JP2020049766A - Heat bonding device and laminate manufacturing method - Google Patents

Abstract

To heat-bond a reinforcing fiber resin sheet to a base sheet.SOLUTION: A heat bonding device heats and bonds a reinforced fiber resin sheet containing carbon fibers and a thermoplastic resin to a base sheet. A surface of the reinforced fiber resin sheet that is located on a side opposite to the base sheet has a base region and a rib region that protrudes further away from the base sheet than the base region. The heat bonding device includes a mold having a convex part including a top surface in contact with the base region of the reinforced fiber resin sheet, and a heating part for heating the reinforced fiber resin sheet.SELECTED DRAWING: Figure 9

Description

  The present invention relates to a heat bonding apparatus and a method for manufacturing a laminate.

  In recent years, among renewable energies, wind power generation, which has excellent cost performance, has attracted attention. In particular, large wind turbines generate a large amount of power per machine and are excellent in cost performance. Specifically, 60 m class wind turbine blades are currently mainly used in Europe, but it is expected that 75 to 150 m class wind turbine blades will be used in the future.

  However, weight and strength are important issues in increasing the size of a wind turbine blade. With respect to such a problem, for example, Patent Literature 1 and Patent Literature 2 disclose a technique using carbon fiber as a reinforcing fiber of a spar cap of a wind turbine blade. Carbon fiber is a lightweight and highly elastic fiber, which is shown to be lighter than a spar cap using glass fiber and to improve performance such as strength. Patent Literature 3 discloses that a sheet including carbon fibers and having a linear convex portion is attached to the surface of a wind turbine blade.

JP 2013-151927 A JP-A-2006-125441 WO 2017/209300

  Simply replacing the spar cap with carbon fiber may not provide sufficient strength and weight reduction of the wind turbine blade. A further consideration is to replace the internal structure of the shear web bonded to the spar cap from glass fibers to carbon fibers.

  The inventors of the present application have tried to simply replace glass fibers of a glass fiber-made shear web having a length of about 10 to 100 m and a height of several meters with carbon fibers. However, it has been extremely difficult to solve the high cost due to the increase in the amount of carbon fiber used and to develop a new extrusion molding technique for carbon fiber.

  Therefore, the inventors have changed the idea, and constructed a large member such as a shear web using a laminate produced by heating and bonding a reinforcing fiber resin sheet having convex portions to a base sheet. Propose that. Specifically, an object of the present invention is to provide a heat bonding apparatus and a method for manufacturing a laminate, which heat bond a reinforcing fiber resin sheet having a rib region to a base sheet.

  The present invention is a heat bonding apparatus for heating and bonding a reinforced fiber resin sheet containing carbon fibers and a thermoplastic resin to a base sheet, and on a side of the reinforced fiber resin sheet opposite to the base sheet, The located surface has a base region and a rib region protruding on a side farther from the base sheet than the base region, and the heat bonding device is in contact with the base region of the reinforcing fiber resin sheet. A heating and bonding apparatus comprising: a mold having a convex portion including a top surface; and a heating unit for heating the reinforcing fiber resin sheet.

  In the heat bonding apparatus according to the present invention, a region between two adjacent convex portions of the mold is located farther from the base sheet than the top surface of the convex portion, and the reinforcing fiber resin sheet is provided. The recess may include a bottom surface facing the rib region.

  In the heat bonding apparatus according to the present invention, the rib region of the reinforcing fiber resin sheet and the convex portion of the mold may linearly extend in parallel with each other.

  In the heat bonding apparatus according to the present invention, a distance between the top surface of the convex portion of the mold and the bottom surface of the concave portion may be equal to or greater than the height of the rib region of the reinforcing fiber resin sheet. .

  In the heat bonding apparatus according to the present invention, a distance between the top surface of the convex portion of the mold and the bottom surface of the concave portion may be 5 mm or more larger than a height of the rib region of the reinforcing fiber resin sheet. .

  In the heat bonding apparatus according to the present invention, the height of the rib region of the reinforcing fiber resin sheet may be 0.2 mm or more.

  In the heat bonding apparatus according to the present invention, the base sheet may include at least one of resin, metal, and ceramic.

  In the heat bonding apparatus according to the present invention, an adhesive layer containing a thermoplastic resin may be provided between the base sheet and the reinforcing fiber resin sheet.

  In the heat bonding apparatus according to the present invention, the thermoplastic resin of the reinforcing fiber resin sheet may be a polypropylene resin, an acrylic resin, a polyvinyl chloride resin, a polyamide resin, or a polyetheretherketone resin.

  In the heat bonding apparatus according to the present invention, the reinforcing fiber resin sheet is located on a first sheet material and a surface of the first sheet material which is opposite to the base sheet, and the rib A core material constituting an area, and a second sheet material laminated on the first sheet material so as to cover the core material, wherein one of the first sheet material and the second sheet material is It may include continuous fibers extending in one direction, and the other may include continuous fibers extending in multiple directions.

  The heat bonding apparatus according to the present invention may heat and bond the reinforced fiber resin sheet to the base sheet to produce a shear web of a windmill rotor.

  The heat bonding apparatus according to the present invention, the mold, the contact position where the top surface of the convex portion of the mold is in contact with the base region of the reinforcing fiber resin sheet, and the convex portion of the mold A vertical movement mechanism for vertically moving the mold between a top position and a separation position where the top surface is separated from the base region of the reinforcing fiber resin sheet; and horizontally moving the mold at the separation position. A horizontal moving mechanism.

  The present invention is a laminate manufacturing method for manufacturing a laminate by heating and bonding a reinforcing fiber resin sheet containing a carbon fiber and a thermoplastic resin to a base sheet, and is located on a side opposite to the base sheet. Surface, the base region, a step of preparing the reinforced fiber resin sheet having a rib region protruding from the base region to the side farther from the base sheet, the base sheet and the reinforced fiber resin sheet, And a heat bonding step of heating the reinforcing fiber resin sheet by bringing the top surface of the mold having a convex portion including a top surface into contact with the base region of the reinforcing fiber resin sheet. And a method for manufacturing a laminate.

