may deform the raw yarn A by combining two or more of these means. The opening part 30 preferably deforms the raw yarn A so that the raw yarn A has a width that is at least twice the diameter of the original raw yarn A.

  The sizing agent imparting unit 40 imparts the sizing agent to the raw yarn A in the opened state. The sizing agent imparts convergence to the carbon fibers of the raw yarn A in the opened state. Examples of the sizing agent include epoxy resins, urethane resins, silane coupling agents, water-insoluble nylons and water-soluble nylons, and water.

  The laser irradiation unit 50 (an example of a dividing mechanism) irradiates the original yarn A in a spread state with a laser along the longitudinal direction. Thus, the laser irradiation unit 50 divides the raw yarn A into a plurality of divided yarns B along the longitudinal direction. (C) of FIG. 2 has shown the cross section of the original yarn A (divided yarn B) after a division | segmentation. In the example shown in the figure, laser is irradiated at three locations along the longitudinal direction, and four split yarns B are obtained from one raw yarn A. However, the present invention is not limited to the illustrated example, and two, three, five, or more divided yarns B may be obtained from one raw yarn A.

  The laser irradiation unit 50 includes a laser output unit 51 that irradiates the raw yarn A with laser, and a nip roller pair 52 that is disposed upstream and downstream of the laser output unit 51. The nip roller pair 52 applies tension to the raw yarn A or the split yarn B so that the portion of the raw yarn A or the split yarn B irradiated with the laser does not bend.

  The post-processing unit (an example of a post-processing mechanism) 60 applies a split yarn sizing agent that imparts convergence to the split yarn B. Examples of split yarn sizing agents include epoxy resins, urethane resins, silane coupling agents, water-insoluble nylons and water-soluble nylons.

  The heating unit 70 heats the split yarn B to which the split yarn sizing agent is applied, and cures the split yarn sizing agent. The heating unit 70 heats the split yarn B by non-contact heating such as high-frequency heating, far-infrared heating, or hot air blowing, or contact heating such as a heat roller or a double belt press, and the sizing for the split yarn. The agent is cured.

  The winding unit 80 includes a separator roller 81, a dancer roller 82, and a winding bobbin 83. The separator roller 81 separates each divided yarn B from the divided yarn B in a state where a plurality of the separated rollers are arranged in parallel. The dancer roller 82 absorbs fluctuations in the tension of each of the split yarns B so that the tension becomes constant. The split yarn B is wound around the winding bobbin 83.

Next, a method of manufacturing the carbon fiber split yarn B using the manufacturing apparatus 1 described above will be described. FIG. 3 is a flowchart of the manufacturing method according to the present embodiment. As shown in FIG. 3, first, the raw yarn A is sent out from the delivery part 10 toward the downstream side (step S01).
Next, the pre-processing unit 20 performs pre-processing on the raw yarn A (step S02). By performing the pretreatment, the sizing agent for raw yarn adhering to the raw yarn A is removed.
Next, the raw yarn A is opened by the fiber opening unit 30, and the width of the raw yarn A is increased to reduce the thickness (step S03). Subsequently, the sizing agent applying unit 40 applies a sizing agent to the unfolded raw yarn A, and sets the carbon fibers forming the raw yarn A in a good state (step S04).
Next, a laser is irradiated to the raw yarn A that has been spread and provided with a sizing agent by the laser irradiation unit, and the raw yarn A is divided into a plurality of divided yarns B (step S05).
A split yarn sizing agent is applied to the split yarn B by the post-processing unit 60 (step S06). Further, the split yarn B is heated by the heating unit 70 to cure the split yarn sizing agent (step S07).
The split yarn B in which the split yarn sizing agent is cured is wound up by the winding unit 80 (step S08). In this way, a plurality of thin split yarns B are obtained from the raw yarn A.

  As shown in FIG. 4, after the dividing step (step S <b> 05), in the divided yarn B cut along the longitudinal direction, the so-called transition yarn W is oblique with respect to the longitudinal direction of the aligned divided yarns B. Extend to. Therefore, in the post-processing step (step S06) in the post-processing unit 60, a sizing agent is applied to the plurality of split yarns B in which the cross yarns W extend obliquely with respect to the longitudinal direction.