  In the method for manufacturing a laminate according to the present invention, the heating and bonding step includes bringing the top surface of the mold into contact with the base region of the reinforcing fiber resin sheet at a first position in a horizontal direction, thereby forming the reinforcing fiber resin sheet. A first heat bonding step of heating, and after moving the mold in a horizontal direction to a second position different from the first position, the top surface of the mold is attached to the base region of the reinforcing fiber resin sheet. A second heating bonding step of heating the reinforcing fiber resin sheet by contacting the reinforcing fiber resin sheet.

  In the method for producing a laminate according to the present invention, the heat bonding step includes a step of contacting the top surface of the mold at a temperature of 130 ° C. or more with the base region of the reinforcing fiber resin sheet at a pressure of 20 MPa or less. May be.

  In the method for producing a laminate according to the present invention, an angle formed by a side surface of the rib region of the reinforcing fiber resin sheet with respect to a normal direction of the base region may be not less than −30 ° and not more than + 30 °.

  ADVANTAGE OF THE INVENTION According to the heat bonding apparatus of this invention, a reinforcing fiber resin sheet can be heat-bonded to a base material sheet.

FIG. 1 is a diagram illustrating an example of a wind turbine that can use a laminate manufactured by a method of manufacturing a laminate according to an embodiment of the present invention as a material. FIG. 2 is a sectional view taken along the line II-II in FIG. FIG. 3 is a perspective view of a laminate manufactured by the laminate manufacturing method according to the present embodiment. FIG. 4 is a sectional view taken along the line IV-IV in FIG. FIG. 5 is a perspective view of a reinforcing fiber resin sheet. FIG. 6 is a sectional view taken along the line VI-VI in FIG. FIG. 7 is a diagram for explaining a method of manufacturing a reinforcing fiber resin sheet. FIG. 8 is a view for explaining a method of manufacturing a laminate according to one embodiment of the present invention. FIG. 9 is a perspective view showing a heat bonding apparatus according to one embodiment of the present invention. FIG. 10 is a diagram illustrating a mold of the heat bonding apparatus according to the present embodiment. FIG. 11 is a diagram for explaining the method of manufacturing a laminate according to the present embodiment. FIG. 12 is a diagram for explaining the method of manufacturing a laminate according to the present embodiment. FIG. 13 is a diagram for explaining an example of a method of manufacturing a laminate using the heat bonding apparatus according to the present embodiment. FIG. 14 is a diagram showing a modification of the mold. FIG. 15 is a view showing a modification of the heat bonding apparatus. FIG. 16 is a view showing a modified example of the reinforcing fiber resin sheet. FIG. 17 is a perspective view showing a modification of the base sheet.

  Hereinafter, an embodiment of a heat bonding apparatus of the present invention will be described with reference to the drawings. In the present embodiment, as an example, a description will be given of a heating and bonding apparatus that can be used when manufacturing a laminate included in a shear web included in a wind turbine rotor blade of a wind turbine described below. 1 to 10 are diagrams for explaining an embodiment according to the present invention. In addition, in the drawings attached to the present specification, for convenience of understanding, the scales and the dimensional ratios in the vertical and horizontal directions are appropriately changed from those of the actual ones and exaggerated. In addition, the dimensional ratios in the drawings may be partially omitted from the drawings for convenience of description. For example, in the drawings, the number of mold protrusions described later may be different from the actual number.

(Windmill)
First, a windmill will be described. FIG. 1 is a diagram of a wind turbine for wind power generation. The wind turbine 80 shown in FIG. 1 can rotate with a column 82 erected on the foundation B, a nacelle 83 installed at the upper end of the column 82, and a substantially horizontal line provided on the nacelle 83 as a rotation axis. And a rotor head 84. The wind turbine 80 shown in FIG. 1 further has a plurality (for example, three) of wind turbine rotor blades 90 radially arranged around the rotation axis of the rotor head 84. The force of the wind that hits the wind turbine rotor blades 90 from the direction of the rotation axis of the rotor head 84 is converted into power for rotating the rotor head 84 about the rotation axis.

The wind turbine rotor 90 will be described. FIG. 2 is a sectional view of the wind turbine rotor 90 taken along the II-II direction in FIG. The wind turbine rotor 90 shown in FIG. 2 includes a skin material 91, a leading edge intermediate layer material 92, a spar cap 93, a trailing edge intermediate layer material 94, a shear web 95, and an endothelial material 97. . The leading edge intermediate layer material 92 and the trailing edge intermediate layer material 94 are made of, for example, a resin foam such as PVC or wood such as balsa. In the wind turbine rotor 90, a portion where the outer skin material 91, the leading edge intermediate layer material 92 and the endothelial material 97 overlap, and a portion where the outer skin material 91, the trailing edge intermediate layer material 94 and the endothelial material 97 overlap, are the outer skin material 91 and the inner skin material. A material 97 is used as a skin material, and a front edge intermediate layer material 92 or a rear edge intermediate layer material 94 is used as a core material to form a sandwich structure.
In the wind turbine rotor 90 shown in FIG. 2, the outer skin material 91, the spar cap 93, and the inner skin material 97 are each formed (configured) of fiber reinforced plastic (FRP). The spar cap 93 is a member in which fiber reinforced plastics are laminated in multiple layers, and is in contact with the rear (upper in FIG. 2) end face and the abdominal (lower in FIG. 2) end face of the shear web 95. One is provided on each of the back side and the ventral side of the rotary wing 90. Further, the spar cap 93 and the shear web 95 are connected (connected) via, for example, an epoxy adhesive that cures at room temperature.

(Laminate)
The share web 95 shown in FIG. 2 includes the laminate 1 manufactured using the heating and bonding apparatus of the present embodiment. FIG. 3 is a perspective view of the laminate 1. FIG. 4 is a cross-sectional view along the IV-IV direction in FIG. The laminate 1 shown in FIGS. 3 and 4 includes a reinforcing fiber resin sheet 10, a base sheet 20, and an adhesive layer 30 located between the reinforcing fiber resin sheet 10 and the base sheet 20. In the following description, the surface of the reinforcing fiber resin sheet 10 on the side of the base material sheet 20 is referred to as a first surface 11, and the surface located on the opposite side to the base material sheet 20 is also referred to as a second surface 12. As shown in FIG. 4, the second surface 12 of the reinforcing fiber resin sheet 10 has a base region 13 and a plurality of rib regions 14 protruding from the base region 13 on the side farther from the base sheet 20.

  In the reinforced fiber resin sheet 10 according to the present embodiment, the plurality of rib regions 14 are arranged in one direction, and each rib region 14 is linearly arranged in a direction non-parallel to one direction which is the arrangement direction. Extending. In the example shown in FIG. 4, a plurality of rib regions 14 are arranged in the X direction, and each rib region 14 extends linearly in the Y direction orthogonal to the X direction. The plurality of rib regions 14 are arranged with an interval therebetween. The base region 13 is formed between two rib regions 14 adjacent in the arrangement direction.

  As an example, the dimensions shown in FIG. 4 can be designed as follows. The width w1 of each base region 13 along the X direction can be 2 mm or more and 50 mm or less. Further, the width w2 of each rib region 14 along the X direction can be 1 mm or more and 50 mm or less. The height h1 of each rib region 14 can be 5 mm or more. The height h1 of each rib region 14 can be, for example, 50 mm or less. The reinforcing fiber resin sheet 10 shown in FIGS. 3 and 4 is a sheet-like member as a whole. Further, the angle formed by the side surface of the rib region 14 of the reinforcing fiber resin sheet 10 with respect to the normal direction of the base region 13 may be −30 ° or more and + 30 ° or less. 4, the straight line L1 extending in the Z direction which is the normal direction of the base region 13 is included in the side surface of the rib region 14, that is, the side surface of the rib region 14 is in the normal direction of the base region 13. The case where the angle formed with respect to the angle is 0 ° is shown.

  The base sheet 20 is a member bonded to the reinforced fiber resin sheet 10 for the purpose of reinforcing the reinforced fiber resin sheet 10 and the like. The base sheet 20 includes, for example, any one or more of resin, metal, and ceramics. The base sheet 20 may include a carbon fiber and a thermoplastic resin described later, similarly to the reinforcing fiber resin sheet 10. The thickness of the base sheet 20 is, for example, 0.1 cm or more and 10 cm or less. Since the laminate 1 further includes the base sheet 20 in addition to the reinforcing fiber resin sheet 10, when a member having a required thickness such as the above-described shear web 95 of the wind turbine rotor 90 is manufactured, the laminate 1 Can be ensured in thickness.

  The adhesive layer 30 is a layer including an adhesive for bonding the base sheet 20 and the reinforcing fiber resin sheet 10. The adhesive layer 30 is, for example, a hot melt adhesive containing a thermoplastic resin. As the thermoplastic resin of the adhesive layer 30, for example, a polyolefin resin such as polypropylene, a polyester resin, a polyamide resin, or the like can be used. When the adhesive layer 30 contains a thermoplastic resin, the adhesive layer 30 can be softened by heating and removed from the laminate 1 and recovered. For this reason, the recyclability of the laminate 1 can be further improved.

Next, the reinforcing fiber resin sheet 10 will be described in detail with reference to FIGS. FIG. 5 is a perspective view of the reinforcing fiber resin sheet 10. FIG. 6 is a cross-sectional view along the VI-VI direction in FIG. In the example shown in FIGS. 5 and 6, the reinforcing fiber resin sheet 10 includes a first sheet material 15 and a plurality of cores provided on a surface of the first sheet material 15 that is located on the second surface 12 side. And a second sheet material 18 laminated on the first sheet material 15 so as to cover the core material 17. Although not shown, the first sheet material 15, the core material 17, and the second sheet material 18 may be bonded via an adhesive layer.
The area of the reinforcing fiber resin sheet 10 in which the second sheet material 18 covers the core 17 is the above-described rib area 14. The area of the reinforcing fiber resin sheet 10 where the second sheet material 18 does not cover the core 17 is the base area 13.

  The reinforcing fiber resin sheet 10 contains carbon fibers and a thermoplastic resin. In the present embodiment, the reinforcing fiber resin sheet 10 is a member manufactured using a so-called carbon fiber reinforced resin (Carbon Fiber Reinforced Plastics) material. Therefore, the reinforcing fiber resin sheet 10 has features such as light weight and high strength, that is, high specific strength.

  At least one of the first sheet material 15, the second sheet material 18, and the core material 17 included in the reinforced fiber resin sheet 10 shown in FIGS. 5 and 6 contains the above-described carbon fiber reinforced resin. Hereinafter, an example of the material of the first sheet material 15, the second sheet material 18, and the core material 17 will be described.