FIG. 5A and FIG. 5B are diagrams showing a state of the post-processing process according to the reference example. FIG. 5A shows a side view, and FIG. 5B shows a top view.
As shown in FIG. 5A, for example, the split yarn B is guided by the feed roller 102 to the sizing bath 101 in which the sizing agent S for split yarn is stored, and the split yarn B is immersed in the sizing agent S and applied. Think about what to do. Then, as shown in FIG. 5 (b), when the transition yarn W extending obliquely with respect to the longitudinal direction of the plurality of divided yarns B is immersed in the sizing agent S, it receives a fluid resistance R and turns. As a result, it is separated from other yarns such as the split yarn B. The detached transition yarn W may be deposited on the bottom of the sizing bath 101 or may be entangled with the feed roller 102 in the sizing bath 101, thereby impairing productivity.

  For this reason, in the manufacturing method according to the present embodiment, the accumulation of the transition yarn W and the entanglement on the roller are suppressed in the post-processing step (step S06).

  FIG. 6 is a side view showing the post-processing unit 60 of the manufacturing apparatus 1 according to this embodiment. As illustrated in FIG. 6, the post-processing unit 60 includes a feeding mechanism 62, an applying mechanism 63, and a blower mechanism 64. The feed mechanism 62 includes a plurality of feed rollers 62a, 62b, and 62c provided on the upstream side and the downstream side in the feed direction X of the split yarn B. The feed mechanism 62 feeds the split yarn B in the feed direction X, which is the horizontal direction, by a plurality of feed rollers 62a, 62b, and 62c. One feed roller 62a, 62b, and 62c is provided on the upstream side in the feed direction X, and two on the downstream side in the feed direction X. The feed roller 62 a provided on the upstream side is provided below the split yarn B. The feed rollers 62b and 62c provided on the downstream side are arranged at positions facing each other, take the sandwiched yarn B between them, and feed it downstream.

  The applying mechanism 63 is disposed above the split yarn B conveyed by the feeding mechanism 62. The applying mechanism 63 drops the sizing agent S for the split yarn on the split yarn B, and thereby applies the sizing agent S to the split yarn B. The applying mechanism 63 may apply the sizing agent S by spraying the split yarn B from above.

  The blower mechanism 64 includes two blowers 64a and 64b that blow out air. These blowers 64 a and 64 b are arranged on the upstream side in the feed direction X above and below the split yarn B conveyed by the feed mechanism 62. The upper blower 64a blows air at an angle of about 45 degrees obliquely from above with respect to the feeding direction X of the divided yarn B being conveyed. The blower 64b on the lower side blows air at an angle of about 45 degrees obliquely from below with respect to the feeding direction X of the divided yarn B being conveyed. The angle θ formed by the air feeding direction from the fans 64a and 64b with respect to the feeding direction X of the split yarn B may be 0 ° or more and less than 90 °. The angle θ formed by the air feeding direction from the blowers 64a and 64b and the feeding direction X of the split yarn B is preferably 0 degree or more and less than 60, more preferably 0 degree or more and less than 45 degree, and further preferably 0 degree. The angle may be less than 30 degrees.

  The two blowers 64 a and 64 b apply air toward the application location where the sizing agent S is applied by the application mechanism 63 to the split yarn B conveyed by the feed mechanism 62. Accordingly, the sizing agent S is applied to the split yarn B by the applying mechanism 63 while air is applied by the blowing mechanism 64.

  The post-processing unit 60 has a receiving container 65. The receiving container 65 is disposed on the lower side of the divided yarn B to be conveyed, and receives the sizing agent S falling from the divided yarn B.

  Next, the post-processing step (step S06) of the sizing agent S to the split yarn B by the post-processing unit 60 of the manufacturing apparatus 1 will be described.