First, the materials of the first sheet material 15 and the second sheet material 18 will be described. The first sheet material 15 and the second sheet material 18 include, for example, a fiber and a synthetic resin impregnated in the fiber. The fibers included in the first sheet material 15 and the second sheet material 18 may be glass fibers or carbon fibers. When the first sheet material 15 and the second sheet material 18 include carbon fibers, the first sheet material 15 and the second sheet material 18 are made lighter and have higher strength as compared with the case where glass fibers are included. be able to. Moreover, since carbon fibers have higher thermal conductivity than glass fibers, heat can be more efficiently transferred to the bonding surface during heat bonding. Specifically, the first sheet material 15 and the second sheet material 18 can be manufactured as a portion obtained by impregnating a fibrous base material with a synthetic resin. The fibrous base material is not particularly limited, and may include, for example, unidirectional continuous fibers, may include woven continuous fibers extending in a plurality of directions, or may be cut instead of continuous fibers. It may contain fibers. Here, the continuous fiber means, for example, a fiber having a length of 100 mm or more. The continuous fiber may not have a cut surface from one end of the sheet material to the other end facing the one end. For example, one of the first sheet material 15 and the second sheet material 18 may include continuous fibers extending in one direction, and the other may include continuous fibers extending in multiple directions. For example, the first sheet material 15 may include continuous fibers extending in a plurality of directions, and the second sheet material 18 may include continuous fibers extending in one direction.
When the first sheet material 15 or the second sheet material 18 contains carbon fibers, for example, PAN-based carbon fibers, PITCH-based carbon fibers, or the like can be used as the carbon fibers. When the first sheet material 15 or the second sheet material 18 contains glass fiber, for example, E glass fiber or the like can be used as the glass fiber. For example, the first sheet material 15 may include continuous fibers of glass fibers extending in a plurality of directions, and the second sheet material 18 may include continuous fibers of carbon fibers extending in one direction.

  As the synthetic resin impregnated in the fibrous base material, either a thermoplastic resin or a thermosetting resin may be used, but it is preferable to use a thermoplastic resin. As the thermoplastic resin, for example, a polypropylene resin, an acrylic resin, a polyvinyl chloride resin, a polyamide resin, or a polyether ether ketone resin is preferable. When the first sheet material 15 and the second sheet material 18 include a thermoplastic resin, the thermoplastic resin can be softened and recovered by heating. For this reason, the recyclability of the laminate 1 can be further improved. Examples of the thermosetting resin include an epoxy resin, an unsaturated polyester resin, a phenol resin, a melamine resin, and a polyurethane resin, and an unsaturated polyester resin and an epoxy resin are preferable.

  One of the first sheet material 15 and the second sheet material 18 includes a fibrous base material, but the other may not include the fibrous base material. For example, the first sheet material 15 may be made of a fiber reinforced resin including a fibrous base material and a synthetic resin impregnated in the fibrous base material, and the second sheet material 18 may be made of a synthetic resin.

  As an example of a method of obtaining the first sheet material 15 or the second sheet material 18 by impregnating the fiber with a synthetic resin, when impregnating a carbon fiber with a synthetic resin, for example, laminating the carbon fiber and the synthetic resin, By raising the temperature to a temperature equal to or higher than the melting point of the synthetic resin and pressing the laminate at a high pressure, the synthetic resin can be impregnated into the carbon fibers.

  The material of the core 17 will be described. In the present embodiment, as the synthetic resin constituting the core material 17 of the reinforcing fiber resin sheet 10, the same synthetic resin as the synthetic resin contained in the first sheet material 15 or the second sheet material 18 may be used. For example, a polypropylene-based resin can be used. The core 17 has, for example, a rectangular cross section.

(Method of manufacturing reinforced fiber resin sheet)
Next, a method for manufacturing the reinforced fiber resin sheet 10 exemplified above will be described. The reinforced fiber resin sheet 10 is produced, for example, by welding the first sheet material 15, the second sheet material 18, and the core material 17 by hot pressing. Extrusion molding or press molding can be used for the hot press.

  In the example shown in FIG. 7 as an example, the first sheet material 15, the second sheet material 18, and the core material 17 are hot-pressed in a cavity C formed between the first mold 61 and the second mold 62. By doing so, the reinforcing fiber resin sheet 10 is obtained. In the example shown in FIG. 7, first, the first sheet material 15 is arranged, and then, a plurality of core materials 17 are arranged on the first sheet material 15. At this time, the elongated core members 17 are arranged on the first sheet member 15 at intervals in the X direction orthogonal to the Y direction so as to extend in the Y direction.

  Next, the second sheet member 18 is arranged on the side of the core member 17 opposite to the side where the first sheet member 15 is located so as to sandwich the core member 17 with the first sheet member 15. Next, as shown in FIG. 7, the second sheet material 18 is bent so as to extend along the first sheet material 15 and the core material 17.

  Then, the first die 61 and the second die 62 are closed with the first sheet material 15, the second sheet material 18 and the core material 17 arranged in the cavity C, and the core material 17 is sandwiched therebetween. The first sheet material 15 and the second sheet material 18 are hot pressed toward each other. As a result, the resin is welded, so that the integrated reinforcing fiber resin sheet 10 is obtained.

(Production method of laminate)
A method for manufacturing the laminate 1 shown in FIGS. 3 and 4 will be described. First, the reinforcing fiber resin sheet 10 shown in FIGS. 5 and 6 is prepared. In the present embodiment, while the reinforcing fiber resin sheet 10 is prepared, an adhesive used as a material of the base sheet 20 and the adhesive layer 30 is prepared.

  Next, the base sheet 20 and the reinforcing fiber resin sheet 10 are laminated. The lamination of the base sheet 20 and the reinforcing fiber resin sheet 10 is performed such that the base sheet 20 is located on the side of the reinforcing fiber resin sheet 10 opposite to the side having the base region 13 and the rib region 14. In the present embodiment, the adhesive layer 30 is arranged on one surface of the base sheet 20, and then the reinforcing fiber resin sheet 10 is placed on the side of the adhesive layer 30 opposite to the side where the base sheet 20 is located. By arranging, as shown in FIGS. 3 and 4, the base sheet 20, the adhesive layer 30, and the reinforcing fiber resin sheet 10 are laminated.

  A method for forming the adhesive layer 30 on one surface of the base sheet 20 will be described. FIG. 8 is a diagram illustrating a method of forming the adhesive layer 30. As shown in FIG. 8, the adhesive layer 30 is formed by supplying the adhesive to one surface of the base sheet 20 while the base sheet 20 is being conveyed in the conveying direction d1. Specifically, first, the base sheet 20 is arranged on the base 64. Next, by moving the pedestal 64 using the rollers 65, the adhesive is supplied to one surface of the base sheet 20 using the adhesive supply mechanism 63 while the base sheet 20 is being transferred in the transfer direction d1. . The adhesive supply mechanism 63 supplies the adhesive to one surface of the base sheet 20 by, for example, a spray coat method or a die coater method. The adhesive layer 30 is formed by the above method.

(Heat bonding equipment)
After laminating the base sheet 20 and the reinforcing fiber resin sheet 10, at least the base region 13 of the reinforcing fiber resin sheet 10 is heated from the second surface 12 side using the heating and bonding device 40 according to the present embodiment, The base sheet 20 and the reinforcing fiber resin sheet 10 are bonded. First, the heat bonding apparatus 40 will be described with reference to FIG. FIG. 9 is a perspective view showing the heat bonding apparatus 40 according to the present embodiment, together with the reinforcing fiber resin sheet 10, the base sheet 20, and the adhesive layer 30, which are objects of the heat bonding. Note that the dimensions of the reinforcing fiber resin sheet 10 and the like shown in FIG. 9 and the numbers of the base regions 13 and the rib regions 14 of the reinforcing fiber resin sheet 10 are changed from the examples shown in FIGS. Is shown. The heating bonding apparatus 40 illustrated in FIG. 9 includes a heating unit 41, a vertical movement mechanism 42, and a horizontal movement mechanism 43. As shown in FIG. 9, the heating and bonding apparatus 40 may further include a support 44 that supports the base sheet 20.

  The heating unit 41 will be described in detail with reference to FIG. FIG. 10 is a diagram illustrating the heating section 41 according to the present embodiment, together with the reinforcing fiber resin sheet 10, the base sheet 20, and the adhesive layer 30, which are the targets of heat bonding. The heating unit 41 has a mold 50. The mold 50 has a plurality of protrusions 51 protruding toward the reinforcing fiber resin sheet 10. The protrusion 51 may extend linearly. The direction in which the protrusions 51 of the mold 50 extend is parallel to the direction in which the rib regions 14 of the reinforcing fiber resin sheet 10 extend.

  The protrusion 51 includes a top surface 51a located at the tip. In the example shown in FIG. 10, the top surface 51a is a flat surface. Although not shown, the top surface 51a may be curved. The mold 50 can be in contact with the base region 13 of the reinforcing fiber resin sheet 10 at least on the top surface 51a of the projection 51.

  Although not shown, the heating unit 41 includes a heating unit that heats at least the top surface 51 a of the projection 51 of the mold 50. By bringing the top surface 51a of the convex portion 51 of the mold 50 in a high-temperature state heated by the heating means into contact with the base region 13, the bonding surface between the reinforcing fiber resin sheet 10 and the base material sheet 20 is at least partially. Can be heated. For example, the adhesive layer 30 located between the reinforcing fiber resin sheet 10 and the base sheet 20 can be heated. By heating, the reinforcing fiber resin sheet 10 and the base sheet 20 can be bonded.

  The maximum temperature of the convex portion 51 when the convex portion 51 comes into contact with the reinforcing fiber resin sheet 10 is preferably equal to or higher than the melting point of the adhesive layer 30, for example, preferably 130 ° C. or higher. If the temperature is high, the reinforcing fiber resin sheet is likely to be deformed.

  In the example shown in FIG. 10, the region between two adjacent convex portions 51 of the mold 50 is located farther from the base sheet 20 than the top surface 51 a of the convex portion 51, and the region of the reinforcing fiber resin sheet 10 is The recess 52 includes a bottom surface 52a facing the rib region 14.

  The width w3 of the protrusion 51 of the mold 50, the width w4 of the recess 52, and the distance h2 between the top surface 51a of the protrusion 51 of the mold 50 and the bottom surface 52a of the recess 52 shown in FIG. The width w1 of the ten base regions 13, the width w2 of the rib regions 14, and the height h1 of the rib regions 14 are appropriately determined. For example, the width w3 of the convex portion 51 of the mold 50 is equal to or less than the width w1 of the base region 13 of the reinforcing fiber resin sheet 10, and the width w4 of the concave portion 52 of the mold 50 is width of the rib region 14 of the reinforcing fiber resin sheet 10. w2 or more. In the example shown in FIG. 10, the width w3 is smaller than the width w1, and the width w4 is larger than the width w2. The distance h2 between the top surface 51a of the convex portion 51 of the mold 50 and the bottom surface 52a of the concave portion 52 is, for example, not less than the height h1 of the rib region of the reinforcing fiber resin sheet 10. The example shown in FIG. 10 shows a case where the distance h2 is equal to the height h1. The width w5 of the mold 50 is, for example, 50 cm.

  The vertical movement mechanism 42 will be described with reference to FIG. The vertical movement mechanism 42 is a mechanism for moving the mold 50 in the Z direction, which is the thickness direction of the reinforcing fiber resin sheet 10 shown in FIG. Specifically, the vertical movement mechanism 42 includes a contact position where the top surface 51 a of the protrusion 51 of the mold 50 contacts the base region 13 of the reinforcing fiber resin sheet 10, and a top surface of the protrusion 51 of the mold 50. The mold 50 can be moved in the Z direction between the separation position where 51 a is separated from the base region 13 of the reinforcing fiber resin sheet 10. Hereinafter, the thickness direction of the reinforcing fiber resin sheet 10 is also referred to as an “up-down direction”.