  In the post-processing unit 60, the sizing agent S is applied by dropping the sizing agent S from the applying mechanism 63 to the split yarn B that has been divided by the laser irradiation unit 50 and fed into the post-processing unit 60. At this time, the blower 64a of the blower mechanism 64 sends air along the feed direction X of the split yarn B, so that air is applied to the split yarn B in the region where the sizing agent S drops and the upstream region. . Thereby, the sizing agent S is reliably given to the split yarn B. At this time, since the separation force such as fluid resistance is not applied to the crossover yarn W, the problem that the crossover yarn W is entangled does not occur.

  The split yarn B to which the sizing agent S has been applied is then fed out by being sandwiched by a pair of feed rollers 62a of the feed mechanism 62 disposed on the downstream side. Thereby, the surplus portion of the applied sizing agent S is removed by the feed roller 62a, and the split yarn B is fed out to the heating unit 70 on the downstream side. The surplus sizing agent S removed from the split yarn B by the feed roller 62a is received by the receiving container 65 disposed below and collected. In the post-processing unit 60, surplus sizing agent S applied by the applying mechanism 63 and dripped from the split yarn B is also received and collected by the receiving container 65 disposed below.

  Thus, according to the carbon fiber split yarn manufacturing method and manufacturing apparatus 1 according to the present embodiment, the sizing agent is fed while air is applied to the split yarn B by sending air along the feed direction X of the split yarn B. The sizing agent S is applied to the split yarn B by dropping S. Therefore, it is possible to prevent the transition yarn W from turning up in the direction opposite to the feed direction X, and to make it difficult to separate from the other yarns of the split yarn B. As a result, it is possible to improve the quality and productivity by suppressing the accumulation of the transition yarn W and the entanglement of the rollers.

  Further, by setting the angle formed by the air feeding direction and the feeding direction X of the split yarn B to be not less than 0 degrees and less than 90 degrees, it is possible to make the transition yarn W less likely to be entangled with other yarns of the split yarn B. .

  Further, air is applied to the region where the sizing agent S of the split yarn B is dropped and the upstream region thereof, and further, air is applied to the split yarn B from the same side as the side where the sizing agent S is dropped. . This makes it easier for the transition yarns W to be bundled with other yarns in the vertical direction, and to easily prevent the transition yarns from being separated from the other yarns.

  Moreover, in the said embodiment, in the post-processing part 60, with respect to the split yarn B, the upper side that is the same side as the side on which the sizing agent S is dropped, and the lower side that is opposite to the side on which the sizing agent S is dropped. Although the case where air was applied with the air blower 64a of the air supply mechanism 64 from both sides was illustrated, how to apply air to the split yarn B is not limited to both the upper and lower sides.

  For example, in the post-processing unit 60, air may be applied only to the upper side which is the same side as the side on which the sizing agent S is dropped on the split yarn B, and the sizing agent S is dropped on the split yarn B. Air may be applied only to the lower side opposite to the side. However, it is preferable to apply air to the lower side of the split yarn B because the transition yarn W that has moved downward as the dropped sizing agent S can be pushed back upward to be combined with other yarns.

Next, a modified example will be described.
(Modification 1)
FIG. 7 is a schematic side view showing a post-processing unit 60A according to the first modification. As shown in FIG. 7, the application mechanism 63 a of the post-processing unit 60 </ b> A in Modification 1 is a sprayer that sprays the sizing agent S. The applying mechanism 63a including the sprayer sprays the mist-like sizing agent S from above the split yarn B. The applying mechanism 63a including the sprayer applies the sizing agent S to the split yarn B without spraying pressure. In the first modification, the feed roller 62a of the feed mechanism 62 is provided only on the upstream side. Further, in the first modification, the blower mechanism 64 includes one blower 64a. The blower 64a is provided on the upper side of the split yarn B, and blows air at an angle of approximately 45 degrees obliquely from above with respect to the feed direction X of the split yarn B being conveyed.

  In the first modification, the sizing agent S is sprayed from the applying mechanism 63 a to the split yarn B, and air is blown by the blower 64 a of the blower mechanism 64. Thereby, it can provide favorably, suppressing the provision of the excessive sizing agent S to the split yarn B as much as possible. In addition, since excessive application of the sizing agent S to the split yarn B can be suppressed, the pair of feed rollers 62a for drawing on the downstream side can be eliminated.

(Modification 2)
FIG. 8 is a schematic side view showing the post-processing unit 60 according to the second modification. As shown in FIG. 8, in Modification 2, the providing mechanism 63 b of the post-processing unit 60 also serves as the air blowing mechanism 64. The application mechanism 63b is a spray that ejects the sizing agent S together with air. The applying mechanism 63 b sprays the sizing agent S in the form of a mist onto the split yarn B. The spray applying mechanism 63b is provided on the upper side of the split yarn B, and sprays the sizing agent S at an angle of about 45 degrees obliquely from above with respect to the feeding direction X of the split yarn B being conveyed. Also in the second modification, the feed roller 62a of the feed mechanism 62 is provided only on the upstream side.

  In the second modification, the sizing agent S is sprayed together with air by spraying the sizing agent S at an angle of about 45 degrees obliquely from above with respect to the feed direction X of the divided yarn B being conveyed. Also in this case, it is possible to satisfactorily apply the sizing agent S to the split yarn B while suppressing it as much as possible, and the pair of feed rollers 62a for drawing on the downstream side can be dispensed with.

1 Manufacturing apparatus 30 Opening part (opening mechanism)
50 Laser irradiation part (splitting mechanism)
60 Post-processing section (post-processing mechanism)
62 Feeding mechanism 63 Giving mechanism 64 Blowing mechanism A Raw yarn B Split yarn S Sizing agent X Feeding direction

Claims (10)

An opening process that widens the width of the carbon fiber yarn and reduces the thickness,
A dividing step of dividing the raw yarn into a plurality of divided yarns along the longitudinal direction;
A post-treatment step of applying a sizing agent to the split yarn,
In the post-processing step, carbon is applied to the split yarn by blowing or dropping the sizing agent while sending air along the feed direction of the split yarn and applying air to the split yarn. A method for producing a split yarn of a fiber.   2. The method for producing a carbon fiber split yarn according to claim 1, wherein an angle formed by the air feeding direction and the split yarn feeding direction is not less than 0 degrees and less than 90 degrees.   The method for producing a carbon fiber split yarn according to claim 1, wherein the air is applied to a region of the split yarn where the sizing agent is dripped.   The method for producing a carbon fiber split yarn according to claim 1, wherein the air is applied to a region upstream of a region of the split yarn where the sizing agent is dripped.   The carbon fiber split yarn manufacturing method according to claim 1, wherein the air is applied to a region of the split yarn where the sizing agent drops and an upstream region thereof.   The method for producing a carbon fiber split yarn according to claim 1, wherein the air is applied to the split yarn from the same side as the side on which the sizing agent is dropped.   The carbon fiber split yarn manufacturing method according to claim 1, wherein the air is applied to the split yarn from a side opposite to a side on which the sizing agent is dropped.   The carbon fiber split yarn manufacturing method according to claim 1, wherein the air is applied to the split yarn from the side opposite to the side on which the sizing agent is dropped.   The method for producing a carbon fiber split yarn according to claim 1, wherein the atomized sizing agent is sprayed onto the split yarn together with the air. An opening mechanism that widens the width of the carbon fiber yarn and reduces the thickness,
A dividing mechanism for dividing the raw yarn into a plurality of divided yarns along the longitudinal direction;
A post-processing mechanism for applying a sizing agent to the split yarn,
The post-processing mechanism is
A feed mechanism for feeding the split yarn in the feed direction;
An application mechanism for spraying or dropping the sizing agent on the split yarn and applying the sizing agent to the split yarn;
A blower mechanism that applies air to the split yarn,
The blower mechanism is a carbon fiber split yarn manufacturing apparatus that sends air along the feed direction of the split yarn and applies the sizing agent to the split yarn while applying air to the split yarn.

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