  The horizontal movement mechanism 43 will be described with reference to FIG. The horizontal movement mechanism 43 is a mechanism for moving the mold 50 in the surface direction of the first surface 11 of the reinforcing fiber resin sheet 10 shown in FIG. Hereinafter, the surface direction of the first surface 11 of the reinforcing fiber resin sheet 10 is also referred to as “horizontal direction”. The horizontal movement mechanism 43 moves the mold 50 in the horizontal direction when the mold 50 is at a separated position where the mold 50 is not in contact with the reinforcing fiber resin sheet 10. The horizontal moving mechanism 43 shown in FIG. 9 moves the mold 50 in the X direction in which the rib regions 14 of the reinforcing fiber resin sheet 10 are arranged. The horizontal movement mechanism 43 has, for example, a wheel unit 43a provided so that the heating unit 41 including the mold 50 and the vertical movement mechanism 42 can be moved in the horizontal direction. In this case, as shown in FIG. 9, the heating and bonding apparatus 40 may further include a rail 36 that restricts the direction in which the wheel 43 a of the horizontal moving mechanism 43 moves. In the example shown in FIG. 9, the rail 36 restricts the direction in which the wheel 43a of the horizontal moving mechanism 43 moves to the X direction.

(Heat bonding process)
A heat bonding step of bonding the base sheet 20 and the reinforcing fiber resin sheet 10 using the above-described heat bonding apparatus 40 will be described. In the heat bonding step, the top surface 51 a of the convex portion 51 of the mold 50 is brought into contact with the base region 13 of the reinforcing fiber resin sheet 10 to heat the reinforcing fiber resin sheet 10.

  In the heat bonding step according to the present embodiment, the first step of heating the reinforcing fiber resin sheet 10 by bringing the top surface 51 a of the mold 50 into contact with the base region 13 of the reinforcing fiber resin sheet 10 at the first position in the horizontal direction. After the heat bonding step and moving the mold 50 in the horizontal direction to the second position different from the first position, the top surface 51 a of the convex portion 51 of the mold 50 contacts the base region 13 of the reinforcing fiber resin sheet 10. And a second heat bonding step of heating the reinforcing fiber resin sheet 10.

  The first heat bonding step will be described. FIG. 11 is a diagram showing a state of the first heat bonding step. In FIG. 11, the illustration of the horizontal direction moving mechanism 43 and the support portion 44 is omitted. In the first heat bonding step, the mold 50 at the first position A1 in the horizontal direction is used. First, the mold 50 located at the separated position in the vertical direction is moved to the contact position in the vertical direction using the vertical movement mechanism 42. Thereby, as shown in FIG. 11, the top surface 51a of the mold 50 is brought into contact with the base region 13 of the reinforcing fiber resin sheet 10 at the first position A1 in the horizontal direction. The temperature of at least the top surface 51 a of the convex portion 51 of the mold 50 may be high before contacting the base region 13, or may be heated after contacting the base region 13. . The temperature of the top surface 51a of the protrusion 51 is, for example, 130 ° C. or higher. By contacting the top surface 51a of the high-temperature projection 51 with the base region 13 of the reinforcing fiber resin sheet 10, the reinforcing fiber resin sheet 10 can be heated and bonded to the base sheet 20 at the first position A1. Thereafter, the mold 50 is moved to the vertically separated position by using the up-down movement mechanism 42.

  Next, the second heat bonding step will be described. FIG. 12 is a diagram illustrating a state of the second bonding heating step. 12, the illustration of the horizontal movement mechanism 43 and the support portion 44 is omitted as in FIG. In the second heat bonding step, first, the mold 50 is horizontally moved to the second position A2 different from the first position A1 using the horizontal movement mechanism 43. In the present embodiment, as shown in FIG. 11, the second position A2 is located downstream of the first position A1 in the X direction, which is the direction in which the rib regions 14 of the reinforcing fiber resin sheet 10 are arranged. Next, the mold 50 is moved to the contact position in the up-down direction using the up-down movement mechanism 42 so that the top surface 51 a of the projection 51 of the mold 50 comes into contact with the base region 13 of the reinforcing fiber resin sheet 10. . Thereby, similarly to the case of the first heat bonding step, the reinforcing fiber resin sheet 10 can be heat bonded to the base sheet 20 at the second position A2.

  Thereafter, although not shown, the reinforcing fiber resin sheet 10 is heat-bonded to the base sheet 20 using the mold 50 at each position in the horizontal direction, similarly to the above-described first heat bonding step and second heat bonding step. . According to the present embodiment, by moving the mold 50 in the horizontal direction by using the horizontal moving mechanism 43, it has a large size in a small work space as compared with the case where the reinforcing fiber resin sheet 10 is moved. The laminate 1 can be manufactured.

  In the heat bonding step, when the top surface 51a of the convex portion 51 of the mold 50 is brought into contact with the base region 13 of the reinforcing fiber resin sheet 10, it is preferable to apply pressure to the base region 13 by the top surface 51a. The pressure applied to the base region 13 by the top surface 51a of the convex portion 51 may be a pressure due to the weight of the mold 50 or an external pressure. For example, a pressure of 0.01 MPa or more and 20 MPa or less may be applied. .

In the present embodiment, an operation of bringing top surface 51a of mold 50 into contact with base region 13 of reinforcing fiber resin sheet 10 will be described.
First, as a comparative example, a case is considered in which heating and bonding of the reinforcing fiber resin sheet 10 to the base sheet is performed using a heating air supply mechanism or a heating mechanism such as an oven. In this case, since the rib region 14 of the reinforcing fiber resin sheet 10 is closer to the surrounding atmosphere than the adhesive layer 30, there is a possibility that the thermoplastic resin in the rib region 14 melts before the adhesive layer 30. is there.
On the other hand, in the present embodiment, the top surface 51 a of the convex portion 51 of the heated mold 50 is brought into contact with the base region 13 of the reinforcing fiber resin sheet 10. Therefore, the adhesive layer 30 can be heated while suppressing the heating of the rib region 14 of the reinforcing fiber resin sheet 10. Therefore, it is possible to prevent the shape of the rib region 14 from changing due to melting.

  The laminated body 1 can be manufactured by heat-bonding the reinforcing fiber resin sheet 10 to the base sheet 20 using the heat bonding apparatus 40. A shear web 95 of the wind turbine rotor 90 may be manufactured using the manufactured laminate 1. According to the present heating bonding apparatus 40 and the method for manufacturing a laminate using the present heating bonding apparatus 40, for example, as shown in FIG. 13, a plurality of reinforcing fiber resin sheets 10 and a plurality of base sheets 20 are bonded to each other. As the laminate 1, a large lattice-shaped rib structure can be easily formed. Such a rib structure has industrial utility value as a share web of a windmill.

(Modification of mold)
In the above-described embodiment, an example in which the distance h2 between the top surface 51a of the convex portion 51 of the mold 50 and the bottom surface 52a of the concave portion 52 is equal to the height h1 of the rib region of the reinforcing fiber resin sheet 10 will be described. did. However, the distance h2 in the mold 50 is not limited to this. FIG. 14 is a view showing a modified example of the mold together with the reinforcing fiber resin sheet 10, the base sheet 20, and the adhesive layer 30. FIG. 14 shows a case where the mold 50 is at a contact position where the top surface 51 a of the convex portion 51 of the mold 50 contacts the base region 13 of the reinforcing fiber resin sheet 10. In the modified example of the mold, the distance h2 between the top surface 51a of the convex portion 51 of the mold 50 and the bottom surface 52a of the concave portion 52 is larger than the height h1 of the rib region 14 of the reinforcing fiber resin sheet 10. ing. In this case, as shown in FIG. 14, when the mold 50 is at the contact position, the bottom surface 52a of the concave portion 52 of the mold 50 does not contact the rib region 14 of the reinforcing fiber resin sheet 10. That is, when the mold 50 is at the contact position, a gap exists between the bottom surface 52 a of the concave portion 52 of the mold 50 and the rib region 14 of the reinforcing fiber resin sheet 10. Thereby, it is possible to prevent the rib region 14 of the reinforcing fiber resin sheet 10 from being heated and melted. The distance between the top surface 51a of the convex portion 51 of the mold 50 and the bottom surface 52a of the concave portion 52 is preferably 5 mm or more larger than the height of the rib region 14 of the reinforcing fiber resin sheet. As a result, the distance between the bottom surface 52a of the concave portion 52 of the mold 50 and the rib region 14 of the reinforcing fiber resin sheet 10 is sufficiently increased, so that the heating and melting of the rib region 14 of the reinforcing fiber resin sheet 10 are further suppressed. Can be made easier.

(Modified example of the heat bonding device)
In the above-described embodiment and modified examples, the heating and bonding apparatus 40 having one heating unit 41 has been described. However, the number of the heating units 41 included in the heat bonding apparatus 40 is not limited to one. FIG. 15 is a view showing a modification of the heat bonding apparatus. FIG. 15 shows a case where the heat bonding apparatus 40 has a plurality of heating units 41. As shown in FIG. 15, the heating and bonding apparatus 40 may include a plurality of heating units 41, a plurality of vertical movement mechanisms 42, and a plurality of horizontal movement mechanisms 43.

(Modified example of reinforced fiber resin sheet)
In the above-mentioned embodiment and each modification, the example where rib region 14 of reinforcing fiber resin sheet 10 extends in a direction orthogonal to one side of reinforcing fiber resin sheet 10 has been described. However, the direction in which the rib region 14 of the reinforcing fiber resin sheet 10 extends is not limited to this. FIG. 16 is a plan view showing the reinforcing fiber resin sheet 10 together with the mold 50. The dashed line in FIG. 16 is a virtual line indicating the position of the protrusion 51 in the mold 50. In FIG. 16, the vertical movement mechanism 42, the horizontal movement mechanism 43, and the support 44 are not shown.
In FIG. 16, the reinforcing fiber resin sheet 10 has a rectangular shape including a long side 19 extending in the direction d2. In this modification, the direction d3 in which the rib region 14 of the reinforcing fiber resin sheet 10 extends is inclined by an angle θ with respect to the direction d2 in which the long side 19 of the reinforcing fiber resin sheet 10 extends. Is preferably 30 ° or more and less than 90 °. Angle θ is more preferably 45 °. In this case, in the heat bonding step, the mold 50 may be moved in the direction d2 in which the long side 19 of the reinforcing fiber resin sheet 10 extends. In this case, as shown in FIG. 16, the direction in which the protrusions 51 of the mold 50 extend may be parallel to the direction d2 in which the rib regions 14 of the reinforcing fiber resin sheet 10 extend. That is, the direction in which the protrusions 51 of the mold 50 extend may be inclined by the angle θ with respect to the direction d2, which is the horizontal movement direction of the mold.

(Modification of base sheet)
In the above-described embodiment and each of the modifications, the stacked body 1 using the sheet member having a constant thickness as the base sheet 20 has been described. However, the base sheet 20 is not limited to this. FIG. 17 is a perspective view showing a modification of the base sheet. In a modified example of the base sheet, a reinforcing fiber resin sheet 10 having a plurality of rib regions 14 is used as the base sheet 20. In the example shown in FIG. 17, the laminated body 1 is manufactured by bonding the first surfaces 11 of the two reinforcing fiber resin sheets 10 to each other. In this case, it is preferable that the rib region 14 of one reinforcing fiber resin sheet 10 and the rib region 14 of the other reinforcing fiber resin sheet 10 linearly extend in different directions in plan view. The rib region 14 of the one reinforcing fiber resin sheet 10 and the rib region 14 of the other reinforcing fiber resin sheet 10 linearly extend in different directions in plan view, so that the laminate 1 is formed in two different directions. Strength can be improved. In the example shown in FIG. 17, the rib region 14 of one reinforcing fiber resin sheet 10 and the rib region 14 of the other reinforcing fiber resin sheet 10 extend in directions orthogonal to each other in plan view. The shape and size of one reinforcing fiber resin sheet 10 and the shape and size of the other reinforcing fiber resin sheet 10 may be the same or different. For example, the width of the rib region 14 of one reinforcing fiber resin sheet 10 and the width of the rib region 14 of the other reinforcing fiber resin sheet 10 may be the same or different.

DESCRIPTION OF SYMBOLS 1 Laminated body 10 Reinforced fiber resin sheet 11 First surface 12 Second surface 13 Base region 14 Rib region 15 First sheet material 17 Core material 18 Second sheet material 19 Long side 20 Base sheet 30 Adhesive layer 40 Heat bonding device 41 heating unit 42 vertical moving mechanism 43 horizontal moving mechanism 43a wheel unit 44 support unit 50 mold 51 convex unit 51a top surface 52 concave unit 52a bottom surface 61 first mold 62 second mold 63 adhesive supply mechanism 64 pedestal 65 roller 80 Windmill 82 Prop 83 Nacelle 84 Rotor head 90 Windmill rotating wing 91 Skin material 93 Supercap 95 Share web 97 Endothelium material

Claims (16)

A heating bonding apparatus for heating and bonding a reinforcing fiber resin sheet containing a carbon fiber and a thermoplastic resin to a base sheet,
Among the surfaces of the reinforcing fiber resin sheet, a surface located on a side opposite to the base sheet has a base region and a rib region protruding from the base region to a side farther from the base sheet than the base region. ,
The heat bonding device is
A heating and bonding apparatus, comprising: a mold having a projection including a top surface in contact with the base region of the reinforcing fiber resin sheet; and a heating unit for heating the reinforcing fiber resin sheet.   An area between two adjacent convex portions of the mold is located farther from the base sheet than the top surface of the convex portion, and a bottom surface facing the rib region of the reinforcing fiber resin sheet. The heating and bonding apparatus according to claim 1, wherein the heating and bonding apparatus is a recess including:   The heat bonding apparatus according to claim 2, wherein the rib region of the reinforcing fiber resin sheet and the protrusion of the mold extend linearly in parallel with each other.   4. The heat bonding according to claim 2, wherein a distance between the top surface of the convex portion and the bottom surface of the concave portion of the mold is equal to or greater than a height of the rib region of the reinforcing fiber resin sheet. 5. apparatus.   5. The heat bonding apparatus according to claim 4, wherein a distance between the top surface of the convex portion of the mold and the bottom surface of the concave portion is 5 mm or more larger than a height of the rib region of the reinforcing fiber resin sheet.   The heat bonding apparatus according to any one of claims 1 to 4, wherein a height of the rib region of the reinforcing fiber resin sheet is 5 mm or more.   The heat bonding apparatus according to claim 1, wherein the base sheet includes any one or more of a resin, a metal, and a ceramic.   The heat bonding apparatus according to any one of claims 1 to 7, wherein an adhesive layer containing a thermoplastic resin is provided between the base sheet and the reinforcing fiber resin sheet.   The thermoplastic resin of the reinforcing fiber resin sheet is a polypropylene resin, an acrylic resin, a polyvinyl chloride resin, a polyamide resin or a polyetheretherketone resin, according to any one of claims 1 to 8. The heating and bonding apparatus according to claim 1. The reinforcing fiber resin sheet, a first sheet material, a core material that is located on a surface of the first sheet material that is opposite to the base sheet and that constitutes the rib region, A second sheet material laminated on the first sheet material so as to cover the core material,
10. The method according to claim 1, wherein one of the first sheet material and the second sheet material includes continuous fibers extending in one direction, and the other includes continuous fibers extending in a plurality of directions. The heating and bonding apparatus as described in the above.   The heat bonding apparatus according to any one of claims 1 to 10, wherein the heat bonding apparatus heats and bonds the reinforcing fiber resin sheet to the base sheet to produce a shear web of a windmill rotor. The heat bonding device is
The mold, the contact position where the top surface of the convex portion of the mold is in contact with the base region of the reinforcing fiber resin sheet, and the top surface of the convex portion of the mold is the reinforcing fiber resin sheet. A vertical movement mechanism for vertically moving the mold between a separated position separated from the base region,
The heating and bonding apparatus according to any one of claims 1 to 11, further comprising: a horizontal moving mechanism that horizontally moves the mold at the separated position. A laminate production method for producing a laminate by heating and bonding a reinforcing fiber resin sheet containing a carbon fiber and a thermoplastic resin to a base sheet,
A step of preparing the reinforcing fiber resin sheet having a surface located on the side opposite to the base sheet, a base region, and a rib region protruding from the base sheet further away from the base sheet than the base region. ,
Laminating the base sheet and the reinforcing fiber resin sheet,
A heat bonding step of heating the reinforcing fiber resin sheet by bringing the top surface of a mold having a convex portion including a top surface into contact with the base region of the reinforcing fiber resin sheet. The heat bonding step,
A first heat bonding step of heating the reinforcing fiber resin sheet by bringing the top surface of the mold into contact with the base region of the reinforcing fiber resin sheet at a first position in a horizontal direction;
After moving the mold in a horizontal direction to a second position different from the first position, the top surface of the mold is brought into contact with the base region of the reinforcing fiber resin sheet, and the reinforcing fiber resin sheet The method according to claim 13, further comprising: a second heat bonding step of heating the laminate.   The method according to claim 13, wherein the heat bonding step includes a step of contacting the top surface of the mold at a temperature of 130 ° C. or more with the base region of the reinforcing fiber resin sheet at a pressure of 20 MPa or less. Laminated body manufacturing method.   The laminate according to any one of claims 13 to 15, wherein an angle formed by a side surface of the rib region of the reinforcing fiber resin sheet with respect to a normal direction of the base region is from -30 ° to + 30 °. Production method.